د أ ر 21 - المواصفات الإنشائية القياسية - الجزء الثاني PDF

PART 2
ROAD STRUCTURES
TABLE OF CONTENTS
16 Introduction
17 Drilled Piles
18 Driven Piles
19 Ground Anchors
20 Earth Retaining Systems
21 Concrete Structures
22 Prestressing Systems
23 Steel Structures
24 Painting
25 Bearing Devices
26 Bridge Deck Joint Systems
27 Railings
28 Waterproofing
29 Miscellaneous Items for Structures
30 Miscellaneous Metals
31 Metal Culverts
32 Precast Concrete Culverts
33 Bridge Access Systems
34 Road Tunnels
35 Bridge and Underpass Load Testing
STANDARD CONSTRUCTION SPECIFICATIONS
PART 2
ROAD STRUCTURES
DOCUMENT NO: TR-

FIRST EDITION
JANUARY 2018
Document No:
First Edition
2018
Department of Transport
PO Box 20
Abu Dhabi, United Arab Emirates
© Copyright 2018, by the Department of Transport. All Rights Reserved. These specifications, or
parts thereof, may not be reproduced in any form without written permission of the publisher.
PART 2
ROAD STRUCTURES
CHAPTER 16 - INTRODUCTION
DOCUMENT NO: TR-

FIRST EDITION
JANUARY 2018
STANDARD CONSTRUCTION SPECIFICATIONS PART 2 – ROAD STRUCTURE
Chapter 16: Introduction

TABLE OF CONTENTS
Table of Contents........................................................................................................................... i
16 Introduction ..................................................................................................................... 16-1
Page i
CHAPTER 16: INTRODUCTION First Edition -January 2018
16 INTRODUCTION
Part 2, Road Structures, is intended to be read in line with Part 1 of these Standard Construction
Specifications, to ensure consisten0t construction requirements throughout.
This document defines standard construction specifications for Road Structures, providing a
contractual basis for the requirements for implementing such works. These standard construction
specifications shall be part of the Contract documents for all works of road and road structures
projects.
Part 2 of these Standard Construction Specifications sets forth the minimum criteria and
specifications for both public and private construction projects including bridges, tunnels,
underpasses, culverts, and other road structures related works. Additionally, these specifications
provide the minimum construction requirements for other road structures to be accepted by the
Owner, which may substitute more stringent construction standards and specifications where special
conditions warrant.
Page 16-1
CHAPTER 16: INTRODUCTION First Edition -January 2018
PART 2
ROAD STRUCTURES
CHAPTER 17 - DRILLED PILES
DOCUMENT NO: TR-

FIRST EDITION
JANUARY 2018
STANDARD CONSTRUCTION SPECIFICATIONS PART 2 – DRILLED PILES
Chapter 17: Drilled Piles

TABLE OF CONTENTS
Table of Contents...........................................................................................................................ii
List of Tables ............................................................................................................................. 17-4
17 Drilled Piles ..................................................................................................................... 17-1
17.1 Reference Standards and Codes ................................................................................. 17-1
17.2 Working Drawings ........................................................................................................ 17-2
17.3 Ground Investigation .................................................................................................... 17-2
17.4 Piling Method and Programme..................................................................................... 17-3
17.5 Ensuring Safety when Drilling Piles.............................................................................. 17-3
17.5.1 General Safety Requirements for Drilled Piles ...................................................... 17-3
17.5.2 Life-saving Appliances .......................................................................................... 17-3
17.6 Avoiding Disturbances and Damage when Drilling Piles .............................................. 17-3
17.6.1 Reducing Noises and Disturbances from Pile Drilling............................................ 17-3
17.6.2 Avoiding Damage to Adjacent Structures .............................................................. 17-3
17.6.3 Avoiding Damage to Piles ..................................................................................... 17-3
17.7 Obstructions ................................................................................................................ 17-4
17.8 Pile Construction Record ............................................................................................. 17-4
17.9 Construction Tolerances .............................................................................................. 17-5
17.10 Pile Construction.......................................................................................................... 17-5
17.10.1 Protection of Existing Structures ........................................................................... 17-5
17.10.2 Submittals for Drilled Pile Construction ................................................................. 17-5
17.10.3 Drilled Pile Construction Sequence ....................................................................... 17-6
17.10.4 Drilled Pile Construction Methods ......................................................................... 17-6
17.10.5 Drilling .................................................................................................................. 17-8
17.11 Support for Pile Bores .................................................................................................. 17-9
17.11.1 Support Fluid ........................................................................................................ 17-9
17.11.2 Use of Bentonite ................................................................................................... 17-9
17.11.3 Polymer Slurry .................................................................................................... 17-10
17.11.4 Casings .............................................................................................................. 17-11
17.12 Placement of Pile Concrete........................................................................................ 17-12
17.12.1 Concrete for Drilled Piles .................................................................................... 17-12
17.12.2 Placing Concrete under Water or Support Fluid .................................................. 17-12
17.13 Steel Reinforcement .................................................................................................. 17-13
17.14 Withdrawal of Temporary Casing ............................................................................... 17-14
17.15 Finishing Pile Heads .................................................................................................. 17-14
17.16 Pile Testing ................................................................................................................ 17-16
17.16.1 Measuring Devices ............................................................................................. 17-16
17.16.2 Reaction System................................................................................................. 17-17
17.16.3 Equipment for Applying Load .............................................................................. 17-19
17.16.4 Special Requirements for Test Piles ................................................................... 17-19
17.16.5 Maintained Compression Load Testing for Piles ................................................. 17-20
17.16.6 Working Piles ...................................................................................................... 17-20
17.16.7 Pile Testing Procedure........................................................................................ 17-20
17.16.8 Abandonment of Pile Test ................................................................................... 17-22
17.16.9 Pile Testing Record ............................................................................................ 17-22
17.16.10 Failure of Working Load Test .............................................................................. 17-24
17.16.11 Compensating Piles ............................................................................................ 17-24
17.16.12 Reinstatement of Piles After Testing ................................................................... 17-25
17.17 Osterberg Cell Load Testing ...................................................................................... 17-25
17.17.1 General............................................................................................................... 17-25
17.17.2 Materials ............................................................................................................. 17-25
Page ii
CHAPTER 7: DRILLED PILES FIRST EDITION - JANUARY 2018
17.17.3 Equipment .......................................................................................................... 17-26

17.17.4 Procedure ........................................................................................................... 17-26
17.17.5 Testing and Reporting......................................................................................... 17-27
17.18 Tension and Lateral Load Testing .............................................................................. 17-28
17.19 Integrity Testing for Piles ........................................................................................... 17-28
17.19.1 Low Strain Integrity Testing for Piles ................................................................... 17-28
17.19.2 Cross-hole Sonic Logging ................................................................................... 17-28
17.20 High Strain Dynamic Test .......................................................................................... 17-30
17.20.1 General............................................................................................................... 17-30
17.20.2 Measuring Instruments ....................................................................................... 17-30
17.20.3 Hammer .............................................................................................................. 17-30
17.20.4 Preparation of the Pile Head ............................................................................... 17-31
17.20.5 Time of Testing ................................................................................................... 17-31
17.20.6 Results ............................................................................................................... 17-31
Index ...................................................................................................................................... 17-32
Page 17-3
List of Tables
Table 17-1: Designations and titles for AASHTO and ASTM standards that apply to drilled piles works
.................................................................................................................................................. 17-1
Table 17-2: Requirements for drilled pile construction submittals ............................................... 17-5
Table 17-3: Bentonite slurry properties .................................................................................... 17-10
Table 17-4: Polymer slurry properties ...................................................................................... 17-11
Table 17-5: Casting tolerance for piles cast in dry bores using temporary casing and without a
permanent lining ...................................................................................................................... 17-15
Table 17-6: Casting tolerance for piles cast in dry bores within permanent lining tubes, permanent
casings, or where cut-off levels are in stable ground below the base of any casing used ......... 17-15
Table 17-7: Casting tolerance for piles cast under water or drilling fluid* .................................. 17-15
Table 17-8: Loading cycles for test piles .................................................................................. 17-21
Page iv
17 DRILLED PILES
This chapter defines standards and requirements for the construction of drilled foundation piles, with
or without bell footings, including the placement of reinforcing steel and concrete. All such work shall
comply with the contractual requirements for the Project and the specifications outlined in this
chapter.
17.1 Reference Standards and Codes

Standards and codes for Drilled Piles shall be as specified in these specifications, in the Contract
documents, if any, and the following, in their latest edition:
• AASHTO LRFD American Association of State Highway and Transportation Officials -
Load and Resistance Factor Design, Bridge Construction Specifications;
Load and Resistance Factor Design, Bridge Design Specifications;
• AASHTO Standard Specifications for Transportation Materials and Methods of
Sampling and Testing;
• ADQCC (TR-516) Road Structures Design Manual;
• API American Petroleum Institute;
• ASTM American Society for Testing and Materials.
Table 17-1 presents AASHTO and American Society for Testing and Materials (ASTM) standards
that are related to materials for drilled piles. It includes designations and titles.
Table 17-1: Designations and titles for AASHTO and ASTM standards that apply to drilled
piles works
AASHTO ASTM
TITLE
DESIGNATION DESIGNATION
Standard Test Method for Density of Bentonitic

ASTM D4380-12
Slurries
ASTM Standard Test Method for Marsh Funnel Viscosity

D6910/D6910M-09 of Clay Construction Slurries
ASTM Standard Test Method for Sand Content by Volume

D4381/D4381M-12 of Bentonitic Slurries
ASTM
Standard Test Methods for Deep Foundations
D1143/D1143M-
Under Static Axial Compressive Load
07e1
Standard Test Methods for Deep Foundations

ASTM D3689-07
Under Static Axial Tensile Load
Standard Test Methods for Piles Under Lateral

ASTM D3966-07
Loads
Standard Test Method for Low Strain Impact

ASTM D5882-07
Integrity Testing of Deep Foundations
Page 17-1
AASHTO ASTM
TITLE
Standard Test Method for Integrity Testing of

ASTM D6760-08 Concrete Deep Foundations by Ultrasonic
Crosshole Testing
Standard Test Method for High-Strain Dynamic

ASTM D4945-12
Testing of Deep Foundations
17.2 Working Drawings

When required by the Contract documents, at least four weeks before work on piles is to begin, the
Contractor shall submit to the Engineer for review and approval, an installation plan for the
construction of drilled piles. The submittal shall include the following:
a. List of proposed equipment to be used, including cranes, drills, augers, bailing buckets, final
cleaning equipment, desanding equipment, slurry pumps, sampling equipment, tremies or
concrete pumps, casings, etc.
b. Details of overall construction operation sequence and the sequence of piles construction in
bents or groups.
c. Details of pile drilling methods.
d. When slurry is required, details of the method proposed to mix, circulate, and desand slurry.
e. Details of methods to clean the pile drilling.
f. Details of reinforcement placement, including support and centralization methods.
g. Details of concrete placement, curing, and protection.
h. Details of any required load tests.
i. Other information shown in the contract documents or requested by the Engineer.
The Contractor shall not start the construction of drilled piles for which working drawings are required
until such 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 documents.
17.3 Ground Investigation

The Contractor shall investigate the Project site to a depth sufficient to identify all ground formations
and layers that affect pile construction and to recognize the capacity and deformation properties of
the ground. In accordance with the Project requirements, a site investigation shall determine the
Project site’s characteristic ground conditions.
If the maintenance of stability of pile bore is likely to be difficult, the Contractor shall complete a trial
bore of relevant dimensions. To determine the extent of a ground investigation, the Contractor shall
consider their own experience and available information that is relevant to the execution of
comparable foundation works under similar conditions and within the general vicinity of the Project
site.
The Contractor shall backfill all boreholes sufficiently to ensure that subsequent pile construction
and performance are not affected.
A number of test piles as defined in the Contract Documents shall be constructed and load tested
before permanent construction.
Page 17-2
17.4 Piling Method and Programme

The Contractor shall supply for approval all relevant details of the proposed method of piling and
plant use. Any method other than that specified in the Contract documents shall be subject to
approval by the Engineer.
Every day, the Contractor shall inform the Engineer of the intended programme for piling for the
following day and shall give adequate notice of intentions to work outside normal hours or on
holidays. The Contractor shall submit to the Engineer a proposed sequence and timing for boring
piles. Such schedules shall ensure that boring does not damage adjacent piles.
17.5 Ensuring Safety when Drilling Piles

The Contractor shall comply with the requirements outlined in this section and the Owner’s
Environmental, Health and Safety procedures to ensure that drilling operations and drilled foundation
piles are safe.
17.5.1 General Safety Requirements for Drilled Piles

A competent person who is properly qualified and experienced, on behalf of the Contractor, shall
supervise all piling operations. This person shall be capable of responding to and assessing any
potential dangers, such as unexpected ground conditions that may require different construction
techniques or unusual smells that may indicate the presence of noxious or dangerous gases.
17.5.2 Life-saving Appliances

The Contractor shall provide sufficient, proper, and effective life-saving appliances of types and
natures that have the Engineer’s approval. Such appliances shall be conspicuous on the Project site
and shall be available at all times for possible use.
At least one site operative shall be instructed in the use of such safety equipment and shall
participate in periodic drills to ensure that any such operative can correctly observe all necessary
procedures.
17.6 Avoiding Disturbances and Damage when Drilling

Piles
The Contractor shall ensure that foundation pile drilling is not a nuisance and does not cause damage
to adjacent structures or piles.
17.6.1 Reducing Noises and Disturbances from Pile Drilling

When working, the Contractor shall keep noises, vibrations, and other disturbances to a minimum
and shall comply with all current environmental legislation, as applicable, particularly in urban areas.
The Contractor shall understand the nature and levels of noise produced by mechanical equipment
they use and take appropriate steps, as possible, to reduce noise levels and annoying
characteristics.
17.6.2 Avoiding Damage to Adjacent Structures

If the Contractor believes that pile drilling is likely to damage mains, services, or adjacent structures,
they shall submit proposals for conducting preconstruction surveys, monitoring movements or
vibrations, and minimizing or avoiding such damage to the Engineer for review and approval.
17.6.3 Avoiding Damage to Piles

The Contractor shall ensure that pile drilling does not cause displacement or damage that could
impair either performance or durability of completed piles. The Contractor shall submit to the
Page 17-3
Engineer a proposed sequence and timing for drilling piles, including plans and methods to avoid
damaging adjacent piles.
17.7 Obstructions
When unexpected manmade materials prevent the Contractor from advancing an excavation, the
Contractor shall remove such manmade obstructions after notifying the Engineer and explaining the
proposed method for removal. If the Contractor seeks additional compensation to remove such
obstructions, the Contractor must also provide a cost estimate to the Engineer. The Contractor shall
not remove any obstructions without approval from the Engineer, including specific approval for the
proposed method for removal.
The Owner does not consider naturally-occurring material, regardless of difficulty or removal method,
to be an obstruction. The Contractor shall remove all such naturally-occurring impediments at their
own expense as part of the pile drilling activity.
The Owner does not consider the removal of tools that the Contractor loses in an excavation to be
an obstruction. The Contractor shall promptly remove all such tools from the excavation at their own
expense. The Contractor is responsible for all costs for the removal of lost tool, including costs to
correct hole degradation that result from removal operations and any associated time delays.
17.8 Pile Construction Record

The Contractor shall keep records, as outlined in this section, for the installation of each pile and
shall submit two signed copies of these records to the Engineer no later than noon of the next working
day after the pile was installed. Such signed documents constitute a historical and legal record of
the work.
The Contractor shall note any unexpected boring conditions in these records.
Pile construction records shall include the following data:
• The Contract
• Pile reference number (location)
• Pile type
• Nominal cross sectional dimensions or diameter
• Nominal diameter of underream or base
• Standing groundwater level from direct observation or given site investigation data
• Date and time of boring
• Date of concreting
• Ground level at pile position upon commencement of pile installation.
• Working level on which piling base machine stands
• Depth from ground level at pile position to pile toe level
• Toe level
• Pile head level, as constructed
• Pile cut-off level
• Length of temporary casing
• Length of permanent casing
• Soil samples taken and in situ tests carried out during pile formation or adjacent to piles
• Length and details of reinforcement
• Type of concrete mix (materials and composition)
• Volume of concrete supplied to pile (where this can be measured)
• All information regarding obstruction delays and other interruptions to the sequence of work
• Integrity testing (whether this is low or high frequency)
• Verticality and tolerance achieved
• Treatment of pile base to minimise contamination
Page 17-4
17.9 Construction Tolerances

The Contractor shall maintain the following tolerances when constructing drilled piles:
a. A drilled pile shall be within 75 mm of its planned position in the horizontal plane at the plan
elevation for the top of the pile.
b. A pile excavation’s vertical alignment shall not vary from its planned alignment by more than
1 in 75.
c. After placement of all the pile concrete, the top of a reinforcing steel cage shall be no more
than 150 mm above and no more than 75 mm below its planned position.
d. Casing, when used, shall have an outside diameter not less than the pile diameter shown in
the Contract documents. When casing is not used, the minimum diameter for a drilled pile
with a diameter of 600 mm or less shall exactly match the diameter shown in the Contract
documents, whereas drilled piles with diameters greater than 600 mm shall have diameters
that are no smaller than 25 mm less than the diameter shown in the Contract documents.
e. Excavation of the bearing area of bells shall have an area that is no less than the planned
bearing area.
f. All other plan dimensions shown for the bells may vary, when approved by the Engineer, to
accommodate equipment used.
g. A pile’s top elevation shall be within 50 mm of its planned elevation.
h. A pile excavation’s bottom shall be normal to the axis of the pile within 60 mm per meter of
pile diameter.
The Owner shall not accept drilled pile excavations that cannot be completed within the required
tolerances. In such cases, the Contractor shall submit correction methods to the Engineer for
approval, which must be obtained before the Contractor continues with the construction of drilled
piles.
The Contractor shall furnish materials and work that are necessary to effect correction for out-of-
tolerance drilled pile excavations at no cost to the Owner.
17.10 Pile Construction

Construction of drilled foundation piles shall meet all requirements outlined in this section.
17.10.1 Protection of Existing Structures

The Contractor shall take all reasonable precautions to prevent damage to existing structures and
utilities. Such measures shall include, but are not limited to, the following activities:
a. Construction methods and procedures that prevent excessive caving of the pile excavation
b. Monitoring and controlling vibrations caused by the driving of casing or sheeting, drilling of
the pile, dewatering or leakage of bentonite, or blasting (when such is permitted by the
Engineer)
17.10.2 Submittals for Drilled Pile Construction

Submittals for drilled pile construction shall meet all requirements outlined in Table 17-2.
Table 17-2: Requirements for drilled pile construction submittals
Requirement Details
Pile Design Tentative pile depths shown on the Contract plans shall be confirmed or modified
Confirmation based on the Contractor’s soil investigation and geotechnical report submitted
to the Engineer for review and approval.
Page 17-5
Requirement Details
Shop Drawings The Contractor shall submit shop drawings to the Engineer for approval in
accordance the Contract standard specifications.
Method The Contractor shall submit a method statement to the Engineer for approval.
Statement This statement shall propose equipment and procedures for constructing piles
and include details of Non-working pile load tests. No work shall commence until
the Engineer approves the method statement and Non-working pile load testing
is complete and approved.
Materials The Contractor shall submit all proposed materials to the Engineer in
Submittals accordance with the relevant sections of the Contract standard specifications.
The Contractor’s submittals shall include full details of the proposed mix design
for concreting the piles, casing, rebar, spacers, and concrete. No work shall
commence until the Engineer approves the proposed materials.
Quality Control The Contractor shall submit a detailed quality control plan for all activities related
to drilled piles. Such plan shall define selected tests to be performed, test
methods to be used, and property requirements that must be met to ensure that
the material and operation functions as intended. A quality plan must take into
consideration the anticipated subsurface conditions and pile construction
methods, in accordance with the slurry manufacturer's recommendations and
these specifications.
Reports The Contractor shall inform the Engineer each day of the intended piling program
for the following day and shall give adequate notice of intention to work outside
normal hours or over weekends.
17.10.3 Drilled Pile Construction Sequence

All excavations of the foundation in which drilled piles are to be constructed shall be complete before
the Contractor begins pile construction.
Unless the Contract documents indicate that drilled piles are to be installed in conjunction with
embankment placement, the Contractor shall construct them after placing the fill. Otherwise,
allowance for negative drag shall be considered. The Contractor shall investigate a pile’s group
action to determine the proximity of adjacent boring.
17.10.4 Drilled Pile Construction Methods

Excavations required for piles and bell footing, through whatever materials are encountered, shall
comply with the dimensions and elevations specified in the Contract documents or as directed by
the Engineer. Methods and equipment shall be suitable for the intended purpose and the materials
encountered. Generally, the Contractor may apply either the dry method, the wet method, the
temporary casing method, or the permanent casing method, as necessary to produce sound, durable
concrete foundation piles that have no defects.
The Contractor shall use the permanent casing method only when required by the Contract
documents or with the Engineer’s direct authorization. When the Contract documents require a
particular method of construction, the Contractor shall use that method. If the Contract documents
do not specify a particular method, the Contractor shall select and use the most effective method to
properly accomplish the work, as determined by site conditions. Such methods are subject to
Page 17-6
17.10.4.1 Dry Method

When a site is on relatively dry land with a very deep groundwater table and site conditions are
suitable to permit pile construction, the Contractor shall use the dry construction method.
With the dry method, a pile’s sides and bottom remain stable without any caving, sloughing, or
swelling and may be visually inspected before the placement of concrete.
Steps for the dry method include drilling the pile, removing accumulated water and loose material
from the excavation, placing the reinforcing cage, and placing the pile concrete in a relatively dry
excavation.
17.10.4.2 Wet Method

When a site is in an area where a dry excavation cannot be maintained for the placement of the pile
concrete, the Contractor shall use the wet construction method. This method consists of using water
or mineral slurry to maintain stability of a hole's perimeter while advancing the excavation to its final
depth, placing a reinforcing cage, and concreting the pile.
Using the wet method involves the following work:
a. Desanding and cleaning the slurry
b. Cleaning the excavation using a bailing bucket, air lift, submersible pump, or other approved
device
c. Place pile concrete with a tremie or concrete pump, beginning at a pile’s bottom
d. Providing, as needed, temporary surface casings to aid pile alignment and positioning
e. Providing temporary surface casings to prevent sloughing of the top of the pile excavation,
unless it can be satisfactorily demonstrated that the surface casing is not required
17.10.4.3 Temporary Casing Construction Method

The Contractor shall use the temporary casing construction method when neither the dry or wet
construction method is appropriate.
As an alternative to using the wet excavation method, the Contractor may use vibratory or driving
procedures to install temporary casing before excavation to the lower limits of the caving material.
Before and during the withdrawal of casing, 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 pile
concrete.
To remove casing, the Contractor shall apply a rotary movement, downward pressure, and tapping
with a vibratory hammer to ease the extraction. Casing extraction shall be at a slow and uniform rate
with the pull aligned with the pile axis.
17.10.4.4 Permanent Casing Construction Method

The Contractor shall use the permanent casing construction method when required by the Contract
documents. This method involves driving or drilling a casing to a prescribed depth before excavation
begins. If this method cannot attain full penetration, the Engineer may require either excavation of
material within the embedded portion of the casing or excavation of a pilot hole ahead of the casing
until the casing reaches the desired penetration. Some cases may require over reaming to the
outside diameter of the casing to advance the casing.
A casing shall be continuous between the elevations shown in the Contract documents. The
Contractor shall not substitute temporary casing for permanent casing or add temporary casing to
permanent casing, except when specified in the Contract documents or so authorized, in writing, by
the Engineer.
After installing a casing and completing pile excavation, the Contractor shall place the reinforcing
steel and pile concrete within the portion of the casing that remains in place.
Page 17-7
17.10.4.5 Alternate Construction Methods

The Contractor may propose alternate methods to prevent caving and control ground water. Such
proposals, accompanied by supporting technical data, shall be submitted to the Engineer for
approval before the commencement of any related work.
17.10.5 Drilling
If the Engineer determines that foundation material encountered during pile drilling is unsuitable or
differs from design expectations, the Contractor may, during construction, adjust a pile’s bottom
elevation from that shown in the Contract documents.
The Contractor shall take soil samples or rock cores in accordance with the Contract documents or
directions from the Engineer to determine the characteristics of materials directly below a pile
excavation. After inspecting the samples or cores, the Engineer shall determine the final depth of a
pile’s excavation.
Disposal of excavated materials that are removed from a pile excavation and any used drilling fluids
shall comply with the Contract documents or directions from the Engineer.
When the Contract documents show bell footings, the Contractor shall excavate them, using
mechanical methods, to form a bearing area of the size and shape shown.
The Contractor shall give special consideration to the following requirements:
a. Before boring, the Contractor shall check the casing position for each pile during and
immediately after placing the casing; they shall get verification for such positions from the
Engineer.
b. The Contractor shall bore piles sufficiently far from other piles that have recently been cast
or that contain workable or unset concrete to avoid the induction of concrete flow from such
piles or damage to any such piles. A minimum spacing of 3.0m or three times the pile
diameter shall be provided.
c. Any proposals from the Contractor for ground treatment of any nature or for temporary
lowering of the water table (by well pointing or any other method) shall be subject to approval
by the Engineer. The Contractor shall, however, retain full responsibility for any effects to
existing roads, buildings, and structures in the vicinity of the Project works that result from
such ground treatment or control of water table levels.
d. Any proposals from the Contractor for underpinning, needling, and shoring structures in the
vicinity of the works shall reflect careful design. Such proposed designs shall be subject to
e. Where boring takes place through unstable water bearing strata, the process of excavation
and the depth of casing employed shall be such that soil from outside the area of the pile is
not drawn into the pile section and cavities are not created outside the casing as it is
advanced.
f. Where the use of drilling fluid is specified or approved for maintaining the stability of a bore,
the Contractor shall maintain the level of drilling fluid in the pile excavation within the cased
or stable bore so that it is not less than 1.0 meter above the level of external standing
groundwater at all times.
g. If a pile excavation loses drilling fluid rapidly, the Contractor shall backfill the bore without
delay and obtains instructions from the Engineer before resuming boring activity at that
location.
h. The Contractor shall take all reasonable steps to prevent the spillage of drilling fluid on the
site in areas outside the immediate vicinity of boring. Discarded drilling fluid shall be removed
from a site without undue delay. Any disposal of the drilling fluid shall comply with the
regulations of the local authorities.
i. For a pile constructed in a stable cohesive soil without the use of casing or other form of
support, the Contractor shall bore piles and place concrete without so long a delay that
significant impairment of the soil strength can occur.
Page 17-8
j. Each pile bore that does not contain standing water or drilling fluid shall be inspected directly
or indirectly before concrete placement. The Contractor shall provide equipment to enable
his representative and the Engineer such inspection. The Contractor shall verify the capacity
of the excavated base for each end-bearing pile.
k. After completing boring, when inspection of a pile bore indicates that such action is
necessary, the Contractor shall remove loose, disturbed, or softened soil from the bore.
Where pile bores contain water or drilling fluid, thorough cleaning shall precede concrete
placement. To remove large debris or accumulated sediment, the Contractor shall use
appropriate approved methods that clean bores while minimizing ground disturbance below
pile bases. Water or drilling fluid shall remain at controlled levels throughout and following
cleaning to preserve bore stability.
17.11 Support for Pile Bores

The Contractor shall bear full responsibility for selecting and executing methods to stabilize and
maintain pile excavations. Walls and bottoms of pile excavations shall have sufficient protection to
prevent sidewall caving and bottom heaving. Such protection shall ensure that soil adjacent to a
pile’s bore shaft is not disturbed.
17.11.1 Support Fluid

Pile drilling processes shall use mineral slurry with both a mineral grain size that will remain in
suspension and sufficient viscosity and gel characteristics to transport excavated material to a
suitable screening system. Such fluid shall have a percentage and specific gravity that are sufficient
to maintain an excavation’s stability and to allow proper concrete placement.
During drilling, slurry levels shall remain sufficiently high to prevent a hole from caving in.
Mineral slurry shall be premixed thoroughly with clean fresh water, and adequate time shall be
allotted for hydration prior to introduction into the pile excavation.
The Contractor shall provide adequate slurry tanks when such are a specified requirement in the
Contract documents. The Owner does not permit excavated slurry pits. The Contractor shall provide
adequate desanding equipment when such is specified in the Contract documents. The Contractor
shall take necessary steps, such as agitation, circulation, and property adjustment, to prevent slurry
from hardening in a pile excavation.
Using suitable apparatuses, the Contractor shall conduct control tests on the mineral slurry to
determine its unit weight (density), viscosity, and acidity (pH value). Table 17-3 and
Table 17-4 show acceptable values for those physical properties.
17.11.2 Use of Bentonite

All use of bentonite shall conform to the following requirements:
a. Bentonite, as supplied to a site and before mixing, shall comply with Specification DFCP-4 of
the Oil Companies Materials Association.
b. The Contractor shall obtain a certificate from the bentonite manufacture that shows the
properties of each consignment delivered to the Project site. The Contractor shall make this
certificate available to the Engineer on request.
c. Certified properties shall include the apparent viscosity range (in centipoises) and the gel
strength range (in newtons per square metre) for solids in water.
d. Bentonite shall be mixed thoroughly with clean fresh water to make a suspension that will
maintain a pile bore’s stability for the period necessary to place concrete and complete
construction. Temperatures of water used in mixing a bentonite suspension and of the
suspension itself when supplied to the borehole shall exceed 5° C.
Page 17-9
e. Wherever saline or chemically contaminated groundwater occurs, the Contractor shall take
special precautions to modify a bentonite suspension or to prehydrate the bentonite in fresh
water to render it suitable in all respects for pile construction.
f. The Contractor shall propose drilling fluid testing frequencies, sampling methods, and
sampling procedures to the Engineer for approval before commencing work. With the
Engineer’s approval, the Contractor may subsequently vary testing frequencies, depending
on fluid consistency.
g. The Contractor shall conduct control tests on bentonite suspensions, using suitable
apparatus. The Contractor shall measure the density of a freshly mixed bentonite suspension
every day to verify the quality of the suspension being formed. A measuring device for such
test shall be calibrated to read to within 5g/L. Tests to determine density, viscosity, shear
strength, and acidity (pH value) shall be applied to bentonite supplied to a pile bore. For sites
with average soil conditions for the Project, results of bentonite suspension tests shall
generally fall within the ranges shown in Table 17-3.
h. Testing shall continue until a consistent working pattern has been established, taking into
account the mixing process, any blending of freshly mixed bentonite suspension, and
previously used bentonite suspension. When test results show that bentonite for the Project
has consistent behaviour, the Contractor may discontinue tests for shear strength and acidity,
but shall continue tests to determine density and viscosity in accordance with direction from
the Engineer. In the event of a change in the established working pattern, the Contractor
shall reintroduce tests for shear strength and acidity as necessary.
Table 17-3: Bentonite slurry properties
Slurry Unit Range of results at 20o C Test method

property
Fresh Before
concreting
Density g/cm3 <1.10 <1.15 Mud density balance
Viscosity Sec 32 to 50 32 to 50 Marsh funnel and cup
pH 8.0 ~ 11 - pH indicator paper strips or electrical pH

meter
Sand content % - 4.0 %
Testing methods pertaining to Table 17-3 shall conform to American Petroleum Institute (API)
standards, as outlined in their standard procedure for testing drilling fluids (API–RP13B). The
following equivalent test methods as per ASTM Standards can also be followed:
• ASTM D4380-12: Standard Test Method for Density of Bentonitic Slurries
• ASTM D6910/D6910M-09: Standard Test Method for Marsh Funnel Viscosity of Clay
Construction Slurries.
• ASTM D4381/D4381M-12: Standard Test Method for Sand Content by Volume of
Bentonitic Slurries.
17.11.3 Polymer Slurry

Polymer slurries shall be used in conformance with a manufacturer's recommendations and shall
conform to the quality control plan specified in Section 17.10.2. Only synthetic slurry systems that
have been approved by the Engineer may be used. The polymer slurry shall conform to the
requirements shown in Table 17-4.
Page 17-10
Table 17-4: Polymer slurry properties
Slurry property Unit Requirements Test method
Density g/cm3 1.03 Max Mud density balance
Viscosity Sec 32 to 135 Marsh funnel and cup
pH 8.0 ~ 11.5 pH indicator paper strips or

electrical pH meter
Sand content % 1.0% Max
When doing so is approved by the Engineer, the Contractor may use polymer slurry in salt water and
increase allowable densities to up to 3.0% over the value in
Table 17-4.
A polymer slurry’s sand content before final cleaning and immediately before concrete placement
shall be less than or equal to 1.0 percent, in accordance with the section 5 of the American Petroleum
Institute’s standard procedure for testing drilling fluids (API 13B-1). Slurry temperature shall be at
least 4.4° C when tested.
17.11.4 Casings
Casings for drilled foundation piles shall comply with the requirements outlined in this section.
17.11.4.1 General Casing Requirements for Drilled Piles

Casings shall be metal, smooth, clean, watertight, and of ample strength to withstand handling,
driving, extraction stresses, and the pressure of both concrete and surrounding earth materials. A
casing’s inside diameter shall not be less than the pile’s specified size.
If the Project plans specify a minimum thickness for casing, this thickness only satisfies structural
design requirements. The Contractor shall ensure that casing thicknesses satisfy the requirements
of construction installation, even when such thicknesses exceed the minimum.
17.11.4.2 Permanent structural Casing

A permanent structural casing is a part of the pile structure that provides stiffness or load carrying
capacity and shall remain in place after construction is complete.
17.11.4.3 Permanent Non-structural Casing

A permanent non-structural casing assists in the construction of the drilled pile and, like a permanent
structural casing, shall remain in place after construction is complete.
17.11.4.4 Temporary Casing

A temporary casing facilitates pile construction only, is not part of the pile structure, and shall be
removed completely after pile construction is complete, unless the Contract plans indicate otherwise.
All temporary casings shall be smooth-walled structural steel, unless the Contract plans indicate that
corrugated metal pipe is an acceptable alternative.
The casing shall be easy to remove without deforming or damaging the completed pile and without
disturbing surrounding soil.
Page 17-11
The Contractor shall remove temporary casings while concrete remains workable. Generally, the
Contractor shall begin to remove a temporary casing when concrete placement in a pile is at or
above ground level.
To remove casing, the Contractor shall apply a rotary movement, downward pressure, and tapping
with a vibratory hammer to ease the extraction. Casing extraction shall be at a slow, uniform rate
with the pull aligned with the pile axis. The Contractor shall not excessively rotate a casing to limit
deformation of the reinforcing steel cage.
Maintenance of a sufficient head of concrete above the bottom of a casing shall overcome the
hydrostatic pressure of water or drilling fluid outside the casing.
17.12 Placement of Pile Concrete

The Contractor shall place concrete as soon as possible after completion of drilled pile excavation
and after the Engineer inspects and approves the excavation.
Before placing concrete, the Contractor shall take measures to ensure that silt and other materials
do not accumulate at the base of a boring. The Contractor shall clean a pile’s bottom (bearing
stratum) immediately before placing concrete.
17.12.1 Concrete for Drilled Piles

When the Contract documents specify a designed concrete mix, the Contractor shall be responsible
for selecting the mix proportions to achieve the required strength and workability, but the Engineer
will be responsible for specifying the minimum cement content and any other properties required to
ensure durability.
Concrete for drilled piles shall have sufficient workability to enable it to be placed and compacted by
the methods used in forming the piles.
For piles that are exposed to potentially aggressive ground or groundwater, the Contractor shall take
approved measures to ensure durability.
A mix’s cement content shall not be less than 360 kg per cubic metre. Where concrete will reside
under water or drilling mud, such mix shall not contain less than 380 kg of cement per cubic metre.
Where a pile will be exposed to sea water, a mix shall contain at least 400 kg of cement per cubic
metre. No mix shall have a water-to-cement (W/C) ratio greater than 0.4 and as described in Table
4-16 of Chapter 4, Concrete Works, of the Standard Specifications.
All concrete aggregates, cement, and water shall be sampled and tested as frequently as the
Engineer deems necessary. The Contractor shall supply all test samples at their own expense.
The Contractor shall prepare concrete trial mixes to show that the proposed mix proportions and
manufacture will produce concrete of the required strength and quality and shall have adequate
workability for compaction by the method to be used in placement.
The Contractor shall keep a detailed record of the results of all tests on concrete and concrete
materials. Each test shall be clearly identified to associate it with the piles to which it relates.
17.12.2 Placing Concrete under Water or Support Fluid

To place concrete that will reside under water or drilling fluid, the Contractor shall use the tremie
method and shall ensure that concrete is not discharged freely into the water or drilling fluid. Where
appropriate, the Engineer may approve pumping concrete.
A sample of the drilling fluid shall be taken from the base of the boring by using an approved sampling
device. If the specific gravity of the suspension exceeds 1.2 g/cm3, the Contractor shall not proceed
with concrete placement. In this event, the Contractor shall use a method approved by the Engineer
to modify or replace the drilling fluid to meet the specification.
Page 17-12
Concrete shall be placed in such manner that segregation does not occur.
Throughout concrete placement, the tremie’s hopper and pipe shall be clean and watertight. A
tremie’s pipe shall extend to the base of the bore and include a sliding plug or barrier to prevent
direct contact between the first charge of concrete in the tremie and the water or drilling fluid.
At all times until placement of concrete is complete, a tremie pipe shall penetrate the concrete that
was previously placed and shall be withdrawn at a rate such that ensures a minimum concrete head
of 2.0 m over the end of the tremie. A tremie pipe’s internal diameter shall not be less than 150 mm
and its maximum size aggregate shall be 20 mm. External projections on a tremie pipe shall be
minimized to enable the tremie to pass within the reinforcing cages without causing damage. A
tremie pipe’s internal face shall not have any projections.
Concrete placement shall be one continuous operation. If the Contractor suspects that any
interruption to concrete placement has caused a cold joint, they shall chip the concrete, clean the
pile with compressed air to a level 50 mm below the joint’s surface, and apply a suitable bonding
agent of a type that the Engineer has approved.
Sufficient concrete should overflow the top of a pile to ensure that the pile’s shaft is clear of any
contaminating soil or slurry.
If a concrete placement operation is interrupted, the Engineer may require the Contractor to drill
cores and conduct other tests to prove that the pile contains no voids or horizontal joints. If such
testing reveals voids or joints, the Contractor shall repair them or replace the pile at no additional
cost.
The Contractor shall complete a concrete yield plot for each pile poured by tremie methods and
submit such yield plots to the Engineer no later than 24 hours after pouring concrete.
The Contractor shall not perform pile excavation operations within three diameters of a newly poured
pile any sooner than 24 hours after concrete placement.
17.13 Steel Reinforcement

The Contractor’s shop drawings shall show all bracing and any extra reinforcing steel that is required
to fabricate a reinforcing cage. The Contractor shall be responsible for engineering the temporary
support and bracing of reinforcing cages to ensure that they maintain their planned configuration
during assembly, transportation, and installation. Steel reinforcement shall meet the following
minimum requirements and as described in Chapter 5, Reinforcing Steel, of the Standard
Specifications:
a. At least four vertical bars of each cage, equally spaced around a cage’s circumference, shall
be tied to all reinforcement intersections with double wire ties.
b. At least 25 percent of remaining reinforcement intersections in each cage shall be tied with
single wire ties. Tied intersections shall be staggered from adjacent ties.
c. Bracing shall prevent the collapse of each cage during its assembly, transportation, and
installation. At no additional cost, the Contractor shall provide any additional reinforcement
that is needed to allow a cage to be safely lifted and lowered.
d. Hoops, links, or helical reinforcement shall fit closely around the main longitudinal bars and
be bound to them by approved wire, the ends of which shall be turned into a pile’s interior.
Successful compliance with these minimum baseline requirements for reinforcement cages shall in
no way relieve the Contractor of full responsibility for engineering the temporary supports and bracing
of the cages during construction. Such reinforcement shall be carefully positioned and securely
fastened to provide minimum clearances (as described in this section) and to ensure that no
displacement of the reinforcing steel cage occurs during concrete placement.
Each steel reinforcing cage shall be securely held in position throughout concrete placement to
provide the specified projection of reinforcement above the final cut-off level.
Page 17-13
Reinforcing steel in a pile shall be tied and supported so that the location of the reinforcing steel will
remain within allowable tolerance. The Contractor shall tie the bars to lateral tie bars at all
intersections. Concrete spacers or other approved noncorrosive spacing devices along a pile’s
bottom, along a pile’s top, and at sufficient intervals (not more than 2.0 meters vertically) shall ensure
concentric spacing for the entire cage length. Each level requires at least four spacers. Such spacers
shall be of adequate dimension to ensure an annular space between the outside of a reinforcing
cage and the side of the excavation along the entire length of a pile, as shown in the Contract plans.
The cover to all reinforcement in cast in place piles shall be not less than 100 mm unless otherwise
approved by the Engineer.
Acceptable feet made of plastic or concrete (bottom supports) shall ensure that the bottom of each
cage remains at the proper distance above the base of an excavation, unless a cage is suspended
from a fixed base when the Contractor pours concrete.
To allow concrete placement after lifting a cage, the Contractor shall remove bracing steel that
constricts the interior of a reinforcing cage.
Longitudinal steel bars shall have as few laps as possible. Joints in reinforcement shall be such that
the full strength of each bar is effective across the joint and shall be made so that there is no
detrimental displacement of the reinforcement during the construction of a pile.
17.14 Withdrawal of Temporary Casing

The Contractor shall extract temporary casings while the concrete within them remains sufficiently
workable to ensure that the concrete is not lifted. During extraction, the motion of a temporary casing
shall remain in an axial direction relative to its associated pile.
When extracting a casing, the Contractor shall maintain a sufficient quantity of concrete within it to
resist pressure from external water, drilling fluid, or soil and to ensure that the associated pile is
neither reduced in section nor contaminated.
When extracting a temporary casing, the Contractor shall top off the concrete level as necessary to
ensure that the base of the casing is always below the concrete surface until the casting of the
associated pile is complete.
When withdrawing a temporary casing could displace water or fluid as concrete flows into its final
position against the walls of a pile bore, causing excess heads of water or drilling fluid, the Contractor
shall take adequate precautions. Where two or more discontinuous lengths of casing (double casing)
are used in the construction, the Contractor shall obtain approval from the Engineer for their
proposed method of working.
During extraction of temporary casings, where circumstances are such that newly placed unset
concrete is brought into contact with external groundwater, the Contractor shall take precautions to
ensure that the internal concrete pressure at all levels within a pile exceeds the external groundwater
pressure.
17.15 Finishing Pile Heads

For piles cast in dry bores using temporary casing and without the use of a permanent lining, pile
heads shall be cast to a level above the specified cut-off so that, after trimming, a sound concrete
connection with the pile can be made. A pile’s casing level shall be within the tolerance above the
cut-off level shown in Table 17-5, but shall not be above the commencing surface level. No pile shall
be cast with its head below standing water level unless the Contractor takes approved measures to
prevent the inflow of water from causing segregation of the concrete when a temporary casing is
extracted.
Page 17-14
Table 17-5: Casting tolerance for piles cast in dry bores using temporary casing and without
a permanent lining
Cut-off distance below Casting tolerance above Cut-off Level (m)

commencing surface H (m)
0.15 - 10.00 meters 0.3+H/12+C/8 meters

H = Height of the commencing surface
C = length of temporary casing below the
commencing surface
For piles cast in dry bores within permanent lining tubes or permanent casings, or where pile cut-off
levels are in stable ground below the base of any casing used, pile heads shall be cast to a level
above the specified cut-off so that, after trimming, a sound concrete connection with the pile can be
made. Casting levels shall be within the tolerance above a pile’s cut-off level as shown in Table 17-6,
but shall not be above the commencing surface level.
Table 17-6: Casting tolerance for piles cast in dry bores within permanent lining tubes,
permanent casings, or where cut-off levels are in stable ground below the base of any
casing used
Cut-off distance below Casting tolerance above Cut-off Level

0.15 - 10.00 meters 0.3 + H / 10 meters

H = Height of the commencing surface
For piles cast under water or drilling fluid, the pile heads shall be cast to a level above the specified
cut off so that, after trimming to remove all debris and contaminated concrete, a sound concrete
connection with the pile can be made. The casing level shall be within the tolerance above the cut
off level shown in Table 17-7, but shall not be above the commencing surface level. Cut off levels
may be specified below the standing groundwater level, and where this condition applies the
borehole fluid level shall not be reduced below the standing groundwater level until the concrete has
set.
Table 17-7: Casting tolerance for piles cast under water or drilling fluid*
Cut off distance below Casting tolerance above Cut-off Level (m)
0.15 - 10.00 0.3+H /12+C/8

Where C = length of temporary casing below the
commencing surface
* In cases where a pile is cast so that the cut-off is within a permanent lining tube, the appropriate
tolerance is given by deletion of the casing term (C/8).
Where a pile’s cut-off level is deeper than 10 meters below the commencing surface, the Contractor
must alter the tolerances given in Table 17-5, Table 17-6, Table 17-7, taking special conditions into
account and based on discussion with the Engineer, before commencing piling.
When cutting off and trimming a pile to its specified cut-off level, the Contractor shall avoid shattering
or otherwise damaging the rest of the pile. The Contractor shall cut away any cracked or defective
Page 17-15
concrete and repair the pile repaired in a manner approved by the Engineer to provide a full and
sound section at the cut-off level.
17.16 Pile Testing

The Contractor shall conduct a total number of pile tests on working piles as specified in the Contract
plans or as required by the Engineer. An independent testing organization that has been approved
by the Engineer shall monitor and analyse all load tests.
Terms and their definitions given below apply to pile testing.
Compression Pile: A pile that, by design, resists axial force that would cause it to penetrate further
into the ground.
Non-working Pile: A pile installed before the commencement of the main piling works as a test pile
specifically installed to establish suitability and to confirm a pile’s dimensions and capacity.
Working Pile: Any pile installed as part of the permanent work.
Test Pile: Any pile to which a test is or will be applied.
Kentledge: A dead weight used in a static loading test.
Reaction System: An arrangement of kentledge, piles anchors, or rafts that provides a resistance
against which a pile is tested.
Maintained Load Test: A loading test in which each increment of load is held constant either for a
defined period of time or until the rate of movement (settlement or uplift) falls to a specified value.
Such testing accounts for thermal allowances.
Failure Load Test: A load test applied to a Non-working pile. Normally, a load for this test should
be 200% of a pile’s estimated working load unless specified otherwise. However, in all cases the test
load shall not exceed 300% of the pile’s working load. This test evaluates soil parameters that
designers use to determine the required lengths of working piles.
Working Load Test: A load test that is applied to a selected working pile to confirm that it is suitable
for the load at the specified settlement. Normally, a load for this test should not exceed 150% of a
pile’s service design load. This test serves as a quality control check on working piles.
Allowable Load: A maximum load that may be safely applied to a pile. This load takes into account
a pile’s section ultimate capacity, negative skin friction, pile spacing, overall bearing capacity of the
ground below, and allowable settlement.
Working load: A load that a pile is designed to carry without exceeding the specified allowable
settlement requirement.
Integrity Testing: Low-frequency or high-frequency dynamic testing that verifies that a pile’s body
is free of defects.
17.16.1 Measuring Devices

The Contractor shall submit their proposed method of measuring the movement of pile heads and
load to the Engineer for approval.
17.16.1.1 Measurement of Load

To measure a pile’s load, the Contractor shall use a load measuring device and a recently-calibrated
pressure gauge included in a pile’s hydraulic system. The Contractor shall record readings from both
the load measuring and the pressure gauge. In interpreting the test data, the values given by the
load measuring device shall normally be used. Readings from the pressure gauge provide a check
for gross errors.
Page 17-16
A load measuring device may consist of a proving ring, load measuring column, pressure cell, and
other appropriate systems. Any devices that are sensitive to eccentric loadings shall include a
spherical sheathing. Load measuring devices and jacks shall have short axial lengths to achieve the
best possible stability. The Contractor shall be careful to avoid any risk of buckling. The Contractor
shall also ensure that axial loading remains constant throughout load testing. Loads during testing
shall not fall below 1% of a pile’s specified load.
To modify the load testing requirements outlined in this section in any way, the Contractor must
obtain the Engineer’s authorization in advance.
Load measuring devices shall be calibrated before and after each series of tests, whenever
adjustments are made to the device or at intervals appropriate to the type of equipment. Pressure
gauges and hydraulic jacks shall be calibrated together.
The Contractor shall supply certificates of calibration, performed by an approved testing laboratory,
to the Engineer before conducting load testing. The calibration certificate shall be recent and in all
cases shall not be older than 6 months from the test date.
17.16.1.2 Measurement of Settlement

To measure settlement, the Contractor shall use a reference beam or wire that is supported
independently of the pile begins tested, reaction piles, or piles that support reaction loads.
Settlements shall be measured to the nearest 0.1 mm for reference beams and to the nearest 0.5
mm for reference wires. The Contractor shall use a precise optical level to check movements of the
reference frame against an independent datum. Reference beam supports shall be at least 3 meters
from test piles, reaction piles, or piles that support reaction loads. Reference beams or wires shall
be protected from the effects of temperature changes. Construction equipment and persons not
involved in settlement measurement shall remain well clear to avoid disturbing the measuring
system. Pile drilling or similar operations shall not occur in the vicinity of the test unless the Engineer
is satisfied that such activity will not affect the measuring system.
To obtain precise measurements of deflections, the Contractor shall use at least four dial gauges
that are equally spaced around the head of a test pile to collect measurements. Such measurements
shall be accurate to within 0.01 mm to ensure that the information on pile bending and axial
movement is useful. Dial gauges that are firmly attached to the reference beams shall ensure that
plungers are parallel to a tested pile’s axis. Plunger points shall bear onto reference plates by means
of machined plates or glass slides that are attached to a tested pile’s head. Reference plates shall
be equidistant from the centre of a tested pile’s axis to eliminate axial components that sideways
movements could otherwise produce. The Contractor shall also monitor and document elastic
deformation.
With authorization from the Engineer, the Contractor may implement other suitable and adequate
methods to measure the movement of pile heads.
Before conducting load tests, the Contractor shall give the Engineer certificates that verify that an
approved testing laboratory has calibrated all dial gauges that will be used.
17.16.2 Reaction System

All reaction systems for drilled foundation piles shall comply with the requirements outlined in this
section.
17.16.2.1 Compression Tests

To test compression loaded drilled piles, the Contractor shall use a kentledge reaction system,
tension piles, ground anchors, or otherwise specially-constructed anchorage. The Owner prefers the
use of a kentledge system for load tests on vertical piles; the Engineer shall permit the use of tension
reaction piles, ground anchors, or other tension reaction systems only when use of a kentledge
system proves impractical. The Contractor shall not use a kentledge system to test raking piles.
Page 17-17
A kentledge system, when used, shall be supported on cribwork that is disposed around a tested
pile’s head so that its centre of gravity is on the pile’s axis. Bearing pressures under supporting cribs
shall ensure stability of a kentledge system’s stack. A tested pile’s head shall not directly carry a
kentledge system unless the Engineer specifically directs such as arrangement.
A kentledge system may include concrete blocks, steel weight, and other components, but such
components must be of uniform size so that the Contractor can easily calculate the total weight of
the kentledge.
17.16.2.2 Working Piles in a Reaction System

Without authorization from the Owner, the Contractor shall not use working piles as reaction piles.
When using working piles as reaction piles, the Contractor shall measure their movement to the
nearest 0.5 mm. The Contractor shall revise the design of the working piles that intended to be used
as reaction piles to ensure its adequacy to the applied load.
17.16.2.3 Ground Anchors in a Reaction System

Ground anchors shall be pre-loaded to provide reaction greater than the specified capacity of the
test assembly. Such pre-loading shall prevent unrestrained lateral movement by maintaining
sufficient contact stress throughout pile tests between loading beams and loading beam supports.
The Contractor shall obtain approval from the Engineer to pre-load ground anchors.
Each ground anchor shall be loaded to 1.2 times its approved capacity. A ground anchor shall hold
this load held for five minutes while the Contractor measures and records tendon extension at one
minute intervals. If these measurements indicate that the ground anchor is satisfactory, the
Contractor may lock it at an accepted load that exceeds the anchor’s pre-loading force to allow for
loss due to creep.
Anchor piles and ground anchors, when used, shall be at least 2.5 metres or three times the pile
diameter from the test pile, measured centre to centre, or at a greater distance if the Engineer so
directs. The Contractor must ensure that such anchors cannot be pulled out, with a safety factor of
at least 2.0. Soil and rock properties that the Contractor uses to determine this safety factor shall
have approval of the Engineer.
17.16.2.4 Spacing Between Piles and Reaction System Structures

When the Contractor uses a kentledge reaction system to load vertical piles in compression, the
edge of a test pile shall be at least 1.3 metres from the nearest part of the crib that supports the
kentledge system’s stack that also contacts the ground.
Centre-to-centre spacing between vertical reaction piles, including working piles that function as
reaction piles, and any test pile shall be at least five times the diameter of a test pile, five times the
diameter of the reaction piles, or three metres, whichever is greater. The Engineer may modify the
pile spacing requirement to suit site conditions at no extra costs.
Where ground anchors provide a test reaction for loading in compression, no part of the section of
the anchor that transfers load to the ground shall be closer to a test pile than three times the test
pile’s diameter. The Engineer may modify the pile spacing requirement to suit site conditions at no
extra costs.
17.16.2.5 Requirements for Piles and Anchors in a Reaction System

A reaction system shall have piles and anchors of sufficient sizes, lengths, and quantities to safely
transmit the maximum test load to the ground without excessively moving or influencing test piles.
Page 17-18
17.16.2.6 Care for Piles

The method employed in the installation of any reaction piles, anchors shall be such as to prevent
damage to any test pile or working pile.
17.16.2.7 Loading Arrangement

The loading arrangement shall safely transfer the maximum load required for testing to a test pile.
The Contractor shall submit full details to the Engineer for approval before doing any testing activity
at the Project site.
17.16.2.8 Pile Caps and Structural Elements

The Contractor shall design and build all temporary pile caps and other structural elements that form
part of a reaction system. Before commencing work, however, the Contractor shall submit a proposal
for pile caps and structural elements to the Engineer for approval. The Contractor shall bear the cost
of building and demolishing such pile caps and structural elements.
17.16.3 Equipment for Applying Load

One or more hydraulic rams or jacks shall serve as the principle equipment to apply loads to piles.
Such rams or jacks shall be arranged in conjunction with the reaction system to deliver an axial load
to the associated test pile. A complete system shall be capable of transferring the maximum load
required for each test.
Jacks shall have a total capacity that exceeds the required maximum test load by 20% or more,
thereby avoiding a heavy pumping effort when nearing maximum load and minimizing the possibility
of any oil leakage through seals.
Loading equipment shall be capable of adjustment throughout a load test to ensure smooth loads
increases and a consistent load as required at different stages of load testing.
17.16.4 Special Requirements for Test Piles

Test piles shall comply with the special requirements outlined in this section.
17.16.4.1 General Requirements for Test Piles

When preparing for, conducting, and dismantling a pile test, the Contractor shall provide and
maintain safe working conditions in compliance with all requirements of acts, orders, regulations and
other statutory mandates that apply to the specific work. In addition, the Contractor shall make such
other provisions as necessary to safeguard against hazards that are involved in testing or
preparation for testing. All reinforcement for piles that will be used as tensile piles during testing shall
be welded.
17.16.4.2 Personnel for Pile Testing

An experienced and competent supervisor who is conversant with the test equipment and test
procedures shall actively direct all pile tests. All personnel who operate test equipment shall have
been trained in the use of such equipment.
17.16.4.3 Kentledge for Pile Testing

When using kentledge, the Contractor shall construct the foundations for the kentledge and any
cribwork, beams, and other supporting structures to prevent differential settlement, bending, or
deflection that constitute hazards to safety or that impair the efficiency pile testing. Kentledge shall
be adequately bonded, tied, or otherwise held together to prevent it from the falling apart or becoming
unstable.
Page 17-19
The kentledge reaction system shall weigh at least 1.2 times more than the maximum test load.
When using the density and volume of a kentledge system’s constituent materials to estimate weight,
the Contractor shall allow an adequate margin of error to ensure safety. The Contractor shall take
all reasonable steps to ensure that sufficient excess load capacity is at all times available for the
uninterrupted execution of any load test.
17.16.4.4 Tension Piles and Ground Anchors for Load Testing

When using tension piles or ground anchors, the Contractor shall ensure that the load is correctly
transmitted to all the tie rods and bolts. The Contractor shall not extend rods by welding unless doing
so does not weaken the steel. Bond stresses for rods in tension shall not exceed normal permissible
levels for the type of steel and grade of concrete used.
17.16.4.5 Pile Testing Equipment

In all cases, the Contractor shall ensure that, when a hydraulic jack and load measuring devices are
mounted on a test pile’s head, the whole system will be stable under all loads to be applied up to the
maximum test load. To ensure safety, testers shall be able to read dial gauges from a position that
is clear of the kentledge stack or test frame.
Hydraulic jacks, pumps, hoses, pipes, couplings, and other apparatuses to be operated using
hydraulic pressure shall be able to withstand test pressures equal to of one and a half times the
maximum working pressure without leaking.
Gauges on pile testing equipment shall clearly display maximum test loads or test pressures. All
operators shall be made aware of these limits.
17.16.5 Maintained Compression Load Testing for Piles

Static load tests shall follow American Society for Testing and Materials (ASTM) procedures, as
specified in their Standard Test Methods for Deep Foundations Under Static Axial Compressive Load
(ASTM D1143/D1143M-07e1). Loading procedures shall comply with the Quick Load Test Method,
unless detailed longer-term load-settlement data are needed, in which case load testing shall comply
with the standard procedure.
Testing equipment and measuring systems shall also conform to ASTM D1143/D1143M-07e1.
17.16.6 Working Piles

The Contractor shall conduct pile tests on working piles, as directed by the Engineer, any time before
a pile is built into a structure. Such testing helps to ensure that materials, workmanship and
performance comply with the quality standards and the requirements outline in these specifications.
Such tests help determine the displacement (and recovery) of a pile under a maximum test load that
is 1.5 times the working load indicated in the Contract documents.
The Owner prohibits the use of working piles as tension reaction piles for the purpose of conducting
these tests unless approved otherwise.
17.16.7 Pile Testing Procedure

The Contractor shall submit a detailed load testing proposal to the Engineer for approval, and must
have this approval in writing before conducting any load testing.
This proposal shall specify the number of working load tests to be carried out as per the Contract
Documents. The Engineer may reduce the number of tests after such testing routinely and
consistently indicates that workmanship and pile materials are of high quality and if the nature of soil
conditions encountered does not vary substantially. Conversely, the Engineer reserves the right to
increase the number and frequency of tests as needed to verify the quality of workmanship and pile.
Page 17-20
Unless the Engineer directs otherwise, the Contractor shall adhere to the test procedure outlined in
this section, with the percentage for loading and unloading operations given in terms of the working
load taken as 100%.
Table 17-8 provides an example schedule for compression testing; this example schedule is for
guidance only. Actual compression testing schedules for the Project are subject to variation, as
directed by the Engineer, to meet site conditions.
All loading and unloading operations shall take place during the day as possible. The Contractor
shall take at least three sets of readings during each loading or unloading stage, including one set
of readings at the beginning of a stage, a second set in the middle of a stage, and a third set at the
end of a stage. When applying a test load progressively and maintaining it for more than 30 minutes,
the Contractor shall take readings at least once every 30 minutes thereafter, unless the Engineer
specifies otherwise.
If large discrepancies occur between different measurement systems, testing shall pause until the
Contractor corrects the cause for such discrepancies. Testing shall resume from the beginning of
the test for the corrected instance.
Table 17-8: Loading cycles for test piles
Load Time of holding Remarks

load
(percentage of working
load)
25% 1 hour
50% 1 hour
75% 1 hour
100% 1 hour
75% 10 minutes
50% 10 minutes
25% 10 minutes
0% 1 hour
100% 6 hours
125% 1 hour
150% 6 hours
125% 1 hour
100% 10 minutes
75% 10 minutes
50% 10 minutes
25% 10 minutes
Page 17-21
Load Time of holding Remarks

load
(percentage of working
load)
0% 1 hour Applicable to tests on Non-working piles only
100% 6 hours
150% 6 hours
175% 1 hour
200% 6 hours
175% 10 minutes
150% 10 minutes
125% 10 minutes
100% 10 minutes
75% 10 minutes
50% 10 minutes
25% 10 minutes
0% 1 hour
17.16.8 Abandonment of Pile Test

The Contractor shall discontinue testing under any of the following conditions:
a. A jack or gauge is faulty
b. A kentledge reaction system is unstable
c. A data setting is incorrect or improper
d. Bench marks or scales are unstable
e. Measuring instruments have been tampered with by anyone
f. Measuring instruments have not been calibrated
g. Pre-jacking of pre-loading occurred before commencement of testing
h. Settlement exceeded the limits specified for the Project
After halting any test, the Contractor shall rectify the associated errors, consult with the Engineer,
then resume testing in accordance with the Engineer’s instructions.
17.16.9 Pile Testing Record

The Contractor shall submit a written summary of testing to the Engineer no later than 24 hours after
completing a test (unless otherwise directed). This summary shall provide the following details for
each completed test within the 24-hour period:
• The loading stage, the load, the period for which a load was held, and the maximum
settlement or uplift recorded
• Load-to-settlement curve
Page 17-22
The Contractor shall provide a complete set of recorded test data, as described in this section, with
interpretation of test results, within seven days of completion testing. Interpretation of test results
shall comply with directions from the Engineer.
The Contractor shall provide the following details about tested piles, where applicable:
a. General details
Site location
The Contract identification
Proposed structure
The main Contractor
The piling Contractor
The Engineer
The Owner
Date of test
b. Pile details
Identification (number and location)
Position relative to adjacent piles
Brief description of location (for example, whether the tested pile is on a pier, abutment,
cofferdam, or over water)
Ground level at the tested pile’s location
Head level at which the test load was applied
Type of pile (whether vertical, raking, compression, or tension)
Shape and size of the tested pile’s cross-section and the cross-section’s change in
position
Head details
Length in ground
Level of toe
Any permanent casing or core
Pile reference
Concrete mix grading and water-to-concrete (w/c) ratio
Aggregate type and source
Cement type
Slump
Cube test results for the tested pile and cap
Reinforcement
c. Installation details
Dates and times of boring and concreting of test pile and adjacent pile
Date and time when concrete was cast for the tested pile’s cap
Start and finish of each operation during installation of a pile and subsequent testing
Any difficulties in boring, handling, pitching, and driving a pile
Any delays in testing caused by sea, water and weather conditions
Pile diameter
All instrument readings
Concrete strength (when tested)
Date cast
Date of test
Length of reinforcement cage
Water table below ground level
Length of casing
Description of soil for the length of pile (for bored piles and pre-drilling only)
Unusual events or data and movements of the test pile
Any other relevant information requested by the Engineer
Page 17-23
d. Test procedure details

Weight of kentledge
Tension pile, ground anchor, or compression pile details
Plan of test arrangement, showing position and distances of kentledge support, rafts,
tension, or compression piles and relationship of the reference frame to the tested
pile
Jack capacity
Calibration certificates of pressure gauges and dial gauges
Method of load measurement
Proof test by maintained loading
Relevant dates and times
e. Test results
Result data (in a table)
Result data, including load plotted against settlement, load, and settlement (in graphic
form, plotting resultant values over time)
Ground heave
f. Site investigation details
Site investigation report number
Borehole reference
17.16.10 Failure of Working Load Test

Load testing for a pile or pile group shall indicate failure if any one of the following observations is
recorded:
a. A pile’s settlement under one working load exceeds 10 mm or the allowable settlement
defined in the Contract standard specifications
b. Residual settlement after removal of the test load of one working load exceeds 4 mm or the
allowable settlement defined in the Contract standard specifications
c. Instability of the kentledge prevented completion of the test
d. Failure of the pile cap, through whatever cause, prevented completion of the test
e. An involved measuring instrument was tampered with in any way
f. A pile tested cracked, crumbled, distorted from its original shape, was deflected from its
original position, or was otherwise dislocated, marred, damaged, or destroyed
The Contractor shall not be paid for any pile or pile group that fails testing. The Contractor shall bear
the cost for redesign and enlargement of pile caps or, if necessary, for replacement piles. The Owner
shall pay for piles that successfully pass testing, as specified in the Contract documents for the
Project.
17.16.11 Compensating Piles

The Contractor shall replace any pile or pile group that fails under the working load test with one or
more piles in accordance with directions from the Engineer and at no extra cost to the Owner.
If, in the opinion of the Engineer, it is impractical or unadvisable to install substitute piles in place of
a failed pile, the Contractor shall propose a solution to the Engineer for consideration and approval.
The Contractor shall be fully responsible for all costs incurred and any losses incurred by the Owner
for changes in the design of the structure or delay to the Contract that arising from the Contractor’s
proposal.
For each working load test that fails, the Contractor shall carry out, at no extra cost to the Owner, an
additional working load test on a pile selected by the Engineer.
If the additional working load test on the selected pile also shows that this pile is unable to satisfy
the acceptance requirements, then all the piled installed in a similar condition will be considered as
Page 17-24
failed. The capacity of piles installed shall be suitably downgraded based on the working load test
results. Any additional piles required as a result of such reduction in pile capacity, including the cost
for amending pile caps and ground beams, shall be entirely at the Contractor’s expense. The
Engineer’s decision on this matter shall be final.
17.16.12 Reinstatement of Piles After Testing

After completing a test, the Contractor shall check all equipment and measuring devices, dismantle
them, and either store them on the Project site for future tests or remove them from the site.
The Contractor shall remove kentledge systems and their supporting structures from the piles they
tested and either store these systems on the Project site for future tests or remove them from the
site.
After completing a Non-working load test, the Contractor shall cut off temporary piles and ground
anchors at least one metre below ground level or as directed by the Engineer, removed them from
the Project site, and use approved material to restore the ground.
On completing a working load test, the Contractor shall either remove temporary piles and ground
anchors by cutting them off below ground level and using approved materials to restore the ground
or, with the Ownerr’s authorization, incorporate the temporary piles and ground anchors into the
permanents works.
A tested pile’s cap, if concrete, shall be broken up and removed from the Project site. If a tested
pile’s cap is steel, shall be cut off and either stored for use in future tests or removed from the site.
The Contractor shall leave the tested pile in a condition that it is ready for incorporation into the
permanent works.
17.17 Osterberg Cell Load Testing

17.17.1 General
The test shall be carried out in accordance with ASTM D1143/D1143M-07e1. This work shall consist
of furnishing all materials and labour necessary for conducting an Osterberg Cell (O-cell) Load Test
and reporting the results. The Contractor will be required to supply material and labour as hereinafter
specified and including prior to, during and after the load test. The piles used for the load test program
will be instrumented by specialized firm (the Osterberg Cell supplier) or others, as approved by the
Engineer. The Osterberg cell load test will be conducted by (the Osterberg Cell supplier), or others,
as approved by the Engineer, with the Contractor providing auxiliary equipment and services as
deemed required. The O-cell load test is a non-destructive test and is suitable for both dedicated test
piles and working test piles. If the test pile is constructed on working pile (intended to carry structural
service loads) it shall be left in a condition suitable for use in the finished structure.
17.17.2 Materials
The Contractor shall supply all materials required to install the Osterberg cell, conduct the load test,
and remove the load test apparatus as required.
The Contractor shall furnish one (1) or more Osterberg Cells as required for each load test, to be
supplied by approved firm. The Osterberg cell(s) to be provided shall have the required capacity and
shall be equipped with all necessary hydraulic lines, fittings, pressure source, pressure gage and
telltale devices. Required materials include, but not limited to the followings:
a. Fresh, clean, potable water from an approved source to be used as hydraulic fluid to
pressurize the Osterberg Cell.
b. Materials sufficient to construct a stable reference beam system for monitoring movements
of the pile during testing. The system shall be supported at a minimum distance of 3 pile
diameters from the centre of the test pile to minimize disturbance of the reference system. A
good quality, self-levelling surveyor’s level shall be provided to monitor the reference system.
Page 17-25
c. Materials sufficient to construct a protected work area (including provisions such as a tent or
shed for protection from inclement weather for the load test equipment and personnel) of size
and type required by the Engineer and Osterberg Cell supplier. The protected works area
shall be maintained at adequate temperature as recommended by testing equipment supplier
in order to insure proper operation of the load testing equipment.
d. Stable electric power source, as required for lights, welding, instruments, etc.
e. Materials for carrier frame, steel bearing plates and/or other devices needed to attach O-cell
to rebar cage, as required.
Materials supplied, which do not become a part of the finished structure become the responsibility
of the Contractor at the conclusion of the load test and shall be removed from the job site.
17.17.3 Equipment
The Contractor shall supply equipment required to install the Osterberg cell, conduct the load test,
and remove the load test apparatus as required. Required equipment includes but is not limited to:
a. Welding equipment certified welding personnel and labour as required, to assemble the test
equipment under the supervision of Osterberg Cell supplier personnel, attach instrumentation
to the Osterberg cell(s), and prepare the work area.
b. Equipment and labour to construct the steel reinforcing cage and/or placement frame
including any steel bearing plates required for the test pile.
c. Equipment and operators for handling the Osterberg cell, instrumentation and placement
frame or steel reinforcing cage during the installation of the Osterberg cell and during the
conduct of the test, including but not limited to a crane or other lifting device, manual labour,
and hand tools as required by Osterberg Cell supplier. and the Engineer.
d. Equipment and labour sufficient to erect the protected work area and reference beam system,
to be constructed to the requirements of the Engineer and “Osterberg Cell supplier”.
e. Air compressor for pump operation during the load test.
17.17.4 Procedure
For the pile(s) selected for testing by the Engineer, the Contractor shall construct the piles using the
approved pile installation techniques until the piles excavation has been completed.
The Osterberg Cell, hydraulic supply lines and other instruments shall be assembled and made
ready for installation under the direction of “Osterberg Cell supplier” and the Engineer, in a suitable
area, adjacent to the test pile, to be provided by the Contractor. The Osterberg Cell assembly shall
be welded to the bottom of the cage in conjunction with the construction of the cage. The plane of
the bottom plate(s) of the O-cell(s) shall be set at a right angle to the long axis of the cage. The
Contractor shall use the utmost care in handling the test assembly so as not to damage the
instrumentation during installation. The contractor shall limit the deflection of the cage to 0.6m
between pick points while lifting the cage from the horizontal position to vertical. The maximum
spacing between pick points shall be 7.5m. The contractor shall provide support bracing, strong
backs, etc. to maintain the deflection within the specified tolerance. The O-cell assembly must remain
perpendicular to the long axis of the reinforcing cage throughout the lifting and installation process.
When the test pile drilling has been completed, inspected and accepted by the Engineer, the O-cell
assembly and the reinforcing steel may be installed. A seating layer of concrete or grout shall be
placed by an approved method, in the base of the pile to provide a level base and reaction for the
O-cell. The preferred method is to install the O-cell assembly and deliver the seating layer using a
pump line or tremie pipe extending through the O-cell assembly to the base of the pile. Depending
on the configuration of the test assembly, it may be necessary to deliver the seating layer of concrete
prior to installing the O-cell. In this case, the O-cell assembly shall be installed while the concrete or
grout at the base is still fluid, under the direction of “Osterberg Cell supplier” and the Engineer. The
Osterberg Cell should end up at least partially submerged and firmly seated into the base grout or
concrete.
Page 17-26
After seating the Osterberg cell, the remainder of the piles shall be concreted in a manner similar to
that specified for production piles. At least four (4) concrete test cubes sets, in addition to those
specified elsewhere, shall be made from the concrete used in the test pile, to be tested at the
direction of “Osterberg Cell supplier”, at least one of these test sets shall be tested prior to the load
test and at least two sets shall be tested on the day of the load test.
During the load test, no casings may be vibrated into place in the foundation area near the load test.
Drilling may not continue within a 30-m radius of the test pile. If test apparatus shows any interference
due to construction activities outside of this perimeter, such activities shall cease immediately.
After the completion of the load test, and at the direction of the Engineer, the Contractor shall remove
any equipment, material, waste, etc. which are not to be a part of the finished structure. If the load
test pile is constructed at a production location and intended to carry service loads, the Contractor
shall grout the interior of the Osterberg cell and annular space around the outside of the Osterberg
cell using grouting techniques approved by the Engineer and “Osterberg Cell supplier”
17.17.5 Testing and Reporting

The load testing shall be performed by a qualified geotechnical engineer approved in advance by
the Engineer. The geotechnical engineer must have a demonstrated knowledge of load testing
procedures, and have performed at least 10 Osterberg cell load tests within the past two years.
The load testing shall be performed in general compliance with ASTM D 1143/D1143M-07e1
Standard Test Method for Piles Under Static Axial Load. The magnitude of the load increments may
be increased or decreased depending on the Project requirements but should not be changed during
the test.
Direct movement indicator measurements shall be made of the following:
a. O-cell expansion either directly or with telltales (minimum of 3 indicators required),
b. Upward top-of-pile displacement (minimum of 2 indicators required), and
c. Pile compression above O-cell (minimum of 2 indicators required).
Loads shall be applied at the prescribed intervals until the ultimate capacity of the pile is reached in
either end bearing or side friction, until the maximum capacity or maximum stroke of the O-cell is
reached, or unless otherwise directed by the Engineer.
At each load increment, or decrement, movement indicators shall be read at 1, 2, 4 and 8 minute
intervals while the load is held constant.
During unloading cycles the load decrement shall be such that at least 4 data points are acquired for
the load versus movement curve. Additional cycles of loading and unloading using similar
procedures may be required by the Engineer following the completion of the initial test cycle.
Digital dial gages, used to measure O-cell expansion and top-of-pile displacement should have a
minimum travel of 100mm and be capable of being read to the nearest 0.025mm division. When O-
cell expansion is measured directly, dial gages capable of measuring the full stroke of the Osterberg
Cell will be used (typically 150mm). Digital dial gages, used to measure pile compression should
have a minimum travel of 25mm and be capable of being read to the nearest 0.025mm division.
Unless otherwise specified by the Engineer, the Contractor will supply four (4) copies of a report of
each load test, as prepared by “Osterberg Cell supplier” or others approved by the Engineer. An
initial data report containing the load-movement curves and data tables will be provided to the
Engineer within three (3) days of the completion of load testing, to allow evaluation of the test results.
A final report on the load testing shall be submitted to the Engineer within ten (10) working days after
completion of the load testing.
Page 17-27
17.18 Tension and Lateral Load Testing

When specified, the Contractor shall conduct tension static load tests and lateral load tests, which
shall comply with the ASTM’s Standard Test Methods for Deep Foundations Under Static Axial
Tensile Load (ASTM D3689-07) and ASTM’s Standard Test Methods for Piles Under Lateral Loads
(ASTM D3966-07)
17.19 Integrity Testing for Piles

Integrity testing for drilled foundation piles shall comply with the requirements outlined in this section.
17.19.1 Low Strain Integrity Testing for Piles

Integrity testing for piles provides information about physical dimensions, continuity, and the
consistency of materials used. Such tests do not obtain direct information about the performance of
piles under actual loads.
Low strain integrity tests do not replace static load tests; rather, they are a source of supplementary
information.
If the Engineer identifies any anomalies in the results of low strain integrity tests, the Engineer may
call for further testing to determine the cause, nature, and extent of such anomalies and to ascertain
whether the pile is satisfactory for its intended use.
The firm that has been approved by the Engineer shall conduct all low strain integrity testing in
accordance with ASTM D5882-07 and only personnel with the appropriate competence and
knowledge shall interpret such tests. The Contractor shall submit full tests results and findings to the
Engineer no later than ten days after the completion of each phase of testing. The Contractor shall
provide full details of the ground conditions, pile dimensions, and construction methods to the
specialist firm when doing so is necessary to facilitate interpretation.
Integrity tests shall not occur until seven or more days have elapsed after pile casting, unless the
Engineer specifies otherwise.
A test pile’s head shall be clean, free from water, laitance, and loose concrete, and readily accessible
for the testing.
The Contractor shall carry out low strain integrity testing on all in-situ concrete bored piles unless
otherwise directed by the Engineer.
17.19.2 Cross-hole Sonic Logging

As specified in the Contract documents, the Contractor shall perform cross-hole sonic logging (CSL)
tests in accordance with ASTM D6760-08. To accommodate CSL testing, the Contractor shall furnish
and install access tubes in accordance with the following requirements:
a. Access tubes for cross-hole sonic log testing shall be steel pipe with walls at least 3.5 mm
thick and inside diameters of at least 38 mm.
b. Access tubes shall have round, regular inside diameters that lack defects and obstructions.
Access tubes shall have pipe joints that permit the free, unobstructed passage of source and
receiver probes that have diameters up to 33 mm.
c. Access tubes shall be watertight and free from corrosion. They shall have clean internal and
external faces to ensure that they bond well with concrete.
d. Each access tube shall have watertight threaded caps on its bottom and its top.
The Contractor shall install access tubes for CSL testing in all drilled piles, except as otherwise
noted, to permit access for the CSL test probes. If, in the opinion of the Engineer, the condition of
the pile excavation permits pile construction in the dry, the Engineer may specify the omission of
such CSL testing.
Page 17-28
The Contractor shall securely attach access tubes to the interior of a test pile’s reinforcement cage.
One access tube shall be furnished and installed for each 300 mm of pile diameter, rounded to the
nearest whole number, as shown in the Contract plans. Such testing shall involve at least three
tubes. Access tubes shall be placed around the pile to be tested, inside the spiral or hoop
reinforcement, and at least 75 mm away from the vertical reinforcement. Spacing of access tubes
shall be uniform, as measured along the circle passing through the centres of the access tubes. If
space prevents compliance with these minimum requirements, the Contractor shall bundle the
access tubes with the vertical reinforcement. If reinforcing steel does not extend to the bottom of the
test pile, the CSL tubes shall extend to the pile’s bottom.
If a cage requires trimming and access tubes for CSL testing are attached to the cage, the Contractor
shall either shift the access tubes up the cage or cut the access tubes. When cutting tubes, the
Contractor shall ensure that its ends are adapted to receive a watertight cap, as specified.
Access tubes shall be in straight alignment and as parallel to the vertical axis of a reinforcement
cage as possible. Access tubes shall extend from the bottom of a test pile to at least 600 mm above
the top of that pile. Splice joints in the access tubes, if required to achieve full length access tubes,
shall be watertight.
The Contractor shall clear access tubes of all debris and extraneous materials before installing them.
When installing a reinforcement cage and placing concrete, the Contractor shall be careful not to
damage access tubes.
Before placing concrete, the Contractor shall fill the access tubes with potable water and reinstall
the watertight threaded caps on the tube’s top ends.
Before performing any CSL testing operations, as specified in these specifications, the Contractor
shall remove the concrete at the top of the pile to be tested down to sound concrete.
The Contractor shall perform CSL testing and analysis on all completed piles that the Engineer
designates for testing. The Contractor shall notify the Engineer at least 48 hours before the concrete
in each pile will be sufficiently cured for CSL testing.
CSL testing shall occur after the pile concrete has cured for at least 96 hours. Additional curing time
may be necessary if concrete for a test pile contains admixtures, such as a set-retarding admixture
or water-reducing admixture. Additional curing time under these circumstances shall not be grounds
for the Owner to give the Contractor additional compensation or extension of time. Until the Engineer
inspects and approves a CSL-tested pile, the Contractor shall not conduct any subsequent
construction. CSL tested shall be complete no later than seven days after placement of a pile.
After placing concrete for a test pile but before starting CSL testing for that pile, the Contractor shall
inspect the access tubes. Each access tube that the test probe cannot pass through shall be
replaced, at the Contractor's expense, with a 50 mm diameter hole cored through the concrete for
the entire length of the pile. If a single tube is blocked, the Engineer may perform CSL testing on the
remaining tubes. If no anomalies are noted, the Engineer may waive the requirement to provide the
cored alternative hole. The Contractor shall provide computer log information and interpretation in
their original formats.
The Engineer shall review the CSL test results, analyses for tested piles, and the visual inspection
reports for a subject pile to determine whether it has passed such testing.
The Engineer may approve the continuation of pile construction before approval and acceptance of
the first pile, if the Engineer's observes the following conditions:
a. Construction of the first pile is satisfactory
b. A test pile’s installation conforms to the pile installation plan
c. Daily reports provided by the Contractor are satisfactory
d. An inspector’s daily logs concerning excavation, steel reinforcing bar placement, and
concrete placement are satisfactory
Page 17-29
If the Engineer determines that the concrete placed under support fluid for a given pile is structurally
inadequate, that pile shall be rejected. In such cases, placement of concrete under slurry shall be
suspended until the Contractor submits to the Engineer written changes to the methods of pile
construction that will prevent structurally inadequate piles in the future and the Engineer approves
the submittal in writing.
The Engineer may direct the Contractor to drill a core hole in any pile of questionable quality pile (as
determined from CSL testing and analysis or by the Engineer’s direct observation) to further explore
the condition of the pile.
Before beginning coring, the Contractor shall submit the method and equipment to be used to drill
and remove cores from pile concrete to the Engineer. The Contractor shall not begin coring until
receiving the Engineer’s written approval to do so. Coring methods and equipment shall ensure
complete core recovery while minimising abrasion and core erosion.
If subsequent testing at a pile indicates the presence of defects, the Contractor shall bear the testing
costs and any delay costs that result from required additional testing.
For all piles that are determined to be unacceptable, the Contractor shall submit a plan for further
investigation and remedial action to the Engineer for approval. All modifications to the dimensions of
the piles, as shown in the Contract plans, that are required by the investigation and the remedial
action plan shall be supported by calculations and working drawings. The Contractor shall not begin
repair operations until receiving the Engineer's approval of the investigation and remedial action
plan.
All access tubes and cored holes shall be dewatered and filled with grout after tests are completed
and a pile is accepted. Access tubes and cored holes shall be filled using grout hoses that extend to
the bottom of the tube or hole or into the grout already placed.
Grout for filling the access tubes at the completion of the cross-hole sonic log tests shall be a grout
with a maximum water-to-cement (w/c) ratio of 0.45 or as directed by the Engineer.
17.20 High Strain Dynamic Test

17.20.1 General
High strain dynamic tests shall be carried out in accordance with ASTM D4945-12. Dynamic pile
testing involves monitoring the response of a pile to a heavy impact applied at the pile head. The
impact is often provided by a hammer and response is normally measured in terms of force and
acceleration or displacement close to the pile head.
The results directly obtained refer to dynamic loading conditions. Interpretation in terms of static
loading requires soil and pile dependent adjustments, and corroboration from experience may be
required to correlate dynamic testing with normal static load tests
Details of the equipment to be used and of the method of analysis of test results shall be provided
to the Engineer before the commencement of testing.
17.20.2 Measuring Instruments

All instruments affixed to the pile for the purpose of measuring stress and movement, and all
equipment for receiving and processing data shall be suitable for the purpose. The equipment
required to be attached to the pile shall be approximately positioned and fixed to the approval of
Engineer.
17.20.3 Hammer
The hammer and all other equipment used shall be capable of delivering an impact force sufficient
to mobilize the equivalent specified test load without damaging the pile.
Page 17-30
17.20.4 Preparation of the Pile Head

The preparation of the pile head for the application of the dynamic test load shall involve, where
appropriate, trimming the head, cleaning and building up the pile using materials which will at the
time of testing safely withstand the impact stresses. The impact surface shall be flat and normal to
the axis of the pile.
17.20.5 Time of Testing

Dynamic load tests shall be carried out at appropriate and approved times after pile installation. The
time between the completion of installation and testing for a cast-in-place concrete piles shall be
after the concrete has reached 75% of its specified 28 day strength so that the pile is not damaged
under the impact stresses.
17.20.6 Results
a. Initial results shall be provided to the Engineer within 24 hours of the completion of a test.
These shall include:
1. The maximum force applied to the pile head.
2. The maximum pile head velocity.
3. The maximum energy imparted to the pile.
b. Normally within 10 days of the completion of testing final report shall be given to the Engineer
which includes:
1. Date of pile installation
2. Date of test
3. Pile identification number and location
4. Length of pile below ground surface
5. Total pile length, including projection above commencing surface at time of test.
6. Length of pile from instrumentation position to tip.
7. Hammer type, drop and other relevant details.
8. Blow selected for analysis.
9. Test load achieved (i.e. total mobilized deduced static load).
10. Pile head movement at equivalent design verification load.
11. Pile head movement at equivalent design verification load plus 50% of specified working
load.
12. Pile head movement at maximum applied test load.
13. Permanent residual movement of pile head after each blow.
14. Temporary compression.
Page 17-31
Index
adjacent structures, 17-3 lateral load tests, 17-28

allowable settlement, 17-16, 17-24 load measuring device, 17-16, 17-17
augers, 17-2 loading, 17-16, 17-17, 17-18, 17-19, 17-21,
bailing buckets, 17-2 17-22, 17-24, 17-27, 17-30
bell footing, 17-6 loading test, 17-16
Bentonite, 17-9, 17-10 mineral grain, 17-9
boring piles, 17-3 mineral slurry, 17-7, 17-9
casings, 17-2, 17-7, 17-11, 17-12, 17-14, 17- noises, 17-3
15, 17-27 obstructions, 17-4, 17-28
cleaning equipment, 17-2 Osterberg Cell, 17-25, 17-26, 17-27
Concrete, 17-12, 17-13, 17-14, 17-23 permanent casing, 17-4, 17-6, 17-7, 17-23
concrete pumps, 17-2 permanent lining tubes, 17-15
cranes, 17-2 pile construction, 17-2, 17-5, 17-6, 17-10, 17-
cross-hole sonic logging, 17-28 28, 17-29, 17-30
Department of Transport, 17-4 Pile construction records, 17-4
desanding equipment, 17-2, 17-9 pile head, 17-30, 17-31
disturbances, 17-3 pile test, 17-19
drilling fluid, 17-8, 17-9, 17-10, 17-12, 17-13, pile tests, 17-16, 17-18, 17-19, 17-20
17-14, 17-15 piling, 17-3, 17-4, 17-6, 17-15, 17-16, 17-23
drilling operations, 17-3 Polymer slurries, 17-10
drills, 17-2, 17-3 precautions, 17-5, 17-10, 17-14
dry bores, 17-14, 17-15 reinforcing cage, 17-7, 17-13, 17-14, 17-26
dry excavation, 17-7 sampling equipment, 17-2
dynamic testing, 17-16, 17-30 settlement, 17-16, 17-17, 17-19, 17-20, 17-22,
effective life-saving, 17-3 17-24
embankment placement, 17-6 slurry pumps, 17-2
excessive caving, 17-5 Static load tests, 17-20
existing structures, 17-5 temporary casing, 17-4, 17-6, 17-7, 17-11, 17-
ground formations, 17-2 12, 17-14, 17-15
groundwater table, 17-7 tension static load tests, 17-28
halting, 17-22 tolerances, 17-5, 17-15
hammer, 17-7, 17-12, 17-30 tremies, 17-2
High strain dynamic tests, 17-30 unloading, 17-21, 17-27
hydraulic rams, 17-19 utilities, 17-5
Initial results, 17-31 vibrations, 17-3, 17-5
installation plan, 17-2, 17-29 Welding, 17-26
jacks, 17-17, 17-19, 17-20 wet excavation method, 17-7
kentledge, 17-16, 17-17, 17-18, 17-19, 17-20, working pile, 17-16, 17-19, 17-25
17-22, 17-24, 17-25
Page 17-32
PART 2
ROAD STRUCTURES
CHAPTER 18 - DRIVEN PILES
DOCUMENT NO: TR-

FIRST EDITION
JANUARY 2018
STANDARD CONSTRUCTION SPECIFICATIONS PART 2 – ROAD STRUCTURES
Chapter 18: Driven Piles

TABLE OF CONTENTS
List of Tables ................................................................................................................................. ii
18 Driven Piles ..................................................................................................................... 18-3
18.1 Pile Driving Terminology .............................................................................................. 18-3
18.3 Materials for Pile Driving .............................................................................................. 18-4
18.3.1 Steel Piles............................................................................................................. 18-4
18.3.2 Pre-stressed Concrete Piles ................................................................................. 18-5
18.4 Piles Driving ................................................................................................................. 18-6
18.4.1 Pile Driving Equipment.......................................................................................... 18-6
18.4.2 Preparation for Pile Driving ................................................................................. 18-10
18.4.3 Performing Pile Driving ....................................................................................... 18-12
18.4.4 Determination of the Nominal Resistances for Piles ............................................ 18-13
18.4.5 Splicing Piles ...................................................................................................... 18-15
18.4.6 Defective Piles .................................................................................................... 18-16
Index ...................................................................................................................................... 18-17
Page i
CHAPTER 18: DRIVEN PILES First Edition -January 2018
LIST OF TABLES
Table 18-1: Designations and titles for AASHTO and ASTM standards that apply to driven piles
works ......................................................................................................................................... 18-4
Table 18-2: Hammer efficiencies ................................................................................................ 18-7
Page ii
18 DRIVEN PILES
This chapter outlines standards and requirements for driven piles for the Project. Such work consists
of furnishing and driving foundation piles of the type and dimensions designated in the Contract
documents and, when required, cutting off or building up foundation piles. The Contractor shall
comply with the specifications in this chapter whenever providing such work for the Project.
This chapter also requires the Contractor to provide test piles and perform loading tests. In
accordance with the specifications in this chapter, the Contractor shall install piling at the locations
shown in the Contract documents, or as directed by the Engineer, to the required elevations,
penetrations, and nominal resistances.
Except when test piles are required, the Contractor shall furnish piles in accordance with the
dimensions shown in the Contract documents. When Non-working test pile are required, the
Contractor shall use the production pile lengths shown in the Contract documents as estimates; the
Engineer shall determine actual lengths for production piles after test piles have been driven and
tested. The Engineer shall give the Contractor an order list that includes pile lengths for use in the
completed structure.
As necessary to suit the method of operation, the Contractor shall increase the lengths shown in the
Engineer’s ordered list to provide for fresh heading, without additional compensation.
18.1 Pile Driving Terminology

This section defines core terminology for pile driving the related work covered in this chapter.
Blow Count: A total of the hammer blows that are required to cause 300 mm or 25 mm of
penetration.
Driving Record: Record of blow count per unit penetration for the entire driving of a pile.
Dynamic Testing: Also called high strain dynamic pile testing, dynamic testing requires
impacting a pile with a pile driving hammer or a large drop weight and measuring the force and
velocity in the pile with pile analyzer instruments.
Jetting: A technique in which pile installers use water and air to facilitate pile penetration by displacing
soil.
Nominal Resistance: A value that represents a pile’s ultimate capacity.
Pile Shoes: Steel plates that protect all types of piles for which hard driving is expected.
Pre-Drilling: A process in which the Contractor drills a hole with a continuous flight auger or a wet
rotary bit to remove some soil or loosen the strata.
Probe Pile: A pile that is driven to determine the required pile length at various locations on a site.
It may be also called an indicator pile or test pile.

Standards and codes for Driven Piles shall be as specified in these specifications, in the Contract
Page18-3

• ASTM American Society for Testing and Materials.
that are related to materials for driven piles. It includes designations and titles.
Table 18-1: Designations and titles for AASHTO and ASTM standards that apply to driven
piles works
AASHTO ASTM
TITLE
ASTM A36/A36M-
Standard Specification for Carbon Structural Steel
08
ASTM Standard Specification for High-Strength Low-Alloy

A572/A572M-12 Columbium-Vanadium Structural Steel
ASTM
Standard Specification for Structural Steel Shapes
A992/A992M-11
ASTM Standard Specification for Steel Castings, High Strength, for

A148/A148M-08 Structural Purposes
18.3 Materials for Pile Driving

Materials for pile driving shall comply with the standards and requirements outlined in this section.
18.3.1 Steel Piles

18.3.1.1 Rolled Structural Steel Piles
a. Properties of Rolled Structural Steel Piles
Steel used in rolled structural steel piles shall conform to the following standard specifications of the
American Society for Testing and Materials (ASTM):
• Standard Specification for Carbon Structural Steel (ASTM A36/A36M)
• Standard Specification for High-Strength Low-Alloy Columbium-Vanadium Structural Steel
(ASTM A572/A572M)
• Standard Specification for Structural Steel Shapes (ASTM A992/A992M)
In addition to the standards listed above, the Contractor may use steel that is ordered or produced
in compliance with other standards or other published ASTM specifications that establish properties
and suitability for such steel.
Cast steel shoes, if used, shall be grade 90-60 steel that conforms to the ASTM Standard
Specification for Steel Castings, High Strength, for Structural Purposes (ASTM A148/A148M). The
Contractor shall consider using pile shoes when structural steel shapes are driven through
obstructions or into sloping hard rock. Refer to Article 18.4.2.2 for more information on pile shoes.
b. Minimum Dimensions for Rolled Structural Steel Piles
Sections of such piles shall be of “H” or “W” shape and shall comply with the following requirements:
1. A pile’s flange the projection shall not exceed 14 times the minimum thickness of metal in
either the flange or the web, and flange widths shall not be less than 80% of the depth of the
section.
Page18-4
2. A pile’s nominal depth in the direction of the web shall not be less than 200 mm.
Flanges and webs shall have minimum nominal thicknesses of at least 9.5 mm.
18.3.1.2 Steel Pipe Piles

Steel pipe piles shall consist of steel pipe that conform to the Contract plans. Steel pipes for such
piles shall have an outside diameter and a minimum nominal wall thickness as shown in the Contract
documents.
Ends of closed-end pipe piles shall be closed with a flat plate, a forged or cast steel conical point, or
another end closure design that has been approved by the Engineer. End plates shall be at least 20
mm thick. The Contractor shall cut each end plate flush with its outer pile wall. They shall bevel the
end of each pipe before welding it to the end plate using a partial penetration groove weld. Larger
diameter pipes may require thicker end plates, thicker reinforcement, or both.
Before the Contractor places concrete into a pile, they shall use an acceptable inspection method to
confirm that the pile’s length and pile’s bottom is dry. If accumulations of water in pipes are present,
the Contractor shall remove all water before placing concrete.
Concrete for concrete-filled pipe piles shall be of class C20/20 and have a compressive strength of
at least 20.0 MPa and a slump from 150 mm to 250 mm.
For each pile, the Contractor shall place concrete in a single continuous operation.
The Contractor shall not place concrete in a pile until completing all pile driving within 4.5 metres of
that pile. Alternatively, after pouring concrete for a pile, the Contractor shall discontinue all pile driving
within 4.5 metres of that pile for at least two days and until concrete in such pile has completely set.
18.3.1.3 Painting
Unless otherwise provided, when steel piles or steel pile shells extend above the ground surface or
ground water level, they shall be protected by the paint system specified for painting steel piles as
described in Section 24.5 of Chapter 24, Painting, of the Standard Specifications.
This protection shall extend from an elevation 600 mm below the low water or ground level to the
top of the exposed steel
18.3.2 Pre-stressed Concrete Piles

Production of piles shall comply with Pre-stressed Concrete Institute (PCI) standards as outlined in
their Manual for Quality Control for Plants and Production of Structural Precast Concrete Products
(MNL-116).
18.3.2.1 Forms for Pre-stressed Concrete Piles

Forms for pre-stressed concrete piles shall conform to the applicable requirements of Section 1.20.8
of Chapter 1, General Requirements, and Article 21.13.3.1of Chapter 21, Concrete Structures, of
the Standard Specifications and as provided in the PCI’s Manual for Quality Control for Plants and
Production of Structural Precast Concrete Products (MNL-116).
18.3.2.2 Casting for Pre-stressed Concrete Piles

Concrete shall be cast continuously within three days after pretensioning steel; concrete shall not,
however, be cast in forms until a quality control representative from a pile’s manufacturer has
inspected and approved the placement of reinforcement and anchorages. Each pile shall have dense
concrete surfaces that are straight and smooth. During fabrication, each pile shall have
reinforcement retained in its proper position. Unless the Contractor uses self-consolidating concrete,
they shall compact the concrete by vibrating it with a vibrator head that is smaller than the minimum
Page18-5
distance between the pretensioning steel. A pile’s end surfaces shall be perpendicular to its
longitudinal axis.
18.3.2.3 Finish for Pre-stressed Concrete Piles

Each pile’s finish shall comply with the PCI’s Manual for Quality Control for Plants and Production of
Structural Precast Concrete Products (MNL-116).
With standard finishing, a pile’s formed sides shall be reasonably smooth from casting against
approved forms. Standard finish for a pile’s top shall be a float finish with tooled edges.
18.3.2.4 Curing and Protection for Pre-stressed Concrete Piles

Curing of piles shall comply with PCI MNL-116, Manual for Quality Control for Plants and Production
of Structural Precast Concrete Products.
Piles shall be cured using moist curing or accelerated steam curing.
No pile shall be driven until it is sufficiently cured to resist handling and driving stresses without
damage.
18.3.2.5 Pre-stressing for Concrete Piles

Pre-stressing of piles shall comply with PCI’s Manual for Quality Control for Plants and Production
of Structural Precast Concrete Products (MNL-116).
18.3.2.6 Shop Drawings for Pre-stressed Concrete Piles

The Contractor shall submit the required number of shop drawings for pre-stressed concrete piles to
the Engineer. Shop drawing shall indicate pile dimensions, materials, tendon arrangements, and pre-
stressing forces proposed for use, as well as any changes to reinforcing steel from that shown in the
Contract documents. Construction of the piles shall not begin until the Engineer has approved the
shop drawings.
18.3.2.7 Storage and Handling for Pre-stressed Concrete Piles

When handling, storing, and transporting pre-stressed concrete piles, the Contractor shall avoid
excessive bending stresses, cracking, spalling, or other injurious result.
18.3.2.8 Protective Coating for Pre-stressed Concrete Piles

If Contracts Documents indicate that protection is required, the Contractor shall apply protective
coating as specified in these specifications. The Contractor shall be responsible for restoring and
repair any damage to the coating.
18.4 Piles Driving

The Contractor shall comply with the specifications in this section when driving piles.
18.4.1 Pile Driving Equipment

The Engineer shall approve all pile driving equipment, including the pile driving hammer, hammer
cushion, helmet, pile cushion, and other appurtenances, before the Contractor conducts any pile
driving. Pursuant to obtaining this approval, the Contractor shall submit descriptions of all pile driving
equipment to the Engineer at least two weeks before pile driving is to begin. Such descriptions shall
contain sufficient detail to enable the using wave equation analysis to evaluate the proposed driving
system.
Page18-6
If the nominal resistance is to be determined by static load test, dynamic test, quick static load test,
or wave equation analysis, the Contractor shall submit the results of a wave equation analysis to the
Engineer. Such analysis shall verify that the piles are drivable.
If the nominal resistance is to be determined by dynamic formula, a wave equation analysis is not
required. A required blow count, as determined by the dynamic formula, shall not exceed 120 blows
per 300 mm.
The Contractor shall use the hammer efficiencies shown in Table 18-2 in a wave equation analysis
of vertical piles, unless better information is available.
Table 18-2: Hammer efficiencies
Hammer type Efficiency
Single-acting air/steam 67%
Double-acting air/steam 50%
Diesel 80%
Hydraulic or diesel with built-in energy measurement 95%
Hammer efficiencies shall be adjusted for batter driving.

In addition to the other requirements and specifications outlined in this chapter, the Contractor and
the Engineer shall use the following criteria to evaluate the driving equipment shall consist of both
the required number of hammer blows per 300 mm at the required nominal resistance and the pile
driving stresses over the entire driving process.
A driving system, as indicated by a wave equation analysis at the required nominal resistance, shall
require from 24 to 120 hammer blows per 300 mm. The Engineer shall not accept a system that
requires fewer or more hammer blows per 300 mm.
In addition, pile stresses, as determined by a wave equation analysis for the entire driving operation,
shall not exceed the following values:
1. For steel piles, compressive driving stress shall not exceed 90 percent of the yield point of
the pile material.
2. For concrete piles, tensile stresses shall not exceed 0.25 multiplied by the square root of the
concrete cube compressive strength (f′c), in MPa, plus the effective pre-stress value, as
shown in Equation 18-1. Compressive stresses, also in MPa, shall not exceed 85% of the
cube compressive strength minus the effective pre-stress value, as shown in Equation 18-2.
• Tensile stress = 0.25 √f ′ c + Prestress

Equation 18-1: Tensile stress
• Compressive stress = 0.85 (f ′ c) − Prestress
Equation 18-2: Compressive stress
During pile driving operations, the Contractor shall use the approved system. The Engineer shall
consider changes to the driving system only after the Contractor has submitted revised pile driving
equipment data and wave equation analysis. The Engineer shall notify the Contractor of their
acceptance or rejection of proposed changes to a driving system within seven calendar days after
receiving a requested change. Time required for the submission, review, and approval of a revised
driving system shall not constitute grounds for a time extension for the Contractor’s work.
Page18-7
The Engineer’s approval of pile driving equipment shall not relieve the Contractor of responsibility to
drive piles, free of damage, to the required nominal resistances and to any specified minimum
penetrations, as shown in the Contract documents.
18.4.1.1 Hammers for Pile Driving

Piles shall be driven with an impact or vibratory hammer that conforms to the specifications outlined
in this section. Pile driving hammers shall be of the size needed to develop the energy required to
drive the piles at a blow count that does not exceed 120 blows per 300 mm at the required nominal
resistance.
a. Drop Hammers for Pile Driving
The Contractor shall not use drop (gravity) hammers for concrete piles or for piles whose required
nominal resistance exceeds 60.0 tons.
Where the Project permits the use of drop hammers, a drop hammer’s ram shall have a weight of at
least 10.0 kN and drop heights shall not exceed 3.6 metres. A drop hammer’s ram weight shall never
be less than the combined weight of a helmet and a pile. All drop hammers shall have hammer
guides and a helmet to ensure concentric impact.
b. Air Hammers for Pile Driving
If the Contractor uses a dynamic formula to establish the required blow count, the weight of the
striking parts of air hammers used shall not be less than one-third the weight of a pile and its drive
cap, and an air hammer’s striking part shall weigh at least 14.0 kN. If the Contractor uses a wave
equation analysis to establish the required blow count and driving stresses, this limitation on ram
weight shall not apply.
Plant and equipment for air hammers shall have sufficient capacity to maintain, under working
conditions, the pressure specified for the hammer by its manufacturer. A hose that connects a
compressor to an air hammer shall be at least the minimum size recommended by the air hammer’s
manufacturer.
Upon using an air hammer to drive a pile, the Contractor shall evaluate the hammer’s performance
by measuring blows per minute and comparing these blows to the manufacturer’s recommendations.
c. Diesel Hammers for Pile Driving
If open-end (single-acting) diesel hammers are not equipped with a device to measure impact
velocity at all times during pile driving operations, the Contractor shall obtain the stroke by measuring
the speed of operation either manually or with a device that takes the measurement automatically.
Closed-end (double-acting) diesel hammers shall have a bounce chamber pressure gauge in good
working order, mounted near ground level to enable the Engineer to read it easily. The Contractor
shall provide a correlation chart of bounce chamber pressure and potential energy.
d. Hydraulic Hammers for Pile Driving
Hydraulic hammers shall have a system for measuring ram energy. Such systems shall be in good
working order and make their results easily and immediately available to the Engineer.
e. Vibratory Hammers for Pile Driving
Vibratory or other pile driving methods may be used only when specified in the Contract documents
or when approved in writing by the Engineer. Except when pile lengths have been evaluated from
static load test piles, the Contractor shall verify that vibratory hammers are driving piles to their
nominal resistances. Upon driving a group of ten piles with a vibratory hammer, the Contractor shall
use an impact hammer that can measure nominal resistance to further drive the first pile in that
group. If piles reside in different soils, the Contractor shall apply the impact hammer to additional
Page18-8
piles, as directed by the Engineer. The Contractor shall use an impact hammer to complete driving
for any pile that relies primarily on point bearing capacity.
The Contractor shall not use vibratory hammers to drive concrete piles.
f. Additional Equipment or Hammering Methods for Pile Driving
If none of the hammers outlined in previous sections obtains the required penetration, the Engineer
may require that the Contractor provide a hammer of greater energy or to use supplemental
methods, such as jetting or predrilling, as described in Article 18.4.1.2.
18.4.1.2 Pile Driving Appurtenances

Pile driving appurtenances shall comply with the specifications outlined in this section.
a. Hammer Cushions for Pile Driving

All impact pile driving equipment shall include a hammer cushion that is sufficiently thick to prevent
damage to the hammer or pile. Drop hammers and any hammers whose design specifically avoids
the need for a hammer cushion shall be exempt from this requirement.
Where applicable, hammer cushions shall durable, manufactured material that retains uniform
properties during driving. Such cushions shall not be wood, wire rope, or asbestos. A striker plate
on each hammer cushion shall ensure that the cushion material compresses uniformly. Before using
a hammer for driving, the Contractor shall replace any hammer cushion that wear has reduced
original thickness by 25% or more. For air hammers, the Contractor shall comply with the hammer
manufacturer’s recommendations for replacing worn cushions before use.
b. Helmets for Pile Driving

Piles driven with impact hammers shall include a helmet that distributes the hammer’s blows
uniformly and concentrically to the pile’s head. A helmet’s surface that contacts a pile shall be plane
and smooth and shall be parallel with the hammer base and the pile’s top. Such helmet’s shall be
guided by leads, rather than free-swinging. Such helmets shall fit pile heads in a manner that
maintains concentric alignment between the hammer and a pile.
For special types of piles, appropriate driving heads, mandrels, or other devices shall be provided
so that the piles may be driven without damage.
c. Pile Cushions for Concrete Piles

A pile cushion shall protect the head of each concrete pile. To determine how thick such cushions
should be to prevent excessive driving stresses, the Contractor shall apply wave equation analysis.
If the Contractor uses a dynamic formula to determine the required driving blow count, such cushions
shall be at least 100 mm thick.
While using a hammer for concrete piles, If a pile cushion begins to smoke or excessive compression
occurs, the Contractor shall replace the cushion. A pile cushion’s dimensions shall distribute hammer
blows uniformly over a pile’s entire cross-section.
Hard driving conditions may require frequent cushion replacement, perhaps before finishing even a
single pile. In easy driving conditions, however, each pile cushion may last through several piles.
Pile cushions shall be protected from the weather and kept dry before use. Pile cushion shall not be
soaked in any liquid unless the Engineer approves such action. The Contractor may ask the Engineer
to approve the use of manufactured pile cushion materials rather than wood pile cushions on a case-
by-case basis.
For restrike tests, the Contractor shall use a used pile cushion that is still in good condition.
Page18-9
d. Leads for Pile Driving

Throughout a pile driving operations, the Contractor shall use leads that properly align each pile with
a hammer to ensure that each blow strikes with concentric impact. Such leads shall not impede
hammer movement. As applicable, they shall permit proper alignment of battered piles. The
Contractor may use either fixed or swinging leads. Swinging leads shall include a pile gate at their
bottom ends. To maintain alignment between leads and piles, the Contractor shall either embed
each lead adequately in the ground or use a structural frame, such as a template, to constrain each
pile.
e. Followers for Pile Driving

The Contractor shall use followers only when the Engineer approves such use in writing or when the
Contract documents specify such use.
When using followers for a concrete pile, the Contractor shall attach a pile cushion to the top of a
concrete pile. To ensure that followers are suitable for a concrete pile, the Contractor shall conduct
a wave equation analysis to verify blow count, driving stresses, and nominal resistance.
If the Contractor does not use a wave equation analysis to determine impedance for a steel pile,
they shall use a follower with an impedance between 50% and 200% of the steel pile’s impedance.
The Contractor shall apply a wave equation to check piles that are driven with a follower. They shall
test piles with either a static test or dynamic test on the pile, on the follower, or both. Such testing
eliminates the need to drive a longer full length test pile in each footing.
A follower and pile shall be maintained in proper alignment during driving. A follower shall be of such
material and dimensions to permit piles to be driven to the necessary blow count.
After driving a pile with a follower, the Contractor shall verify a pile’s final position by checking the
position and inclination of the follower.
f. Jetting for Pile Driving

The Contractor shall use jetting only when the Engineer approves such use in writing or when the
Contract documents specify such use.
The Contractor shall determine the number of jets and the volume and pressure of water at the jet
nozzles that is necessary to freely erode material that is adjacent to a pile.
The Contractor shall control and dispose of all jet water in a manner that is satisfactory to the
Engineer or as specified in the Contract documents. The Contractor shall be responsible for all
damages to the site caused by their jetting operations.
Unless otherwise indicated by the Engineer or the Contract documents, the Contractor shall remove
jet pipes before or when a pile’s tip is 1.5 metres above the minimum or final tip elevation. The
Contractor shall then drive the pile without jetting to the final tip elevation or to the required nominal
resistance with an impact hammer. If the required nominal resistance is not reached at the final tip
elevation, the Contractor may allow a pile to set up then determine the required nominal resistance
by restriking the pile.
18.4.2 Preparation for Pile Driving

When preparing for pile driving, the Contractor shall comply with the specifications outlined in this
section.
18.4.2.1 Preparation for Site Work

When conducting pile driving work on the Project site, the Contractor shall comply with the
requirements outlined in this section.
Page18-10
a. Excavation for Pile Driving

If practical, piles shall not be driven until after the excavation is complete. Before placing concrete
for a foundation, the Contractor shall remove any material that has been forced up between piles
until surrounding ground is the correct elevation.
Unless otherwise approved by the Engineer, piles at bridge ends shall not be driven until roadway
embankments are placed.
b. Predrilling to Facilitate Pile Driving

When the Contract documents require predrilling, the Contractor shall predrill holes of a size
specified, at pile locations, and to the depths shown in the Contract documents or as directed in
writing by the Engineer.
Predrilling is usually used in the case where driving a pile will displace the upper soil enough to push
adjoining piles out of the proper position or to limit vibration in the upper layers.
Normally, predrilled holes are smaller than the diameter or diagonal of a pile’s cross-section and
sufficient to allow penetration of a pile to its specified elevation. If the Contractor encounters
subsurface obstructions, they may increase a hole’s diameter to the least dimension necessary to
avoid obstructions and install piles.
If, after pile driving, void spaces remain around a pile, the Contractor shall fill them with sand or other
approved material. The Contractor cannot use spuds rather than predrilling, unless the Contract
documents or the Engineer, in writing, approves such use. Material resulting from drilling holes shall
be disposed of as approved by the Engineer.
c. Additional Requirements for Pre-drilled Holes in Embankments

If required by the Contract documents, piles to be driven through compacted fill or embankment of a
depth greater than 1.5 m shall be driven in holes predrilled to natural ground. A predrilled hole should
have a diameter not more than the greatest dimension of the pile cross-section plus 150 mm. After
the Contractor drives a pile, they shall fill the space around the pile to the ground surface with sand
or other approved material. Material resulting from predrilling holes shall be disposed of as approved
by the Engineer.
18.4.2.2 Preparation for Piling

a. Pile Heads
For steel piling, pile heads shall be cut and maintained square to the longitudinal axis of the pile.
Precast concrete pile heads shall be flat, smooth, and perpendicular to the longitudinal axis of a pile
to prevent eccentric impacts from a helmet. Pre-stressing strands shall be cut off below the surface
of the end of the pile. For concrete piles, a pile’s head shall be chamfered on all sides. Pre-stressed
concrete piles may also be chamfered along their length.
A pile’s prepared head shall provide uniform contact and thereby reduce the potential of damage to
the pile’s top. Before assessing blow count acceptance, based on driving criterion, the Contractor
shall remove any distortions from a pile’s top.
b. Pile Shoes and End Plates

Pile shoes shall be used when specified by the Engineer or in the Contract documents to protect all
types of piles when hard driving or obstructions are expected.
Steel pile shoes shall be grade 90-60 cast steel that conforms to ASTM’s Standard Specification for
Steel Castings, High Strength, for Structural Purposes (ASTM A148/A148M).
Page18-11
End plates used on closed-end pipe piles shall be made of steel that complies with or exceeds
ASTM’s Standard Specification for Carbon Structural Steel (ASTM A36/A36M). A steel plate’s
diameter and thickness shall be specified by the Engineer.
A pile driving acceptance criterion should be developed that will prevent damage to the pile toe. Steel
piles driven into soft rock may not require toe protection.
When hard rock, sloping rock, or obstructions are expected, a pile toe should be protected with cast
steel shoes.
Pile shoes used at the option of the Contractor shall be of a type approved by the Engineer.
18.4.3 Performing Pile Driving

Unless the Engineer approves alternatives, the Contractor shall drive piles to their required nominal
resistances and to either their minimum tip elevation or a specified alternative tip elevation.
The Contractor shall always count the hammer blows required to drive a pile, either during initial
driving or when driving a pile again with a warm hammer after a wait period, as determined by the
Engineer.
For diesel hammers, the Contractor shall record strokes. For hydraulic hammers, the Contractor
shall record either energy or impact velocity.
If the Contractor uses water jets are in conjunction with pile driving, they shall determine the nominal
resistance from the results of driving after withdrawing the jets.
A pile driving procedure shall not subject piles to excessive and undue abuse and shall not result in
crushing and spalling of the concrete, injurious splitting, splintering, or excessive deformation of
steel.
18.4.3.1 Driving Heaved Piles

If piles heave, the Engineer shall take level readings referenced to a fixed datum on all piles
immediately after their installation and periodically thereafter as adjacent piles are driven to
determine the range of pile heaving.
The Contractor shall drive a pile again if the driving process for adjacent piles results in either of the
following conditions:
a. Piles heave more than 12.0 mm and end bearing is dominant
b. Piles heave more than 40.0 mm and shaft friction is dominant
If pipe or shell piles that have been filled with concrete heave, the Contractor shall drive such piles
again to their original positions after the concrete has obtained sufficient strength, using a proper
hammer-pile cushion system that the Engineer deems satisfactory.
18.4.3.2 Pile Installation Sequence

The Contractor shall install piles within a pile group sequentially, either starting from the centre of a
group and proceeding outward in both directions or starting at the outside row and proceeding
progressively across the group.
18.4.3.3 Practical Refusal for Pile Driving

A pile reaches a level of practical refusal when resistance to penetration makes driving a pile deeper
impractical. A practical refusal blow count for a pile depends on the site’s soil profile and the pile’s
type, and may possible be limited by the hammers used, in accordance with the hammer
manufacturer’s published limitations to prevent hammer damage. In no case shall driving continue
for more than 75 mm after a pile reaches practical refusal conditions.
Page18-12
18.4.3.4 Limiting Pile Driving Stresses

Unless the Contract documents or the Engineer specify otherwise, stresses induced during driving
shall not exceed the limits set forth in Section 18.4.1.
18.4.3.5 Driving Probe Piles

Where required in the Contract documents, probe piles shall be furnished to the lengths specified
and driven at the locations and to the elevations, nominal resistances, or blow counts directed by
the Engineer before other piles are ordered. All piles shall be driven with approved impact hammers
unless the Contract documents specifically state otherwise. The Contractor shall use hammers of
the same type and size on production piles.
Unless the Engineer approves an alternate approach, the Contractor shall excavate the ground at
each probe pile to the elevation of the bottom of the footing before driving a pile. Additional probe
piles shall be driven at locations selected by the Engineer to explore possible subsurface variations.
When the Engineer so orders, the Contractor shall drive probe piles to plan grade. If any probe pile
fails to attain required nominal resistance, the Contractor shall splice that probe pile and drive it
further until it attains the required bearing.
Any probe piles that do not attain the required hammer blow count or that fail to attain nominal
resistance at the specified depth may be allowed to set for 12 to 24 hours, as determined by the
Engineer, before the Contractor drives them again. If a probe pile still fails to attain the specified
nominal resistance after it is driven again, the Engineer may direct the Contractor to drive a portion
or all of the remaining probe pile and repeating the process of setting up and driving the pile.
18.4.3.6 Accuracy of Pile Driving

Piles shall be driven with a variation of not more than 1:50 from the vertical or not more than 1:25
from the batter shown in the Contract documents. Piles for trestle bents, however, shall be driven so
that the cap may be placed in its proper location without adversely affecting the resistance of the
piles.
After driving, a pile’s head shall be within 150 mm of plan locations for all piles capped below final
grade, and shall be within 75 mm of plan locations for bent caps supported by piles,
No pile shall be nearer than 100 mm from any edge of the cap. Any increase in pile cap dimensions
or reinforcing caused by out-of-position piles shall be at the Contractor’s expense.
The Contractor shall make every effort to install piles at the planned location and at the planned
batter, unless deviations occur due to existing obstructions.
18.4.4 Determination of the Nominal Resistances for Piles

To determine the nominal resistances for piles, the Engineer will use the method specified in the
Contract documents. Any method used to determine resistance of piles during or after installation
shall be consistent with the pile resistance verification methodology assumed during the Project
design phase, in accordance with Article 10.5.5.2.3 of the AASHTO LRFD Bridge Design
Specifications.
Consideration should be given to the potential for change in nominal resistance after the end of
driving. Effects of soil relaxation and setup should be considered in the determination of nominal
resistance for soils that are likely to be subject to these phenomena. Such cases may require a wait
period to allow for gain due to setup, with confirmation of the nominal resistance by a retest (static
or dynamic).
Page18-13
18.4.4.1 Static Load Tests

If a static load test is used to determine a pile’s axial resistance, such test shall not be performed
less than five days after a test pile was driven unless the Engineer or the Contract documents direct
otherwise.
Each static load test shall follow the procedures specified in ASTM’s Standard Test Methods for
Deep Foundations Under Static Axial Compressive Load (ASTM D1143/D1143M), Section 17.16 of
Chapter 17, Drilled Piles, of the Standard Specifications and the loading procedure shall follow the
Quick Load Test Method, unless detailed longer-term load-settlement data are needed, in which
case the standard loading procedure should be used. Testing equipment and measuring systems
shall also conform to ASTM D1143/D1143M.
The Contractor shall submit detailed documents of the proposed loading apparatus to the Engineer
for approval. Such submittals shall include calibrations for the hydraulic jack, load cell, and pressure
gauge conducted within 30 days before mobilization to the job site. 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 size as the production piles and shall be driven in the
location of permanent piles where feasible.
While performing a static load test, the Contractor shall provide safety equipment and employ
adequate safety procedures. Adequate support for the static load test plates, jack, and ancillary
devices shall be provided to prevent them from falling in the event of a release of load due to
hydraulic failure, test pile failure, or other cause.
A pile’s nominal resistance may increase (as soil sets up) or decrease (as soil relaxes) after driving
ends. Therefore, the Contractor shall perform a static load after equilibrium conditions in the soil are
re-established; such testing is essential.
Based on the type of soil and ground that piles shall penetrate, the Contractor shall allow a sufficient
delay between pile driving and load testing, as follows:
a. Piles driven into clays: Delay two weeks

b. Weathered shale: Delay seven days
c. Sandy silts or sands: Delay five to seven days
The Contractor shall use the method for defining failure of the static load test that is defined in the
Contract documents or by the Engineer. Based on the static load test results, the Engineer shall
provide the driving criteria for production pile acceptance.
Tension static load tests shall be ducted in accordance with ASTM’s Standard Test Methods for
Deep Foundations Under Static Axial Tensile Load (ASTM D3689). Lateral load tests shall be
conducted in accordance with ASTM’s Standard Test Methods for Deep Foundations Under Lateral
Load (ASTM D3966).
18.4.4.2 Dynamic Testing

Dynamic testing shall be conducted in accordance with ASTM’s Standard Test Method for High-
Strain Dynamic Testing of Piles (ASTM D4945). The Contractor shall prepare for the required
instrument attachment as directed by the Engineer.
The Contractor shall drive piles for dynamic testing as directed by the Engineer. If the Engineer so
directs, the Contractor shall reduce the driving energy transmitted to the pile by using additional
cushioning or reducing the energy output of the hammer to maintain acceptable stresses in the piles.
If dynamic measurements indicate non-axial driving, the Contractor shall immediately realign the
driving system.
Page18-14
If the required nominal resistance is not achieved at the end of driving, the Contractor shall restrike
the dynamic test pile following a waiting period specified in the Contract documents or as directed
by the Engineer.
After the waiting period, the Contractor shall reattach the dynamic testing instruments, drive the test
pile again, and repeat the dynamic test. Before striking a test pile again, the Contractor shall allow a
hammer to warm up. The Contractor shall stop driving a test pile either upon reaching a depth of
75mm or after delivering 20 blows, whichever occurs first.
18.4.4.3 Wave Equation Analysis

When specified in the Contract documents, the Engineer shall use a wave equation analysis to
determine the driving criterion necessary to reach a pile’s required nominal resistance. Soil and pile
properties to be used in this analysis shall be as shown in the Contract documents or as determined
by the Engineer. The Contractor shall provide the information on proposed driving equipment that
the Engineer needs to perform the wave equation analysis.
18.4.4.4 Dynamic Formula

The Contract documents shall specify the particular dynamic formula to be used, if any. The
Contractor shall not use a dynamic formula if the required nominal resistance is more than 2,700 kN.
Formulas shall be considered applicable only where the head of the pile is not crushed, or otherwise
damaged, and a follower is not used.
If a dynamic formula is used to establish the driving criterion, the FHWA Gates Formula specified in
this chapter should be used. During driving, the Contractor shall use Equation 18-3 to measure
nominal pile resistance.
Rndr = 1.75 √Ed log10 (10Nb ) − 100

Equation 18-3: Dynamic Formula
Where:
Rndr = Nominal pile resistance measured during pile driving (kips)
Ed = Developed hammer energy. This is the kinetic energy in the ram at impact for a given blow.
If ram velocity is not measured, it may be assumed equal to the potential energy of the ram at the
height of the stroke, taken as the ram weight times the stroke (ft-lbs)
Nb = Number of hammer blows for 1.0 in. of pile permanent set (blows/in.)
If the Contractor uses a dynamic formula other than those provided in this chapter, the Contractor
shall calibrate the formula based on measured static load test results to obtain an appropriate
resistance factor, in accordance with article C10.5.5.2 of the AASHTO LRFD Bridge Design
Specifications.
18.4.5 Splicing Piles

Where splices are unavoidable for steel or concrete piles, their number, locations, and details shall
be subject to the Engineer’s approval.
18.4.5.1 Splicing Steel Piles

Full-length piles shall be used where practicable. If splicing is permitted, the method of splicing shall
be approved by the Engineer. Either shielded arc or submerged arc welding should be used when
Page18-15
splicing steel piles. Only certified welders shall perform welding. Mechanical splices that are not
welded shall be used for compression piles only.
18.4.5.2 Splicing Concrete Piles

Full-length piles shall be used where practical. Where splicing is permitted, concrete pile splice
details shall conform to the Contract documents, or as approved by the Engineer. Mechanical
splices, including drive-fit splices, may also be used.
18.4.6 Defective Piles

A pile-driving procedure shall not subject them to excessive and undue abuse or produce crushing
and spalling of the concrete, injurious splitting, splintering, or excessive deformation of steel.
Manipulation of piles to force them into proper position, considered by the Engineer to be excessive,
shall not be permitted. At his own expense, the Contractor shall take action to correct any pile that
has damage resulting from internal defects or improper driving. At his own expense, the Contractor
shall also correct any piles that have been driven out of its proper location or below the butt elevation
(as determined in the Contract documents or by the Engineer). The Contractor shall use one of the
following methods, as approved by the Engineer, to make such corrections:
• If practicable, the Contractor shall withdraw a defective pile and replace it with a new one,
which may need to be longer than the defective pile being replaced.
• The Contractor shall drive one or more replacement piles that are adjacent to the defective
pile.
To correct a pile that has been driven below the specified butt elevation, the Contractor shall use
one of the following methods, as approved by the Engineer:
• The Contractor shall splice and build up the pile in accordance with the specifications outlined
in this chapter.
• The Contractor shall extend a sufficient portion of the footing downward to properly embed
the pile.
To correct a pile that has been driven out of its proper location, the Contractor shall use one of the
following methods, as approved by the Engineer:
• The Contractor shall drive one or more replacement piles next to the pile that is out of
position.
• The Contractor shall extend the footing laterally to incorporate the pile that is out of position.
• The Contractor shall add additional reinforcement.
The Contractor shall provide all such remedial materials and work at his own expense.
18.4.6.1 Pile Cut-Off

The Contractor shall cut all piles to a true plane at the required elevations and anchor them to the
structure as shown in the Contract documents. All cut-off lengths of piling shall remain the property
of the Contractor, who shall dispose of them properly.
Page18-16
INDEX
blow count, 18-1, 18-5, 18-6, 18-8, 18-10, 18- nominal resistances, 18-1, 18-6, 18-7, 18-
11 10, 18-11, 18-12
Concrete, 18-3, 18-4, 18-8, 18-1 paint system, 18-3
cracking, 18-4 pile heads, 18-7, 18-10
cut-off lengths, 18-2 practical refusal, 18-11
diesel hammers, 18-6, 18-10 predrilling, 18-7, 18-9
drop hammers, 18-6 pre-stressed, 18-3, 18-4
Dynamic testing, 18-13 pretensioning steel, 18-3
followers, 18-8 protection, 18-3, 18-4, 18-10
hammer blows, 18-1, 18-5, 18-8, 18-10, 18-1 spalling, 18-4, 18-10, 18-1
hammer cushion, 18-5, 18-7 splices, 18-1
hammer efficiencies, 18-5 static load test, 18-5, 18-7, 18-12, 18-13, 18-1
helmet, 18-5, 18-6, 18-7, 18-10 steel piles, 18-2, 18-3, 18-5, 18-1
Hydraulic hammers, 18-7 ultimate capacity, 18-1
impedance, 18-8 vibratory hammer, 18-6, 18-7
jetting, 18-7, 18-8, 18-9 wave equation analysis, 18-5, 18-6, 18-8, 18-
13
Page18-17
PART 2
ROAD STRUCTURES
CHAPTER 19 - GROUND ANCHORS
DOCUMENT NO: TR-

FIRST EDITION
JANUARY 2018
Chapter 19: Ground Anchors

TABLE OF CONTENTS
List of Tables .................................................................................................................................. ii
19 Ground Anchors .............................................................................................................. 19-1
19.1 Ground Anchor Terminology ........................................................................................ 19-1
19.3 Working Drawings for Ground Anchor .......................................................................... 19-3
19.4 Materials for Ground Anchor ........................................................................................ 19-4
19.4.1 Prestressing Steel for Ground Anchor................................................................... 19-4
19.4.2 Grout for Ground Anchor ...................................................................................... 19-4
19.4.3 Steel Elements for Ground Anchor........................................................................ 19-4
19.4.4 Corrosion Protection Elements for Ground Anchor ............................................... 19-5
19.4.5 Miscellaneous Elements for Ground Anchor ......................................................... 19-5
19.5 Fabrication of Ground Anchor ...................................................................................... 19-6
19.5.1 Tendon Bond Length for a Ground Anchor ........................................................... 19-6
19.5.2 Spacers and Centralisers for a Ground Anchor ..................................................... 19-6
19.5.3 Tendon Unbonded Length for a Fround Anchor .................................................... 19-6
19.5.4 Anchorage and Trumpet for a Ground Anchor ...................................................... 19-7
19.5.5 Tendon Storage and Handling .............................................................................. 19-7
19.6 Installation of a Ground Anchor .................................................................................... 19-7
19.6.1 Drilling for Anchor Installation ............................................................................... 19-7
19.6.2 Tendon Insertion for Anchor Installation ................................................................ 19-7
19.6.3 Grouting for Anchor Installation ............................................................................. 19-8
19.6.4 Trumpet and Anchorage for Anchor Installation .................................................... 19-8
19.7 Testing and Stressing for a Ground Anchor ................................................................. 19-8
19.7.1 Equipment for Ground Anchor Testing .................................................................. 19-9
19.7.2 Performance Testing for Ground Anchors ............................................................. 19-9
19.7.3 Proof Testing for Ground Anchors ...................................................................... 19-11
19.7.4 Creep testing for Ground Anchors ...................................................................... 19-12
19.7.5 Acceptance Criteria for Ground Anchor Testing .................................................. 19-13
19.7.6 Lock-Off .............................................................................................................. 19-14
Index ....................................................................................................................................... 19-15
Page i
CHAPTER 19: GROUND ANCHORS First Edition -January 2018
List of Tables
Table 19-1: Designations and titles for AASHTO and ASTM standards that apply to ground anchors
works ......................................................................................................................................... 19-2
Table 19-2: Performance load test schedule .............................................................................. 19-9
Table 19-3: Proof load test schedule ........................................................................................ 19-11
Table 19-4: Creep test schedule .............................................................................................. 19-13
Page ii
19 GROUND ANCHORS
This chapter outlines standards and requires with which the Contractor shall comply with when
designing, furnishing, installing, testing, and stressing permanent cement-grouted ground anchors.
Such work shall also comply with the Contract documents.
Structural systems ground anchors have the following typical applications:
• Retaining structure tie backs
• Resisting uplift forces
• Serving as tension foundations
• Stabilising slopes
• Underground structures
• Soil nailing (bar type anchors)
• Securing base slabs
• Securing basins
19.1 Ground Anchor Terminology

The listed terminologies are specific to works related to ground anchors chapter only.
Alignment Load (AL): A nominal minimum load applied to an anchor during testing to keep testing
equipment positioned correctly.
Anchor Devices: Wedges or nuts that grip prestressing steel.
Anchor Head: A device by which prestressing force is permanently transmitted from the prestressing
steel to the bearing plate.
Anchorage: A system that combines an anchor head, bearing plate, trumpet, and anchorage
corrosion protection to transmit the prestressing force from the prestressing steel to the surface of
the ground or the supported structure.
Bearing Plate: A steel plate that evenly distributes ground anchor force to the main structure.
Bond Tendon Length: Length of the ground anchor that is bonded to the ground and that transmits
tensile force to the soil or rock.
Centraliser: A device that supports and positions the tendon in the drilled hole to maintain grout
cover.
Coupler: A means to transmit prestressing force from one partial-length of prestressing tendon
to another.
Design Load (DL): An anchor’s anticipated maximum effective load after allowing for time-
dependent losses or gains. An anchor’s design load incorporates appropriate factors to ensure that
the overall structure has adequate capacity for its intended use.
Unbounded Length: Design length for a tendon that is not bonded to the surrounding ground or
grout during stressing.
Ground Anchor: A system, as also called a tieback, that transfers tensile loads to soil or rock.
A ground anchor includes all prestressing steel, anchorage devices, grout, coatings, sheathings, and
any couplers that are used.
Lift-Off Load: A tendon’s load, as checked by lifting its anchor head off a bearing plate with a
hydraulic jack.
Lock-Off Load: Prestressing force in an anchor immediately after transferring load from a jack
to stressing anchorage.
Page 19-1
Performance Test: Application of an incremental cyclic test load, including an alignment load, to
an anchor while recording the anchor’s total movement at each increment.
Permanent Anchor: Any prestressed anchor intended for permanent use, generally with a service
life greater than 24 months.
Post Grouting: Grouting an anchor a second time after primary grout has set.
Prestressing Steel: A group of steel strands that combine to form a tendon or a high strength steel
bar.
Primary Grout: Portland cement grout that is injected into an anchor hole before or after the
installation of the anchor tendon to transfer force to the surrounding ground along the bonded length
of the tendon.
Proof Test Load: An incremental load applied to an anchor while recording the total movement
of the anchor at each increment.
Temporary Anchor: A prestressed anchor intended for temporary use, generally with a service life
of less than 24 months. Temporary anchors installed in corrosive environments may require
corrosion protection.
Test Anchor: An anchor installed before the installation of the production anchors to which load is
applied to verify design parameters.
Test Load (TL): Maximum load to which an anchor is subjected during testing.
Total Anchor Length: A total of a tendon’s unbonded length plus its bond length.

Standards and codes for Ground Anchors shall be as specified in these specifications, in the
Contract documents, if any, and the following, in their latest edition:
ASTM American Society for Testing and Materials.Table 19-1 presents AASHTO and American
Society for Testing and Materials (ASTM) standards that are related to materials for ground anchors.
It includes designations and titles.
Table 19-1: Designations and titles for AASHTO and ASTM standards that apply to ground
anchors works
AASHTO ASTM
TITLE
AASHTO M 203M/M Standard Specification for Steel Strand, Uncoated

203-12 Seven-Wire for Concrete Reinforcement
ASTM A416/A416M- Standard Specification for Steel Strand, Uncoated

12a Seven-Wire for Prestressed Concrete
Standard Specification for Steel Strand, Indented,

ASTM A886/A886M-
Seven-Wire Stress-Relieved for Prestressed
10
Concrete
Page 19-2
AASHTO ASTM
TITLE
ASTM A882/A882M- Standard Specification for Filled Epoxy-Coated

04a(2010) Seven-Wire Prestressing Steel Strand
AASHTO M85-12 ASTM C150-12 Standard Specification for Portland Cement
ASHTO M 270M/M ASTM A709/A709M- Standard Specification for Structural Steel for
270-12 11 Bridges
ASTM A536-
Standard Specification for Ductile Iron Castings
84(2009)
Standard Specification for Pipe, Steel, Black and

ASTM A53/A53M-12
Hot-Dipped, Zinc-Coated, Welded and Seamless
Standard Specification for Cold-Formed Welded

ASTM A500-10a and Seamless Carbon Steel Structural Tubing in
Rounds and Shapes
Standard Specification for Polyethylene Plastics

ASTM D3350-12
Pipe and Fittings Materials
Standard Specification for Polypropylene Injection

ASTM D4101-11
and Extrusion Materials
Standard Specification for Corrugated

AASHTO M 252-09
Polyethylene Drainage Pipe
ASTM Standard Specification for Epoxy-Coated

AASHTO M 317M/M
D3963/D3963M- Reinforcing Bars: Handling Requirements for
317-03(2007)
01(2007) Fabrication and Job Site
19.3 Working Drawings for Ground Anchor

At least four weeks before work is to begin, the Contractor shall submit to the Engineer for review
and approval complete working drawings and design calculations that describe a ground anchor
system or systems intended for use. Such submittals shall include the following information:
a. A ground anchor schedule that includes the following details:
• Ground anchor number
• Ground anchor design load
• Type and size of tendon
• Minimum total anchor length
• Minimum bond length for ground anchors
• Minimum length of bonded tendon
• Minimum length of unbonded tendon
• Inclination
• Failure mechanism
b. A drawing of a proposed ground anchor tendon and its corrosion protection
system, including the following details:
• Spacers for separating tendon elements, with planned locations for such spacers
Page 19-3
• Centralisers, spacers, and their locations

• Corrosion protection system for unbonded length of tendon
• Corrosion protection system for bonded length of tendon
• Anchorage and trumpet
• Anchorage corrosion protection system
• Drilled or formed hole size
• Level of each stage of grouting
• Any revisions to structure details that are necessary to accommodate the ground
anchor system intended for use
c. The grout mix design and placement procedures
The Contractor shall not begin any work on ground anchors until the Engineer has provided written
approval of the working drawings. Such approval shall not relieve the Contractor of any responsibility
defined in the Contract documents for successful completion of the work.
19.4 Materials for Ground Anchor

Materials for ground anchor shall comply with the standards and requirements outlined in this
section.
19.4.1 Prestressing Steel for Ground Anchor

Ground anchor tendons shall consist of single or multiple elements of prestressing steel, anchorage
devices, and, if required, couplers, all of which shall conform to the applicable requirements of
Section 22.7 of Chapter 22, Prestressing Systems. To be acceptable for use as ground anchor
tendons, materials shall comply with the standards listed in Table 19-1.
19.4.2 Grout for Ground Anchor

Cement shall be Type I, II, or V Portland cement that conforms to the Standard Specification for
Portland Cement (AASHTO M 85) or (ASTM C150). Cement used for grouting shall be fresh and
shall not contain any lumps or other indications of hydration or pack set.
A cement shall conform to the applicable requirements mentioned at Section 4.3.1 of Chapter 4,
Concrete Works, of the Standard Specifications.
With the approval of the Engineer, grout may include admixtures. Expansive admixtures may only
be added to grout for filling sealed encapsulations, trumpets, and anchorage covers. Grout shall not
include accelerators.
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.
The grout requirements shall comply with the applicable requirements mentioned at Section 22.7.2
of Chapter 22, Prestressing Systems.
19.4.3 Steel Elements for Ground Anchor

Bearing plates shall be steel of at least AASHTO grade 36 or ASTM grade 250 that conforms to the
Standard Specification for Structural Steel for Bridges (AASHTO M 270M/M 270) or (ASTM
A709/A709M). Bearing plates may also be ductile cast iron that conforms to ASTM’s Standard
Specification for Ductile Iron Castings (ASTM A536).
Trumpets that provide a transition from the anchorage to the unbonded length corrosion protection
shall be fabricated from a steel pipe that conforms to the requirements of ASTM’s Standard
Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless (ASTM
A53/A53M) or steel tubing that conforms to ASTM’s Standard Specification for Cold-Formed Welded
and Seamless Carbon Steel Structural Tubing in Rounds and Shapes (ASTM A500). A trumpet’s
wall shall be at least 5.0 mm thick.
Page 19-4
Covers that enclose exposed anchorages shall be at least 2.5 mm thick. Such covers shall be
fabricated from one of the following materials:
• AASHTO grade 36 steel (AASHTO M 270M/M 270)
• ASTM grade 250 steel (ASTM A709/A709M)
• Steel pipe (ASTM A53/A53M)
• Steel tubing (ASTM A500)
• Ductile cast iron (ASTM A536)
19.4.4 Corrosion Protection Elements for Ground Anchor

Corrosion-inhibiting grease shall conform to the requirements outlined in section 3.2.5 of the
Specification for Unbonded Single Strand Tendons, published by the Post-Tensioning Institute (PTI
M10.2-00).
A Sheath for an unbonded length of a tendon shall consist of one of the following materials:
a. Seamless polyethylene (PE) tube with a minimum wall thickness of 1.5 mm ± 0.25 mm.
Polyethylene shall be classified in accordance with ASTM’s Standard Specification for
Polyethylene Plastics Pipe and Fittings Materials (ASTM D3350).
b. Seamless polypropylene tube with a minimum wall thickness of 1.5 mm ± 0.25 mm.
Polypropylene shall be classified in accordance with ASTM’s Standard Specification for
Polypropylene Injection and Extrusion Materials (ASTM D4101).
c. Heat-shrinkable tube of a radiation cross-linked polyolefin tube that is internally coated with
an adhesive sealant. Walls for such tubes, before shrinking, shall be at least 0.6 mm thick.
Adhesive sealant shall be at least 0.5 mm thick.
d. Corrugated polyvinyl chloride (PVC) tube with a minimum wall thickness of 0.8 mm.
Encapsulation for a length of bonded tendon shall consist of one of the following:
1. Corrugated high-density polyethylene (HDPE) tube that conforms to AASHTO’s Standard
Specification for Corrugated Polyethylene Drainage Pipe (AASHTO M 252). Such tubing shall
have a minimum wall thickness of 0.8 mm.
2. Deformed steel tube or pipe with a minimum wall thickness of 0.63 mm.
3. Corrugated PVC tube with a minimum wall thickness of 0.8 mm.
4. Fusion-bonded epoxy that conforms to the requirements of AASHTO’s Standard
Specification for Epoxy-Coated Reinforcing Bars: Handling Requirements for Fabrication and
Job Site (AASHTO M 317M/M 317) or ASTM’s Standard Specification for Fabrication and
Jobsite Handling of Epoxy-Coated Steel Reinforcing Bars (ASTM D3963/D3963M). In
variance from these standards, however, such epoxy shall have a film thickness of 0.4 mm.
19.4.5 Miscellaneous Elements for Ground Anchor

A bond-breaker for a tendon shall consist of a smooth plastic tube or pipe that is resistant to aging
by ultraviolet light and that can withstand abrasion, impact, and bending during handling and
installation.
Spacers for separation of elements of a multi-element tendon shall permit the free flow of grout. They
shall be fabricated from plastic, steel, or material that is not detrimental to the prestressing steel.
Such spacers shall not be wood.
Centralisers shall be plastic, steel, or other material that is not detrimental to either the prestressing
steel or any tendon corrosion protection element. Centralisers shall not be wood. A centraliser shall
be able to maintain the position of the tendon so that at least 12 mm of grout can cover it or its
encapsulation.
Page 19-5
19.5 Fabrication of Ground Anchor

Tendons for ground anchors may be fabricated either in a shop or the field from materials that
conform to the requirements outlined in Section 19.4, Materials. Tendons shall be fabricated as
shown on the approved working drawings.
Each tendon’s size shall ensure that its maximum test load does not exceed 80 percent of its
minimum guaranteed ultimate strength.
19.5.1 Tendon Bond Length for a Ground Anchor

The Contractor shall determine the tendon bond length that satisfies load test requirements. A
tendon for a ground anchor shall have a bonded section that is at least 3.0 metres long in all cases,
at least 4.5 metres in soil, or the minimum length shown in the Contract documents, if such exceeds
3.0 metres.
A tendon bond length shall be encapsulated by a grout-filled corrugated plastic or deformed steel
tube, or by a fusion-bonded epoxy coating. A tendon shall be grouted inside the encapsulation either
before or after it is inserted into the drill hole. The Contractor shall not punch holes in this
encapsulation or allow grout to flow between the encapsulation and the drill hole.
To provide an average of 5.0 mm of grout covering for the prestressing steel, a tendon shall be
centralized within the encapsulation and a tube shall be of an effective size. For ground anchor
tendons that are protected by grout, the Contractor shall use spacers and centralisers that satisfy
the requirements outlined in Section 19.6.3, Grouting. An anchorage device for tendons protected
with fusion-bonded epoxy shall be electrically isolated from the main structure under construction.
19.5.2 Spacers and Centralisers for a Ground Anchor

Spacers along a tendon’s bond length shall ensure that prestressing steel will bond to grout. Such
spacers shall be located at centres no greater than 3.0 metres. An uppermost spacer shall reside no
more than 1.5 metres from the top of the anchor tendon’s bonded length and a bottommost spacer
shall reside no more than 1.5 metres from the bottom of the tendon’s bonded length.
Centralisers shall reside along the tendon’s bonded length at centres no greater than 3.0 metres. An
uppermost centraliser shall reside no more than 1.5 metres from the top of the bonded length and a
bottommost centraliser shall reside no more than 300 mm from the bottom of the bonded length.
Centralisers are not required on tendons that have been installed using a hollow-stem auger if such
a tendon is grouted through the auger and its drill hole is full of a stiff grout with a slump of 225 mm
or less during extraction of the auger. The Contractor may use a combination centraliser-spacer.
Centralisers are not required on tendons that have been installed in coarse-grained soils using a
pressure injection system and grouting pressures greater than 1.0 MPa.
Centralisers shall ensure a minimum grout cover of 13 mm over the tendon’s bonded length or its
encapsulation, as appropriate. The Contractor shall use centralisers that do not impede the free flow
of grout up the bore hole. Centralisers’ centre-to-centre spacing shall not exceed 3 meters.
19.5.3 Tendon Unbonded Length for a Fround Anchor

A ground anchor’s tendon shall have an unbounded section that is at least 4.5 metres long or as
long as indicated in the Contract documents or approved working drawings.
Either a sheath completely filled with corrosion-inhibiting grease or grout or a heat-shrinkable tube
shall provide corrosion protection. If a protective sheath contains grease, the Contractor shall prevent
grease from escaping at the sheath’s ends. Grease shall completely coat the tendon and fill the
interstices between the wires of seven-wire strands.
Continuity of corrosion protection shall be provided at the transition from the tendon’s bonded length
to its unbonded length.
Page 19-6
If a protective sheath is not a smooth tube, then a separate bondbreaker shall prevent the tendon
from bonding to anchor grout that surrounds the tendon’s unbonded length.
19.5.4 Anchorage and Trumpet for a Ground Anchor

A ground anchor may use nonrestressable anchorages, unless the Contract documents specify the
use of restressable anchorages.
Bearing plate sizes shall ensure that bending stresses in the plate and the average bearing stress
on concrete, if applicable, do not exceed the nominal resistances described in Article 5.10.9.7.2 of
the AASHTO LRFD Bridge Design Specifications (9). Bearing plates shall not be smaller than the
sizes indicated in the Contract documents.
The Contractor shall weld a trumpet to the bearing plate. This trumpet shall have an inside diameter
at least 6 mm greater than the diameter of the tendon at the anchorage.
A trumpet shall be long enough to accommodate movements of the main structure during testing
and stressing. For strand tendons with encapsulation over the unbonded length, a trumpet shall be
long enough to enable the tendons to make a transition from the tendon’s unbonded length to the
anchor head without damaging the encapsulation.
Trumpets filled with corrosion-inhibiting grease shall have a permanent Buna-N rubber seal or a seal
of an approved equivalent between the trumpet and the corrosion protection elements for the
tendon’s unbonded length. Trumpets filled with grout shall have a temporary seal between the
trumpet and the corrosion protection elements for the tendon’s unbonded length.
19.5.5 Tendon Storage and Handling

Storage and handling of tendons shall avoid damage and corrosion.
The Engineer shall reject any prestressing steel with abrasions, cuts, nicks, welds, and weld splatter.
A slight rusting, if it does not cause pits that are visible to the unaided eye, shall not cause the
Engineer to reject prestressing steel for a tendon. Before inserting a tendon into the drilled hole, the
Contractor shall examine its corrosion protection elements for damage and shall repair any damage
found in a manner approved by the Engineer.
Repairs to encapsulation shall comply with the recommendations of the tendon’s supplier.
19.6 Installation of a Ground Anchor

The Contractor shall select the drilling method, grouting procedure, and grouting pressure to be used
for the installation of the ground anchor as necessary to satisfy load testing and durability
requirements.
19.6.1 Drilling for Anchor Installation

As the drilling method for ground anchor installation, the Contractor may use core drilling, rotary
drilling, percussion drilling, auger drilling, or driven casing. Whatever method the Contractor selects
shall prevent loss of ground above the drilled hole that may be detrimental to the main structure or
existing structures in the vicinity. The Contractor shall remove any casings for anchor holes, unless
the Engineer authorises leaving them in place. Each drilled hole’s location, inclination, and alignment
shall comply with the Contract documents. Inclination and alignment shall be within ±3 degrees of
the planned angle at the bearing plate and within ±300 mm of the planned location at the point of
entry on the ground surface.
19.6.2 Tendon Insertion for Anchor Installation

The Contractor shall insert the tendon for a ground anchor into the drilled hole to the desired depth.
When a tendon cannot be completely inserted, the Contractor shall remove it and either clean or re-
drill the drill hole to permit insertion. Partially inserted tendons shall not be driven or forced into the
hole.
Page 19-7
19.6.3 Grouting for Anchor Installation

Ground anchor systems shall use a neat cement grout or sand cement grout that conforms to the
specifications in this section. Admixtures, if used, shall be mixed in quantities that do not exceed
manufacturers’ recommendations.
Grouting equipment shall produce grout without lumps or cement that is not dispersed. A positive-
displacement grout pump shall have a pressure gauge to monitor grout pressures. This pressure
gauge shall be capable of measuring pressures of at least 1.0 MPa or twice the actual grout
pressures used, whichever is greater.
Grouting equipment sizes shall enable grout to be pumped in one continuous operation. A mixer
shall be able to agitate grout continuously.
Grout shall be injected from the lowest point of a drill hole. The Contractor may pump grout through
grout tubes, casings, hollow-stem augers, or drill rods. The Contractor may place grout either before
or after inserting the system’s tendon. During installation, the Contractor shall record quantities of
grout used and grout pressures. To prevent excessive ground heaving or fracturing of rock
formations, the Contractor shall control grout pressures and grout quantities.
Except where indicated in these specifications, the Contractor may plane grout for both a tendon’s
bonded length and above the top of the bonded length at the same time. Such placement, however,
shall not be under pressure.
Grout at the top of a drill hole shall stop 150 mm from the back of the main structure or 150 mm from
the bottom of the trumpet, whichever is lowest.
If the ground anchor is installed in a fine-grained soil in a drilled hole with a diameter that is larger
than 150 mm, then the Contractor shall place grout above the top of the bonded length after the
ground anchor has been load-tested. The Contractor may grout an entire drill hole at the same time
if the ground anchor system does not derive a significant portion of its load resistance from the soil
above the ground anchor’s bonded length.
If ground anchors in rock use grout-protected tendons, the Contractor shall use pressure grouting
techniques. Pressure grouting requires sealing a drill hole and injecting grout until a 0.35 MPa grout
pressure can be maintained on the grout within the tendon’s bonded length for a period of 5 min.
If the Contractor fills a grout tube with grout, it may remain in the drill hole. After grouting, a tendon
shall not be loaded for at least three days.
19.6.4 Trumpet and Anchorage for Anchor Installation

Corrosion protection that surrounds a tendon’s unbounded length shall extend into an anchor
system’s trumpet at least 150 mm beyond the trumpet’s bottom seal.
Corrosion protection that surrounds a tendon’s unbounded length shall not contact the bearing plate
or the anchor head during load testing or stressing.
A bearing plate and anchor head shall be perpendicular to a tendon’s axis.
A trumpet shall be completely filled with corrosion inhibiting grease or grout. Such grease may be
placed any time during construction. Grout placement, however, shall occur after a ground anchor
has been load-tested. The Contractor shall demonstrate that the procedures selected for placement
of either grease or grout will completely fill a trumpet.
19.7 Testing and Stressing for a Ground Anchor

The Contractor shall test each ground anchor using either a performance test or a proof test, as
outlined in this section. No load greater than ten percent of the design load may be applied to a
ground anchor before load testing. Load testing shall occur simultaneously for an entire tendon.
Page 19-8
19.7.1 Equipment for Ground Anchor Testing

The Contractor shall use a dial gauge or vernier scale that can measure displacements to an
accuracy of 0.025 mm to measure ground anchor movement. Such testing equipment shall travel
sufficiently to measure total ground anchor movement without being reset.
A hydraulic jack and pump shall apply test loads. The Contractor shall use a calibrated pressure
gauge to measure applied loads. This pressure gauge shall be graduated in increments no greater
than 0.7 MPa. When an anchor under its maximum test load has a theoretical elastic elongation that
exceeds the jack’s ram travel, working drawings shall include the procedure for recycling the jack
ram. Each increment of test load shall be applied as rapidly as possible.
A calibrated reference pressure gauge shall be available at the site. A separate reference gauge
shall be calibrated with the test jack and pressure gage.
For creep testing, the Contractor shall use an electrical resistance load cell and readout.
Placement of stressing equipment over a ground anchor’s tendon shall ensure that the jack, bearing
plates, load cells, and stressing anchorage are axially aligned with the tendon and that the tendon is
centred within the equipment.
19.7.2 Performance Testing for Ground Anchors

The Contractor shall conduct performance testing, in accordance with the details in this section, on
at least five percent of all ground anchors and no fewer than three ground anchors, whichever is
greater. The Engineer shall select the ground anchors for performance testing. All remaining anchors
shall be proof-tested as outlined in Section 19.7.3.
Performance testing shall involve incrementally loading and unloading a ground anchor in
accordance with the schedule shown in Table 19-2 unless the Contract documents indicate a
different maximum test load and schedule. During Performance testing, the Contractor shall take the
following actions:
a. Raise the load from one increment to another immediately after recording a ground anchor’s
movement.
b. Measure and record each tested ground anchor’s movement to the nearest 0.025 mm with
respect to an independent fixed reference point at the alignment load and at each incremental
load.
c. Use a pressure gauge to monitor load.
d. Place the reference pressure gauge in series with the testing pressure gauge during each
performance test.
If loads indicated by the reference pressure gauge and testing pressure gauge differ by more than
ten percent, the Contractor shall recalibrate the jack, the testing pressure gage, and the reference
pressure gauge. At load increments other than the maximum test load, the Contractor shall hold the
load just long enough to obtain the movement reading.
Table 19-2: Performance load test schedule
Observation Period
Load Remarks
min
AL 10 minutes
0.25 DL* 10 minutes
AL 10 minutes
0.25 DL 10 minutes
Page 19-9
Observation Period
Load Remarks
min
0.50 DL* 10 minutes
AL 10 minutes
0.25 DL 10 minutes
0.50 DL 10 minutes
0.75 DL* 10 minutes
AL 10 minutes
0.25 DL 10 minutes
0.50 DL 10 minutes
0.75 DL 10 minutes
1.0 DL* 10 minutes
AL 10 minutes
0.25 DL 10 minutes
0.50 DL 10 minutes
0.75 DL 10 minutes
1.00 DL 10 minutes
1.20 DL* 10 minutes
AL 10 minutes
0.25 DL 10 minutes
0.50 DL 10 minutes
0.75 DL 10 minutes
1.00 DL 10 minutes
1.20 DL 10 minutes
1.33 DL* 10 minutes If T10-T1>1.0 mm, the holding time to be extended

for an additional 50 minutes
Reduce to lock-off 10 minutes

load
Page 19-10
Observation Period
Load Remarks
min
AL = Alignment load (The alignment load is a small load, normally less than ten percent of the
design load, applied to the ground anchor in order to keep the testing equipment in position during
testing)
DL = Design load for ground anchor
T10 = Ground anchor movement at 10.0 minutes
T1 = Ground anchor movement at 1.0 minute
* = Graph required, as specified herein
For performance testing, the Contractor shall hold an anchor’s maximum test load for 10 minutes,
pumping the jack as necessary to maintain a constant load. This load hold period shall start as soon
as the maximum test load is applied. During this period, the Contractor shall measure and record a
ground anchor’s movement at 1 minute, 2 minutes, 3 minutes, 4 minutes, 5 minutes, 6 minutes, and
10 minutes. If a tested ground anchor moves more than 1.0 mm from the first measurement (at 1
minute) and the last measurement (at 10 minutes), the Contractor shall hold the maximum test load
for an additional 50 minutes.
When extending a performance test by 50 minutes, the Contractor shall measure and record the
ground anchor’s movement again at 15 minutes, 20 minutes, 25 minutes, 30 minutes, 45 minutes,
and 60 minutes. Based on the results, the Contractor shall construct a graph that plots the ground
anchor’s movement for each load increment marked in with an asterisk (*) in Table and a plot 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.
19.7.3 Proof Testing for Ground Anchors

The Contractor shall perform proof testing, as outlined in this section, on every anchor that was not
subjected to performance testing.
A proof test shall be performed by incrementally loading a ground anchor in accordance with the
schedule shown in Table 19-3, unless the Contract documents indicate a different maximum test
load and schedule. During proof testing, the Contractor shall increase the applied load by one
increment immediately after recording the tested anchor’s movement. Ground anchor movement
shall be measured and recorded to the nearest 0.025 mm with respect to an independent fixed
reference point at the alignment load and at each increment of load.
The Contractor shall use a calibrated pressure gauge to monitor load. At load increments other than
the maximum test load, the Contractor shall hold a load just long enough to obtain and record the
tested anchor’s movement.
Table 19-3: Proof load test schedule
Observation
Load Remarks
Period min
AL 10 minutes
0.25 DL 10 minutes
0.50 DL 10 minutes
Page 19-11
Observation
Load Remarks
Period min
0.75 DL 10 minutes
1.00 DL 10 minutes
1.20 DL 10 minutes
1.33 DL 10 minutes If T10-T1>1.0 mm, the holding time to be extended for an

additional 50 minutes
Reduce to lock-off 10 minutes

load
AL = Alignment load
DL = Design load for ground anchor
T10 = Ground anchor movement at 10.0 minutes
T1 = Ground anchor movement at 1.0 minute
For proof testing, the Contractor shall hold an anchor’s maximum test load for 10 minutes, pumping
the jack as necessary to maintain a constant load. This load hold period shall start as soon as the
maximum test load is applied. During this period, the Contractor shall measure and record a ground
anchor’s movement at 1 minute, 2 minutes, 3 minutes, 4 minutes, 5 minutes, 6 minutes, and 10
minutes. If a tested ground anchor moves more than 1.0 mm from the first measurement (at 1 minute)
and the last measurement (at 10 minutes), the Contractor shall hold the maximum test load for an
additional 50 minutes.
When extending a proof test by 50 minutes, the Contractor shall measure a record the ground
anchor’s movement again at 15 minutes, 20 minutes, 25 minutes, 30 minutes, 45 minutes, and 60
minutes. Based on the results, the Contractor shall construct a graph that plots the ground anchor’s
movement for each load increment in the proof test. Format for such graphs shall comply with
directions from the Engineer.
19.7.4 Creep testing for Ground Anchors

The Contractor shall perform Creep tests in accordance with specifications in the Contract
documents. The Engineer shall select which ground anchors shall be subjected to creep testing.
When the Contract mandates creep testing, at least two ground anchors shall be so tested.
A creep test shall be made by incrementally loading and unloading a ground anchor in accordance
with the performance test schedule. At the end of each loading cycle, the load shall be held constant
for the observation period indicated in Table 19-4, unless the Contract documents indicate a different
maximum test load and schedule. The Contractor shall read and record the tested ground anchor’s
movement during each observation period at 1 minute and thereafter at 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 Contractor
shall use a calibrated pressure gage and reference pressure gage to measure the applied load and
a load cell to monitor small changes of load during a constant load-hold period. The Contractor shall
pump the jack as necessary to maintain a constant load.
Page 19-12
Table 19-4: Creep test schedule
Load Observation Period min
0.25DL 10
0.50DL 30
0.75DL 30
1.00 DL 45
1.20 DL 60
1.33 DL 300
Based on the results of creep testing, the Contractor shall construct a graph that plots ground anchor
movement and residual movement as described in Section 19.7.2 for performance tests. The
Contractor shall also construct a graph that plots a creep-tested ground anchor’s movement for each
load-hold as a function of the logarithm of time. Format for such graphs shall comply with directions
from the Engineer.
19.7.5 Acceptance Criteria for Ground Anchor Testing

A performance-tested or proof-tested ground anchor with a 10-minute load-hold shall be deemed to
be acceptable if all of the following conditions apply:
• A tested ground anchor resists the maximum test load with less than 1.0 mm of movement
between 1 minute and 10 minutes.
• A tested anchor’s total movement at the maximum test load exceeds eighty percent (80%) of
the theoretical elastic elongation of the anchor’s unbonded length.
• Total movement of a ground anchor in competent rock that is performance-tested under the
maximum test load does not exceed the theoretical elastic elongation of the anchor’s
unbonded length plus 50 percent of the theoretical elastic elongation of the anchor’s bonded
length.
• Elongation measurements are within calculated tolerances.
A performance-tested or proof-tested ground anchor with a 60-minute load-hold shall be deemed to
be acceptable if all of the following conditions apply:
• A tested ground anchor resists the maximum test load with a creep rate that does not exceed
2.0 mm in the last log cycle of time.
• A tested anchor’s total movement at the maximum test load exceeds eight percent (80%) of
• For a performance-tested ground anchor in competent rock, the total movement at the
maximum test load shall not exceed the theoretical elastic elongation of the anchor’s
unbounded length plus 50 percent of the theoretical elastic elongation of the anchor’s bonded
length.
A creep-tested ground anchor shall be deemed to be acceptable if all of the following conditions
apply:
• A tested ground anchor carries the maximum test load with a creep rate that does not exceed
2.0 mm in the last log cycle of time.
• A tested anchor’s total movement at the maximum test load exceeds eighty percent (80%) of
• Total movement of a ground anchor in competent rock that is performance-tested under the
maximum test load does not exceed the theoretical elastic elongation of the anchor’s
Page 19-13
unbonded length plus 50 percent of the theoretical elastic elongation of the anchor’s bonded
length.
If a ground anchor’s total movement when tested under the maximum test load does not exceeds
80 percent of the theoretical elastic elongation of the anchor’s unbonded length, the Contractor shall
replace the ground anchor without further expense to the Owner.
A ground anchor 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. An
anchor’s failure load is the load it can resist after the load has been allowed to stabilize for 10
minutes.
When a ground anchor fails, the Contractor shall modify the design, the installation procedures, or
both. Such 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 modification that
requires changes to the main structure under construction shall be approved by the Engineer. Any
modifications of design or construction procedures shall be without additional cost to the Owner and
without extension of the time schedule defined in the Contract documents.
Repeating tests for any ground anchor shall not be permitted, except ground anchors have been re-
grouted.
19.7.6 Lock-Off
Upon successful completion of load testing, the Contractor shall reduce the loads on ground anchors
to the lock-off load that is indicated in the Contract documents and transfer load to anchorage
devices. The Contractor may completely unload a ground anchor before lock-off. After transferring
the load and before removing the jack, the Contractor shall take a lift-off load reading. A lift-off load
measurement shall be within 10% of the specified lock-off load.
Page 19-14
INDEX
abrasion, 7 Grouting equipment, 9

Bearing plates, 6, 8 lock-off load, 11, 12, 14
bending stresses, 8 maximum test load, 7, 10, 11, 12, 13, 14
bond length, 4, 5, 7, 8, 14 movement, 3, 4, 10, 11, 12, 13, 14
bond-breaker, 7 nonrestressable, 8
Cement, 4, 6 performance testing, 10, 11, 12
cement-grouted ground anchors, 3 performance-tested, 13
Centralisers, 5, 7, 8 pressure gauge, 9, 10, 12
corrosion protection, 3, 4, 5, 6, 7, 8 prestressing steel, 3, 6, 7, 8
corrugated, 7 proof testing, 12
Creep tests, 12 proof-tested, 10, 13
dial gauge, 10 restressable anchorages, 8
displacements, 10 sand cement, 9
drilled hole, 3, 8, 9 Sheath, 6
existing structures, 9 Spacers, 5, 7, 8
exposed anchorages, 6 Trumpets, 6, 8
grease, 6, 8, 10 ultraviolet light, 7
grout, 3, 4, 6, 7, 8, 9, 10 unbonded length, 4, 5, 6, 8, 13, 14
vernier scale, 10
Page 19-15

PART 2
ROAD STRUCTURES
CHAPTER 20 - EARTH RETAINING SYSTEMS
DOCUMENT NO: TR-

FIRST EDITION
JANUARY 2018
Page
Chapter 20: Earth Retaining Systems First Edition -January 2018
Chapter 20: Earth Retaining Systems

TABLE OF CONTENTS
Table of Contents................................................................................................................................i
List of Tables...................................................................................................................................... ii
20 Earth Retaining Systems ........................................................................................................ 1
20.1 Reference Standards and Codes ........................................................................................1
20.2 Working Drawings for Earth Retaining Systems ..................................................................2
20.3 Materials for Earth Retaining Systems ................................................................................2
20.3.1 Concrete for Earth Retaining Systems .........................................................................2
20.3.2 Reinforcing Steel for Earth Retaining Systems ............................................................3
20.3.3 Structural Steel for Earth Retaining Systems ...............................................................3
20.3.4 Timber for Earth Retaining Systems ............................................................................3
20.3.5 Drainage Elements for Earth Retaining Systems .........................................................3
20.3.6 Backfill Material ............................................................................................................4
20.4 Earthwork for Earth Retaining Systems ...............................................................................5
20.4.1 Structure Excavation ....................................................................................................5
20.4.2 Foundation Treatment ..................................................................................................5
20.4.3 Structure Backfill ..........................................................................................................5
20.5 Drainage for Earth Retaining Systems ................................................................................5
20.5.1 Concrete Gutters ..........................................................................................................5
20.5.2 Weep Holes ..................................................................................................................6
20.5.3 Drainage Blankets ........................................................................................................6
20.5.4 Geocomposite Drainage Systems ................................................................................6
20.6 Construction for Earth Retaining Systems ...........................................................................6
20.6.1 Concrete, Masonry Gravity, and Reinforced Concrete Retaining Walls .......................7
20.6.2 Sheet-pile, Soldier-pile and Secant Pile walls ..............................................................9
20.6.3 Crib and Cellular Walls ...............................................................................................13
20.6.4 MSE Walls ..................................................................................................................14
Index ............................................................................................................................................. 25
Page i
LIST OF TABLES
Table 20-1: Designations and titles for AASHTO and ASTM standards that apply to earth retaining
works................................................................................................................................................. 1
Table 20-2: Backfill requirements ..................................................................................................... 4
Table 20-3: Backfill material for crib and cellular walls ..................................................................... 4
Table 20-4: Reinforced (infill) soil for MSE walls .............................................................................. 4
Table 20-5: Materials for reinforced concrete walls .......................................................................... 7
Table 20-6: Construction tolerances for reinforced concrete walls ................................................... 8
Table 20-7: Materials for soldier-pile and soldier-pile tie-back walls ............................................... 10
Table 20-8: Safety factors ............................................................................................................... 17
Table 20-9: Pervious Backfill Gradation .......................................................................................... 20
Page ii
20 EARTH RETAINING SYSTEMS

This chapter provides specifications and requirements for the designing, furnishing, and installing
earth-retaining systems. Such work shall comply with the Contract documents and the specifications
outlined in this chapter.

Standards and codes for Earth Retaining System shall be as specified in these specifications, in the
 AASHTO LRFD American Association of State Highway and Transportation Officials -
 AASHTO LRFD American Association of State Highway and Transportation Officials -
 AASHTO Standard Specifications for Transportation Materials and Methods of
 ADQCC (TR-516) Road Structures Design Manual
 ASTM American Society for Testing and Materials.
that are related to materials for earth retaining systems. It includes designations and titles.
Table 20-1: Designations and titles for AASHTO and ASTM standards that apply to earth
retaining works
AASHTO ASTM
TITLE
Standard Specification for Dry-Cast Segmental

ASTM C1372-11
Retaining Wall Units
Standard Test Methods for Sampling and Testing

ASTM C140-12a
Concrete Masonry Units and Related Units
ASHTO M ASTM
Standard Specification for Structural Steel for Bridges
270M/M 270-12 A709/A709M-11
Standard Test Method for Sieve Analysis of Fine and

AASHTO T 27-11 ASTM C136-06
Coarse Aggregates
AASHTO T 236-
ASTM D3080-11 Standard Test Method for Direct Shear Test
08
ASTM
AASHTO M
A328/A328M- Standard Specification for Steel Sheet Piling
202M/M 202-08
07(2012)
Standard Specification for High-Strength Low-Alloy

ASTM
Nickel, Copper, Phosphorus Steel H-Piles and Sheet
A690/A690M-
Piling with Atmospheric Corrosion Resistance for Use
07(2012)
in Marine Environments
AASHTO M ASTM Standard Specification for Zinc Coating (Hot-Dip) on

232M/M 232-10 A153/A153M-09 Iron and Steel Hardware
Page 20-1
20.2 Working Drawings for Earth Retaining Systems

Working drawings and design calculations shall be submitted to the Engineer for review and approval
at least four weeks before work begins. Such submittals shall be required for the following:
a. For each alternative proprietary or non-proprietary earth-retaining system proposed, as
permitted or specified in the Contract documents.
b. Complete details for the system to be constructed are not included in the Contract
documents.
c. When otherwise required by the Contract documents or these specifications. Working
drawings and design calculations shall include the following:
1. Existing ground elevations that have been verified by the Contractor for each location
involving construction wholly or partially in original ground
2. Layout of wall that will effectively retain the earth as indicated in the Contract
documents
3. Complete design calculations substantiating that the proposed design satisfies the
design parameters in the Contract documents
4. Complete details of all elements required for the proper construction of the system,
including complete material specifications
5. Earthwork requirements, including specifications for material and compaction of
backfill
6. Details of revisions or additions to drainage systems or other facilities required to
accommodate the system
7. Other information required in the Contract documents or requested by the Engineer
8. Assumption made in design and construction loading
9. Life span for the constructed element
10. Any drainage system required during construction and in service
11. Proprietary systems
12. Compaction method
Work shall not begin 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 drawings
shall not relieve the Contractor of any responsibility under the Contract documents for the successful
completion of the work.
20.3 Materials for Earth Retaining Systems

Materials for earth retaining systems shall comply with the standards and requirements outlined in
this section.
20.3.1 Concrete for Earth Retaining Systems

Concrete for earth retaining systems shall comply with the requirements outlined in this section.
20.3.1.1 Cast-in-Place Concrete

Cast-in-place concrete shall conform to the requirements of Chapter 4, Concrete Works, of the
Standard Specifications. The concrete shall be Class C50/20 or stronger unless otherwise indicated
in the Contract documents.
20.3.1.2 Shotcrete
Shotcrete shall conform to the requirements of Section 4.3.10.5 of Chapter 4, Concrete Works of
these Standard Specifications.
Page 20-2
20.3.1.3 Elements of Precast Concrete

Precast concrete element materials, manufacturing, storage, handling, and erection shall conform to
the requirements of Section 21.13 of Chapter 21, Concrete Structures, of these Standard
Specifications.
Unless otherwise shown in the Contract documents, or in the approved working drawings, Portland
cement (OPC and SRC) concrete used in precast elements shall conform to Class C50/20.
20.3.1.4 Segmental Concrete Facing Blocks

Masonry concrete blocks used as wall-facing elements shall have a minimum compressive strength
of 50 MPa and a water absorption limit of 5 percent.
Facing blocks shall meet the requirements of the American Society for Testing and Materials (ASTM)
C1372, except that acceptance regarding durability under this testing method shall be achieved if
the weight loss 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 C140.
20.3.2 Reinforcing Steel for Earth Retaining Systems

Reinforcing steel shall conform to the applicable requirements of Chapter 5, Reinforcing Steel, of
20.3.3 Structural Steel for Earth Retaining Systems

Structural steel shall conform to the American Association of State Highway and Transportation
Officials (AASHTO) M 270M/M 270 (ASTM A709/A709M), Grade 36 (Grade 250) or equivalent,
unless otherwise specified in the Contract documents.
20.3.4 Timber for Earth Retaining Systems

Timber shall conform to the requirements of Chapter 16, Timber structures of the American
Association of State Highway and Transportation Officials (AASHTO) LRFD Bridge Construction
Specifications, 3rd Edition, 2010 and Chapter 7 of the Standard Specifications, Incidental
Construction.
20.3.5 Drainage Elements for Earth Retaining Systems

Drainage elements for earth retaining systems shall comply with the requirements outlined in this
section.
20.3.5.1 Pipe and Perforated Pipe

Pipe and perforated pipe shall conform to Subsection 708, Concrete, Clay, and Plastic Pipe; and
Section 709, Metal Pipe, of the AASHTO Guide Specifications for Highway Construction.
20.3.5.2 Filter Fabric

Filter fabric shall conform to the requirements of Section 2.5.2.9 of Chapter 2, Earthworks, of the
Standard Specifications.
20.3.5.3 Pervious Backfill

Pervious backfill material shall conform to the requirements of Section 2.5.2.5 of Chapter 2,
Earthworks, of the Standard Specifications, unless otherwise specified in the Contract documents or
in the approved working drawings.
Page 20-3
20.3.5.4 Geocomposite Drainage Systems

Geocomposite drainage systems shall conform to the requirements specified in the Contract
documents or the approved working drawings.
20.3.6 Backfill Material

All backfill material shall consist of material free from organic material or other unsuitable material,
as determined by the Engineer. Gradation shall be determined by AASHTO T 27 (ASTM C136).
Grading shall be as shown in Table 20-2, unless otherwise specified.
Table 20-2: Backfill requirements
Sieve size Percent passing
75 mm 100
No. 4 (4.75 mm) 35 – 100
No. 30 (600 μm) 20 – 100
No. 200 (75 μm) 0 - 15
20.3.6.1 Crib and Cellular Walls

Backfill material for crib and cellular walls shall be of such character that it will not sift or flow through
wall openings in accordance to Table 20-2. For wall heights more than 6.0 m, following grading, as
shown in Table 20-3, shall be required.
Table 20-3: Backfill material for crib and cellular walls
75 mm 100
No. 4 (4.75 mm) 25 – 70
No. 30 (600 μm) 5 – 20
No. 200 (75 μm) 0–5
20.3.6.2 Mechanically Stabilised Earth Walls

Reinforced (infill) soil for mechanically stabilised earth (MSE) walls shall conform to the grading,
internal friction angle, and soundness requirements shown in Table 20-4.
Table 20-4: Reinforced (infill) soil for MSE walls
75 mm 100
No. 40 (425 μm) 5 – 60
No. 200 (75 μm) 0 – 10
*Plasticity index (PI), as determined by AASHTO T 90, shall not exceed 6%.
Page 20-4
Materials shall exhibit an angle of internal friction of not less than 36 degrees, as determined by the
Standard Direct Shear Test, AASHTO T 236 (ASTM D3080), on the portion finer than the No. 10 (2-
mm) sieve, utilising a sample of the material compacted to 95 percent of AASHTO T 99, Methods C
or D at optimum moisture content. No testing is required for reinforced (infill) material where 80
percent of sizes are greater than 19 mm.
Materials shall be substantially free of shale or other soft, poor durability particles; and shall have a
magnesium sulphate soundness loss of less than 30 percent after five cycles.
Additionally, reinforced (infill) material shall meet the following electrochemical requirements when
using steel soil reinforcement:
a. pH of 6 to 10
b. Resistivity not less than 30 ohm.m
c. Chlorides not greater than 100 parts per million
d. Sulphates not greater than 200 parts per million
e. No recycled aggregate material shall be used
20.4 Earthwork for Earth Retaining Systems

Earthwork for retaining systems shall comply with the requirements outlined in this section.
20.4.1 Structure Excavation

Structure excavation for earth-retaining systems shall conform to the requirements of Section
2.4.2.11 of Chapter 2, Earthworks, of the Standard Specifications and as provided below.
20.4.2 Foundation Treatment

If sub-excavation of foundation material is required, 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.
Foundation soil shall be proof rolled and compacted to 95% Modified Proctor density and inspected
by the Engineer prior to placement of levelling pad materials, or as per bearing capacity required
shown on the Contract plans.
20.4.3 Structure Backfill

Placement of structure backfill material shall conform to the requirements of Section 2.5.2.4 of
Chapter 2, Earthworks, of the Standard Specifications and Section 20.6. Material used shall conform
to the requirements of Section 20.3.6.
20.5 Drainage for Earth Retaining Systems

Drainage facilities shall be constructed in accordance with the details shown in the approved working
drawings or in the Contract documents and these specifications.
20.5.1 Concrete Gutters

Concrete gutters shall be constructed to the profile indicated in the Contract documents or in the
approved working drawings. Shotcrete shall conform to the requirements of Section 4.3.10.5 of
Chapter 4, Concrete Works of these Standard Specifications. Outlet works shall be provided at sags
in the profile, at the low ends of the gutter, and at other indicated locations.
Page 20-5
20.5.2 Weep Holes

Weep holes shall be constructed by the Contractor at the locations shown in the Contract documents
or in the approved working drawings. A minimum of 0.06 m3 of pervious material as specified in
Article 20.3.5.3 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 approved adhesive.
Face panels that are to receive the filter fabric shall be dry and thoroughly cleaned of dust and loose
materials.
20.5.3 Drainage Blankets

Drainage blankets consisting of pervious material encapsulated in filter fabric, collector pipes, outlet
pipes, and cleanout pipes shall be constructed as specified in the Contract documents or in the
approved working drawings.
Subgrade receiving 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 installation.
The fabric shall be stretched, aligned, and placed in a wrinkle-free manner. Adjacent borders of the
fabric shall be overlapped from 300 mm to 450 mm. should the fabric be damaged, the torn or
punctured section shall be repaired by placing a piece of fabric that is large enough to cover the
damaged area and to meet overlap requirements.
Pervious materials shall be placed in horizontal layers and thoroughly consolidated along with and
by the same methods specified for structure backfill. Ponding and jetting of pervious material or
structure backfill material adjacent to pervious material shall not be permitted.
During spreading and compaction of the pervious 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.
Perforated collector pipes shall be placed within the pervious material to the flow line elevations
shown.
Outlet pipes shall be placed at sags in the flow line, at the low end of the collector pipe, and at other
locations shown or specified in the Contract documents. Rock slope protection, when required at the
end of outlet pipes, shall conform to the details in the Contract documents, or approved working
drawings, and the applicable requirements in Chapter 7 of the Standard Specifications, Incidental
Construction.
Cleanout pipes shall be placed at the high ends of collector pipes and at other locations, as specified
20.5.4 Geocomposite Drainage Systems

Geocomposite drainage systems shall be installed at the locations shown in the Contract documents
or in the approved working drawings. 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.
20.6 Construction for Earth Retaining Systems

Earth-retaining system construction shall conform to the lines and grades indicated in the Contract
documents, on the working drawings, or as directed by the Engineer.
Page 20-6
20.6.1 Concrete, Masonry Gravity, and Reinforced Concrete

Retaining Walls
Stone and Reinforced concrete block masonry construction shall conform to the applicable
requirements of Section 6.2 of Chapter 6, Masonry, of these Standard Specifications.
Vertical precast concrete wall elements with cast-in-place concrete footing support shall be
adequately supported and braced to prevent settlement or lateral displacement until the footing
concrete has been placed and has achieved sufficient strength to support the wall elements.
The exposed face of concrete walls shall receive a Class 2 finish as specified in Section 21.12 of
Chapter 21, Concrete Structures, of these Standard Specifications, unless a special architectural
treatment is specified in the Contract documents, or in the approved working drawings.
20.6.1.1 Materials
Concrete shall be of the compressive strength shown on the Contract plans, typically Class C30/20.
Materials shall conform to the requirements of the Contract plans, the Engineer, and these standard
specifications, including those sections specifically noted in Table 20-5. Other materials required
shall be as specified in the particular specifications.
Table 20-5: Materials for reinforced concrete walls
Material Standard specification

section
Portland cement concrete and its constituent materials; Chapter 4, Materials

steel reinforcing bar and epoxy-coated steel reinforcing bar; Chapter 5, Reinforcing Steel
premoulded joint filler and water stops. Chapter 4, Water stops
Backfill Chapter 2, Structural backfill
Pipe underdrains Chapter 11, Pipe underdrains
20.6.1.2 Construction Requirements

a. Excavation and Foundation Preparation
Excavation and backfill shall be in accordance with the requirements of applicable Sections of
Chapter 2, Earth Works, of the Standard Specifications.
Excavation shall conform to the requirements of Section 2.4.2.11 of Chapter 2, Earth Works, and to
the limits and construction stages shown in the Contract plans. Foundation soils found to be
unsuitable shall be removed and replaced in accordance with the applicable Sections of Chapter 2,
Earth Works.
b. Precast Concrete Wall Stem Panels

Unless otherwise indicated on the Contract plans, the Contractor may fabricate precast concrete
wall stem panels. Precast concrete wall stem panels may be used for construction of retaining walls,
if allowed by the Contract plans or the particular specifications. Precast concrete wall stem panels
shall conform to Chapter 4, Precast concrete panels, and shall be cast with Class C30/20 or stronger
concrete. Formwork shall comply with Chapter 4, Formwork.
Precast concrete wall stem panels shall conform to the following:
1. Be fabricated per the dimensions and details shown in the Contract plans, except as modified
in the shop drawings or as approved by the Engineer
2. Be fabricated full height
Page 20-7
3. Conform to the construction tolerances as stated in Table 20-6

4. Include a mating shear key between adjacent panels as follows:
 Beveled corners
 Thickness of 40 mm
 Continuous with uniform width over the entire height of the wall stem, with a minimum
width of 90 mm and a maxium width of 140 mm
5. Receive the surface finish specified in the Contract plans to the limits shown in the Contract
plans in conformance with Chapter 21, Concrete finishing or as supplemented in the
particular specifications. Rolled on textured finished shall not be used.
6. Be cast in a vertical position if a form liner texture is required on both sides of the panel.
7. Be rigidly held in place during placement and curing of the footing concrete.
8. Be placed a minimum of 25 mm into the footing to provide a shear key.
9. Be constructed so that the base of the precast concrete wall stem panel is sloped 40 mm per
metre to facilitate proper concrete placement.
Maximum allowable tolerances or deviations from dimensions shown on the Contract plans or the
approved shop drawings shall be as described in Table 20-6.
Table 20-6: Construction tolerances for reinforced concrete walls
Parameter Tolerance
Height of precast wall stem panel ±6 mm
Width of precast wall stem panel ±6 mm
Thickness of precast wall stem panel +6 mm, -3 mm
Concrete cover for steel reinforcing bar +10 mm, -3 mm
Width of precast concrete wall stem panel joints ±6 mm
Offset of precast concrete wall stem panels

(Deviation from a straight line extending 1.5 m on
each side of the panel joint)
- Across panel face
±6 mm
- Across top of wall
±10 mm
Footing cross sectional dimensions +50 mm, -13 mm
Variation in footing thickness +no limit, -5 % of specified thickness up to

a maximum of 13 mm
Average levels of footings ±25 mm
Position of wall 10 mm
Alignment of wall 2 minutes
Average levels of wall +10 mm
Verticality of wall 1 in 400. Maximum 25 mm
Surface regularity of wall 3 mm
Page 20-8
Soil bearing pressure beneath the formwork supports for the precast concrete wall stem panels shall
not exceed the maximum design soil pressure shown in the Contract plans for the retaining wall.
To ensure an even flow of concrete under and against the base of the wall panel, a form shall be
placed parallel to the precast concrete wall stem panel, above the footing, to allow a minimum 300
mm head to develop in the concrete during concrete placement.
Minimum clear cover to the erection block-outs shall be 40 mm.
All precast concrete wall stem panel joints shall be constructed with joint filler installed on the backfill
side of the wall. Joint filler material shall extend from 0.6 m below the final ground level in front of
the wall to the top of the wall. Joint filler shall be a nonorganic flexible material meeting the
requirements for joint filler in Chapter 4 and shall be installed to create a waterproof seal at panel
joints.
c. Cast-in-Situ Concrete Construction

Cast-in-situ concrete for concrete retaining walls shall be formed, reinforced, cast, cured, and
finished in accordance with Chapter 4, Concrete Works, and the details shown in the Contract plans.
All cast-in-situ concrete shall be Class C30/20. Formwork shall comply with Section 1.20.8 of
Chapter 1, General Requirement, of these Standard Specifications.
Cast-in-situ concrete for adjacent wall stem sections between vertical expansion joints shall be
formed and placed separately, with a minimum 12-hour time period between concrete placement
operations or as approved by the Engineer.
Premoulded joint filler, 12 mm thick, shall be placed at the full height of all vertical wall stem
expansion joints. When the Contract plans call for premoulded joint filler, the Contractor shall fasten
it with galvanised wire nails to one side of the joint. Nails must be no more than 150 mm apart and
shall be 40 mm from the edges over the entire joint area. Nails shall be at least 40 mm longer than
the thickness of the filler.
Nails may be substituted by the Contractor with any adhesive approved by the Engineer. This
adhesive, however, shall be compatible with ASTM D 1751(29) materials and capable of bonding the
filler to portland cement concrete (PCC).
d. Backfill, Weepholes, and Gutters

Backfill, weepholes, and gutters shall be constructed as shown on the Contract plans. Unless
otherwise shown in the Contract plans, structural backfill conforming to the requirements of Section
2.5.2.4 of Chapter 2, Earth Works, backfill, shall be installed in the zone between the back of wall
and a vertical plane extending up from the back of the footing or from the back of the wall drain,
whichever is farther from the back of the wall. Structural backfill shall extend the full height of the
wall or to 200 mm below the concrete gutter, if present, unless otherwise shown on the Contract
plans.
Backfill and compaction in bridge approach zones shall be done for each layer. For other areas,
backfill and compaction shall only be required for the top 600 mm of depth. All backfill and
compaction shall be performed in accordance with Section 2.5.3.4 of Chapter 2, Earth Works, of the
Weepholes are typically 75-mm-diameter openings placed in the wall panel above the ground level
at the face of wall and sloped down toward the face of wall, as shown in the Contract plans.
20.6.2 Sheet-pile, Soldier-pile and Secant Pile walls

This work constructs continuous walls of timber, steel, or concrete sheet piles, and constructs
soldier-pile (H-Beam/King Post) walls with horizontal facing elements of timber, steel, or concrete.
Page 20-9
20.6.2.1 Description
This work constructs sheet pile, soldier-pile walls, soldier-pile tie-back walls, concrete soldier-pile
walls, and secant pile walls.
Soldier-pile walls consist of steel piles, which may be wide flanges or pipes, embedded into the
ground along the wall alignment with timber lagging installed to retain soil between the piles. Soldier-
pile tie-back walls are soldier-pile walls with ground anchors installed between piles.
Concrete soldier-pile walls use reinforced concrete shafts instead of steel piles, and the unsupported
length of wall between concrete piles is retained by reinforced shotcrete facing in place of timber
lagging.
Secant pile walls consist of closely spaced concrete shafts with no unreinforced space between the
constructed shafts.
20.6.2.2 Materials
Materials shall meet the requirements of Table 20-7 and as described herein.
Table 20-7: Materials for soldier-pile and soldier-pile tie-back walls
Material Specification section
PCC and its constituent materials; Chapters 4 and 5, Materials

Steel reinforcing bar and epoxy-coated steel reinforcing bar;
Premoulded joint filler and waterstops.
Backfill Chapter 2, Structural backfill
Pipe underdrains Chapter 11, Pipe underdrains
Controlled density fill (CDF) Chapter 4, Controlled density fill
Permanent ground anchors Chapter 19, Ground Anchors
Paints Chapter 24, Painting
Shotcrete Chapter 7, Shotcrete facing
Timber lagging for soldier-pile walls shall be structural grade material of the size, species, and grade
shown on the Contract plans, or as directed by the Engineer. Grades shall be as established by the
United Kingdom Timber Grading Committee, or equivalent international timber grading certification
organisation, as approved by the Engineer.. Unless otherwise specified, timber lagging in walls with
concrete fascia panels shall be untreated. Timber lagging for all other walls shall be treated.
Material for steel piling and pile splices shall conform to ASTM A 36M or ASTM A 992M, except the
material for steel pipe piling and splices shall conform to the requirements of ASTM A 252, Grade 2.
Steel soldier-piles, and associated steel bars and plates, shall conform to ASTM A 36M or ASTM A
992M, except as otherwise noted in the Contract plans. All steel piling material may be accepted by
the Engineer based on the manufacturer’s certificate of compliance.
Other materials required shall be as specified in the particular specifications.
20.6.2.3 Sheet-pile Walls

Steel sheet piles shall be of the type and weight (mass) specified in the Contract documents. Steel
sheet piles shall conform to the requirements of AASHTO M 202M/M 202 (ASTM A328/A328M),
Page 20-10
AASHTO M 270M/M 270 (ASTM A709/A709M) Grade 50 (Grade 345), or to the specifications for
Piling for Use in Marine Environments in ASTM A690/A690M.
Painting of steel sheet piles, when required, shall conform to the requirements of Section 24.5 of
Chapter 24, Painting, of the Standard Specifications.
Timber sheet piles, unless otherwise specified or permitted in the Contract documents, shall be
treated in accordance with American Association of State Highway and Transportation Officials
(AASHTO) LRFD Bridge Construction Specifications, Chapter 17, Preservative treatment of wood.
Piles shall be of the dimensions, species, and grade of timber specified in the Contract documents.
Piles may be either cut from solid material or made by building up with three planks securely fastened
together.
Piles shall be drift sharpened at their lower ends so as to wedge adjacent piles tightly together during
driving.
Concrete sheet piles shall conform to the details specified in the Contract documents or the approved
working drawings. Manufacture and installation of sheet piles shall conform, in general, to the
requirements for precast concrete bearing piles in Chapter 18 of the Standard Specifications, Driven
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 installation, have the upper grooves cleaned
of all sand, mud, or debris and grouted full. Unless otherwise provided in the Contract documents,
or approved in writing by the Engineer, 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 which,
when filled, completely fills the slot.
Sheet piles shall be driven to the specified penetration or bearing capacity in accordance with the
requirements of Chapter 18 of the Standard Specifications, Driven Piles.
After driving, the tops of sheet piles shall be neatly cut-off to a 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, or directed by the Engineer.
Timber waling strips shall be properly lapped and joined at all splices and corners. The wales shall
preferably be in one length between corners and shall be bolted near the tops of the piles.
When specified in the Contract documents, or in the approved working drawings, reinforced concrete
caps shall be constructed in accordance with Chapter 4, Concrete Works, of these Standard
Specifications.
20.6.2.4 Soldier-pile Walls

Soldier-piles (H-Beam/King Post) shall be either driven piles or piles constructed in a drilled shaft
excavation to the specified penetration or bearing capacity indicated in the Contract documents.
Driven piles shall be furnished and installed in accordance with the requirements of Chapter 18 of
the Standard Specifications, Driven Piles. 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 concrete or lean concrete backfill shall be in
accordance with Chapter 17, of the Standard Specifications, Drilled Piles. Structural components of
the soldier-pile placed in the shaft excavation shall be as specified in the Contract documents.
Reinforced concrete, either cast-in-place or precast, shall conform to the requirements of Chapter 4
of the Standard Specifications, Concrete Works.
Page 20-11
Timber members shall conform to the requirements of the American Association of State Highway
and Transportation Officials (AASHTO) LRFD Bridge Construction Specifications, 2010, Chapter 16,
Timber structures and Chapter 17, Preservative treatment of wood of and Chapter 7 of the Standard
Specifications, Incidental Construction.
Steel members shall conform to the requirements of Chapter 23 of the Standard Specifications, Steel
Structures. Painting of steel members, if required, shall conform to the requirements of Section 24.5
of Chapter 24, Painting, of the Standard Specifications.
Concrete backfill placed around precast concrete, timber, or steel pile members in the drilled shaft
excavation shall be of class C20/20 or as shown in the Contract plans. The limits for placement of
concrete and lean concrete shall be specified in the Contract documents.
The facing spanning horizontally between soldier-piles shall conform to the materials and details in
the Contract documents or in the approved working drawings. Timber lagging shall conform to the
requirements of the American Association of State Highway and Transportation Officials (AASHTO)
LRFD Bridge Construction Specifications, Chapter 16, Timber structures, and Chapter 17,
Preservative treatment of wood. Precast concrete lagging or facing panels and cast-in-place
concrete facing shall conform to the requirements in Chapter 4 of the Standard Specifications,
Concrete Works.
Concrete anchors, welded connections, and bolted connections for securing facing elements to the
soldier-piles shall conform to the details in the Contract documents.
Exposed surfaces of concrete wall facing shall receive a Class 1 finish, as specified in Chapter 4 of
the Standard Specifications, Concrete Works, unless a special architectural treatment is specified in
the Contract documents or in the approved working drawings.
20.6.2.5 Secant-Pile Walls

Secant pile walls shall be constructed in the same manner as concrete soldier-pile walls, except that
the sequence of shaft construction shall be as indicated in the particular specifications. Primary
shafts are installed first and allowed to cure undisturbed for the minimum time established in the
particular specifications before secondary piles are constructed in the intermediate areas.
20.6.2.6 Anchored Sheet-pile and Soldier-pile Walls

Anchored wall construction 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 conform to the requirements of Articles 20.6.2.3 and 20.6.2.4, respectively.
a. Wales
Wales consisting of timber, steel, or concrete shall conform to the details in the Contract documents,
or in the approved working drawings. The alignment of wales shall be such that tie-rods or ground
anchors can be installed without excessive bending. Steel wales shall conform to the requirements
of Chapter 23 of the Standard Specifications, Steel Structures. Concrete wales shall conform to the
requirements of Chapter 4 of the Standard Specifications, Concrete Works.
b. Concrete Anchor System
Concrete anchor systems, consisting of 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 documents or in the approved working drawings.
Battered anchor piles shall be driven to the proper batter 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 in the
approved working drawings and be constructed in conformance with Chapter 17 of the Standard
Specifications, Drilled Piles.
Page 20-12
c. Tie-rods
Tie-rods shall be round-steel bars conforming to AASHTO M 270M/M 270 (ASTM A709/A709M),
Grade 36 (Grade 250), unless otherwise specified in the Contract documents.
Corrosion protection shall be provided as specified in the Contract documents. Care shall be taken
in the handling and backfilling operations to prevent damage to the corrosion protection or bending
of the tie-rod itself.
Tie-rod connections to the soldier-piles, wales, wall faces, and concrete anchors shall conform to
the details specified in the Contract documents.
d. Ground Anchors
Ground anchors shall be constructed in conformance with the requirements of Chapter 19 of the
Standard Specifications, Ground Anchors.
Ground anchor connections to soldier-piles, wales, or wall faces shall conform to the details in the
Contract documents, or in the approved working drawings. Anchor elongation shall be monitored
and approved before final cutting of strands.
e. Earthwork
Earthwork shall conform to the requirements in Section 20.4.
Unless otherwise specified in the Contract documents, excavation in front of the wall shall not
proceed more than 900mm below a level of tie-rods or ground anchors until tie-rods and anchors, or
ground anchors, are completed and accepted by the Engineer.
Placement of lagging shall closely follow excavation in front of the wall such that loss of ground is
minimized.
20.6.3 Crib and Cellular Walls

This work constructs timber, concrete, or steel crib walls; and concrete monolithic cell walls,
complete with backfill material, within the cells formed by the members.
20.6.3.1 Foundation
In addition to the requirements of Section 20.4.2, the foundation or bed course material shall be
finished to exact grade and cross slope so that the vertical or battered face alignment shall be
achieved.
When required, timber mud sills, concrete levelling 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 levelling pads, or footings, shall be placed against the sides of excavation in the
foundation material.
20.6.3.2 Crib Members

Unless otherwise specified in the Contract documents, timber headers and stretcher members shall
conform to the requirements of the American Association of State Highway and Transportation
Officials (AASHTO) LRFD Bridge Construction Specifications, Chapter 16, Timber structures, and
shall be the same as for caps, posts, and sills. Preservative treatment shall conform to the
requirements of the American Association of State Highway and Transportation Officials (AASHTO)
LRFD Bridge Construction Specifications, Chapter 17, Preservative treatment of wood. Member
sizes shall be as shown in the Contract documents.
Concrete header and stretcher members shall conform to the requirements of Chapter 4 of the
Standard Specifications, Concrete Works, for precast concrete members. Member dimensions and
Page 20-13
minimum concrete strengths shall be as specified in the Contract documents, or in the approved
working drawings.
Steel crib members consisting of base plates, columns, stretchers, and spacers shall be fabricated
from sheet steel conforming to AASHTO M 218. Member thickness 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 improperly punched shall be replaced. Bolts, nuts, and
miscellaneous hardware shall be galvanized in accordance with AASHTO M 232M/M 232 (ASTM
A153/A153M).
20.6.3.3 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 Chapter 21 of
the Standard Specifications, Concrete Structures. Minimum concrete compressive strengths shall
be of class C30/20.
Exposed cell faces 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 distortions in excess of 6mm. Protruding keys
and recesses for keys on the tops and bottoms of the side walls of the cells shall be accurately
located.
20.6.3.4 Member Placement

Timber and concrete crib members shall be placed in successive tiers at spacing conforming to the
specified details for the particular height of the 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 intersection of concrete header and stretcher
members, asphalt felt shims, or other approved material, shall be used to obtain uniform bearing
between the members.
Steel column sections, stretchers, and spacers shall conform to the proper length and weight, or
mass, as specified in the Contract plans. These members shall be accurately aligned to permit
completing the bolted connections without distorting the members. Bolts at the connections shall be
torque to not less than 34000 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 in 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.
20.6.3.5 Backfilling
Cells formed by the wall members shall be backfilled with structure backfill material conforming to
the requirements in Section 20.3.6. Backfilling shall progress simultaneously with the erection of the
members forming the cells. Placement of backfill material shall not disturb or damage the members.
Overall stability shall be considered, including construction loading and surcharge.
Placement of backfill shall be in uniform layers not exceeding 300mm in thickness, unless otherwise
proposed by the Contractor and approved by the Engineer. Compaction shall be to a density of at
least 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.
20.6.4 MSE Walls

This Section specifies construction of retaining walls using a proprietary reinforced soil wall system
using either Precast Concrete Facing Panels or Modular Block Facing Units, constructed in
Page 20-14
accordance with the supplier's drawings and specifications and in conformity with the alignment,
grades and dimensions shown on the Contract plans or as established by the Engineer.
MSE wall construction shall consist of constructing a facing system to which polymeric soil
reinforcement is connected and the placement of reinforced infill material surrounding the soil
reinforcement.
20.6.4.1 Terminology
Inclusion: is a generic term that encompasses all man-made elements incorporated in the soil to
improve its behaviour. Examples of inclusions are geotextile sheets, or polymeric grids. The term
reinforcement is used only for those inclusions where soil-inclusion stress transfer occurs
continuously along the inclusion.
Mechanically Stabilized Earth Wall (MSEW): is a generic term that includes reinforced soil (a term
used when multiple layers of inclusions act as reinforcement in soils placed as fill).
Reinforced Soil Slopes (RSS): are forms of reinforced soil that incorporate planar reinforcing
elements in constructed earth-sloped structures with face inclinations of less than 70 degrees.
Geosynthetics: is a generic term that encompasses flexible polymeric materials used in geotechnical
engineering such as geotextiles, geomembranes, geonets, and grids (also known as geogrids).
Facing: is a component of the reinforced soil system used to prevent the soil from ravelling out
between the rows of reinforcement. Common facings include precast concrete panels, dry cast
modular blocks, shotcrete, wood lagging and panels, and wrapped sheets of geosynthetics. The
facing also plays a minor structural role in the stability of the structure. For RSS structures it usually
consists of some type of erosion control material.
Retained Soil: is the fill material located between the mechanically stabilized soil mass and the
natural soil.
Reinforced (Infill) Soil: is the fill material in which the reinforcements are placed.
20.6.4.2 References
All work shall conform to the latest edition of all applicable standards and codes. The following is a
representative list of applicable codes and standards however is not an all inclusive list.
a. American Concrete Institute (ACI):
1. 318/318R, Building Code Requirements for Reinforced Concrete.
b. American Society for Testing and Materials (ASTM):
1. A615/A615M, Standard Specification for Deformed and Plain Billet-Steel Bars for
Concrete Reinforcement.
2. A775/A775M, Standard Specification for Epoxy-Coated Reinforcing Steel Bars.
3. ASTM 4595 , Tensile tests for geotextiles and geogrids.
c. American Association of State Highway and Transportation Officials (AASHTO):
1. AASHTO-LRFD "Bridge Design Specifications
2. (AASHTO) LRFD Bridge Construction Specifications,.
d. U.S Federal Highway Administration publications:
1. FHWA No. FHWA-NHI-10-024 and FHWA-NHI-10-025.
20.6.4.3 General Requirements

a. The Contractor shall provide a complete set of drawings issued for construction and complete
specifications of the proposed wall system for the approval of the Engineer prior to ordering
materials to construct these walls.
b. Any particular requirements of the approved detailed specifications for the approved
proprietary system shall govern over any conflicting or incompatible requirement contained
within these Specifications.
Page 20-15
c. The Contractor must demonstrate that the proposed reinforced soil wall system has
previously been used in the UAE.
d. The wall system as a whole shall have a current British Board of Agreement (BBA), passing
the HITEC (Highway Innovative Technology Centre) evaluation protocol, or equivalent
certificate for Roads and Bridges, demonstrating suitability for use in highways walls and
abutments with a minimum 75 year design life.
e. The scope of work shall also include the design and construction of the concrete barrier
above the reinforced fill wall together with its counterbalancing slab all as indicated on the
Contract plans, All exposed faces of the concrete barrier and coping above the reinforced fill
wall shall be precast.
f. A Representative of the reinforced fill retaining wall manufacturer shall be present on site
during the casting and erection phases for a sufficient period to ensure that the quality of the
works performed by the Contractor is in accordance to the Specification. Furthermore the
Engineer/Owner reserves the right to ask for the Manufacturer's Representative whenever
they deem necessary. All expenses relative to his presence on site shall be borne by the
Contractor.
g. The design shall address the climatic and soil conditions existing in UAE and provide a
minimum design life of 75 years. The design must be performed by the supplier of the wall
system, who shall submit proof of professional indemnity insurance coverage. The
specifications as presented to the Engineer shall state any requirements for or limitations on
the reinforced infill to ensure the design life.
20.6.4.4 Submittals
a. Design Calculations
I. The following design criteria shall be considered:
1. The vertical live load to be allowed in the design shall be: 1.5 x [LRFD HL93].
2. However, no vertical load shall be allowed when considering the resistance to
overturning of the concrete barrier/counterbalance slab when subjected to vehicle
impact load. Reference is to be made to Section 11.10 in the above AASHTO (LRFD),
Bridge Design Specifications.
3. The simplified Coherent Gravity Method should be used (Kr=Ka).
4. Live load surcharge shall be in accordance with AASHTO LRFD with an additional
magnification factor of 1.5 fill.
5. Analysis Concept and the Factors of Safety for External and Internal Stability
i. Design reduction factor, due to temperature effects (in addition to creep,
degradation and Installation damage reduction factors) should not be less than
1.11 times the value reported at 20o C.
ii. Design Temperature shall be ≥40o C
iii. The wall supplier should use a 33o friction angle and a unit weight of 1921kg/m2
for the backfill material in their design computations unless otherwise indicated
on the plans.
iv. The factor of safety for pullout resistance in the select fill should not be less than
1.5, based on the pullout resistance at 13mm (1/2”) deformation.
v. Design global factor of safety should be 1.5.
vi. Seismic Stability (Extreme Event Limit State I, with A=0.1 and 0.07):
FOS ≥ 0.75 of static FOS (All failure modes)
Check eccentricity (LRFD; Fig. 11.6.3.2-2 and Cl. 11.6.3.3),
soil bearing capacity (LRFD; Cl. 11.5.7) and
sliding under Extreme Event Limits I & II (LRFD;eq, 10.6.3,3-2).
Safety factors against slope slide at critical sections should be as per Table 20-8
Page 20-16
Table 20-8: Safety factors
Earthquake Acceleration Factor Safety Factors Against Slide
0.0 1.50
0.07 1.40
≥ 0.10 1.30
(min. as per AASHTO-LFD, Cl. 5.2.2.3).
II. The design of MSE walls shall be based on the following information provided by the main
Contractor:
1. Basic section geometry
2. Backfill Tests Results, Permeability and grading should be presented to the Engineer
as well. The minimum value for the coefficient of uniformity (Cu=D60/D10 ≥ 2.0) should
be obtained from the Grading Curve. The Internal angle of friction should be at least
33.0o for the backfill behind the MSE wall. soil-min should be taken as 18KN/m3 and
soil-max = 21KN/m3 . These properties shall be regularly monitored by the Contractor
during construction to ensure compliance with the approved property limits and
confirming to ISO 26021; "Statistical Interpretation of Test Results".
3. The difference between the reinforced infill and embankment backfill elevations is not
to be more than 600mm at any time during backfilling.
III. It is the responsibility of the Designer and Contractor to ensure the MSE panels have:
1. Height less than or equal to some 15.0m.
2. Toe pressure less than or equal to 143 kPa.
3. There are no anticipated bearing and/or settlement problems.
4. Where groundwater is present, a suitable drainage blanket is detailed below and
behind the MSE Wall
5. In off-bridge areas, where MSE panels are used, a counter-balance slab monolithic
with the parapets and above the earth retaining walls should be designed to
counteract for the impact due to vehicle collision.
b. System Information
The system submission shall be accompanied by:
1. A copy of the current BBA certificate or equivalent certificate, which shall include the
following information, as a minimum: a) Design Temperature of Strap. b) Details of
Production Factories. c) ISO Certificate reference of the Production Factories. d)
Design Calculation of the Strap Capacity.
2. Detailed design calculations for the proposed walls in compliance with AASHTO
LRFD, publications No. FHWA-NHI-10-024 & FHWA-NHI-10-025 or the National
Concrete Masonry Association Design Manual for Segmental Retaining Walls, 2nd
edition for modular blocks.
3. Soils test information of the proposed reinforced soil fill.
4. Method statement for construction.
5. Confirmation of the Professional Indemnity insurance cover provided by the Wall
System Supplier.
6. Proven track record that the proposed system and type of reinforcement have been
used previously and successfully In the UAE for similar heights as walls of this project.
7. It is very important that the Geosynthetic Friction Reinforcements that the Contractor
proposes to use in the soli has been successfully used before in the UAE and has all
the necessary certification and test results support It.
Page 20-17
c. Shop Drawings
The Contractor shall submit details and drawings. Any particular requirements of the approved
detailed specifications for the approved proprietary system shall govern over any conflicting or
incompatible requirement contained within this section of the specification. The Contractor shall also
provide a detailed installation method statement.
20.6.4.5 Materials
The MSE retaining walls should conform to the Supplier's standards as previously approved by the
Engineer and AASHTO·LRFD Specification for MSE walls. The soil reinforcing system, which
includes the soil geosynthetic reinforcement, panel embeds and all connection devices, should be
according to the AASHTO-LRFD Standard.
The wall system shall comprise of precast concrete panels with geosynthetic reinforcement and
connectors designed to ensure a high strength, positive connection between wall face and
reinforcement. The Independent approval certificate shall have assessed this connection efficiently.
d. Precast Concrete Facing Panels

Concrete Class C40/20 shall be used for precast panels, coping, and for barriers and concrete
balance footing.
All precast panels should be manufactured according to the following requirements:
1. The minimum panel thickness as required by design but should not be less than 140mm.
2. Fusion bonded epoxy coated reinforcement bars should be used for panels.
3. The minimum reinforcement bar cover should be 50mm to all faces of the panels unless
otherwise approved by the Owner.
4. The panels should have a ship lap or tongue and groove system of overlapping joints
between panels designed to conceal joints and bearing pads.
5. All dimension deviations should be within 5mm.
6. Angular distortion with regard to the height of the panel should not exceed 5mm in 1.5m.
7. Surface defects on formed surfaces measured on a length of 1.5m should not be more than
2.5mm.
8. The panel embed/connection devices should be cast into the facing panels with a tolerance
not to exceed 25mm from the locations specified on the approved shop drawings.
9. The back face of the panel should be roughly screeded to eliminate open pockets of
aggregate and surface distortions in excess of 6mm.
10. To prevent out of plane panel rotations, the soil geosynthetic reinforcement should be
connected to the standard panels In at least two different elevations, vertically spaced no
more than 760mm apart unless evidence is submitted that greater spacing is acceptable.
e. Modular Block Facing Units

1. The blocks shall be machine manufactured from Portland cement concrete specifically
designed for use in a reinforced soli retaining wall system.
2. Colour of the facing units shell be as specified by the Engineer/Owner.
3. The blocks shall have a straight split/textured face finish.
4. Block height shall be 200mm or less.
5. Block units shall be solid through the full depth of the unit.
6. Blocks when Installed shall have gap not greater than 4mm between adjacent units.
7. Block units shall be sound and free of cracks or other defects that would interfere with the
proper placing of the unit or significantly impair the strength or permanence of the structure.
Cracking or excessive chipping may be grounds for rejection. Units showing cracks longer
than 13mm shall not be used within the wall. Units showing chips visible at a distance of 10
meters from the wall shall not be used within the wall.
8. Concrete used to manufacture block units shall have a minimum 28 days compressive
strength of 30N/mm2 and a maximum moisture absorption rate, by weight, of 5% as
Page 20-18
determined In accordance with ASTM C 140. Compressive strength test specimens shall
conform to the saw-cut coupon provisions of Section 5.2.4 of ASTM C140 with the following
exception: Coupon shall be taken from the least dimension of the unit of a size and shape
representing the geometry of the unit as a whole.
9. Block units molded dimensions shall not differ more than ± 3mm from that specified.
10. All modular block facing units will be manufactured by a block manufacturer approved by the
Engineer.
11. Only block systems that provide full face without any "voids" when constructed will be
accepted. The blocks should be interlocking from one level to the next by means of an
integrated mechanical key built into their shape. Blocks must achieve connectivity by a
continuous mechanical connection built into the shape, and/or by a mechanical key formed
as part of the connection device.
12. The shear strength between blocks, and the connection strength between block and
geosynthetic reinforcement must be demonstrated in accordance with the procedures of
NCMA SRWU·1 and SRWU-2 or other recognized test standard.
13. A minimum 300mm drainage layer (with drainage pipe) wrapped in geotextile shall be used
behind the block walls to avoid undue build up of hydrostatic pressure. The drainage
collection pipe shall be a perforated or slotted PVC, or corrugated HDPE pipe. The drainage
pipe shall be manufactured in accordance with ASTM D3034 and/or ASTM D1248. The pipe
shall be a minimum of 100mm in diameter.
14. All units shall be manufactured within the following tolerances:
 the height of the blocks are to be ±3mm.
 the length of the block to be ±3mm
 the squareness of the blocks to be ±2mm
15. Particular care shall be taken during storage to avoid staining the front face of the blocks.
16. Blocks will be subject to rejection because of failure to meet any of the requirements of the
Specifications. In addition, any or all of the following defects shall be sufficient cause for
rejection:
 Defects that indicate imperfect molding.
 Defects indicating honeycombed or open textured concrete.
 A block with a damaged surface finish or staining or is otherwise chipped or cracked
on the front face such that In the opinion of the Engineer is visibly different from other
blocks. Such a block may however be used in positions where it is below final ground
level, subject to the Engineer's approval.
f. Geosynthetic Friction Reinforcement

The geosynthetic friction reinforcement shall be strips of polymeric high tenacity polyester fibers
concentrated in a series of separated bundles and encased in a durable polyethylene sheath.
Polyester fibers shall have a minimum Number Average Molecular Weight of 27000 as per ASTM
D4603 and GGI-GR8 method, and Maximum of Carboxyl End Group Content of 30 as per GRI-GG7
method. The minimum Weight per Unit Area as per ASTM D5261 shall be 270 gm/m2. All polymeric
components shall contain no recycled materials.
All product specific durability testing reports, documented evidence of third party participating, and
any relevant information shall be provided to the Engineer to examine the short-term and long-term
effects of environmental factors. The reports, documents and information shall include, but shall not
be limited to the following:
1. Short-term Tensile Strength, Elongation Tests results and load/strain characteristics
at different testing temperatures as per ASTM D4595.
2. Real time Long Term and Short Term Creep tests results as per ASTM D5262 and
FHWA-NHI-10-024 and FHWA-NHI-10-025. [the manufacturer should have at least
continuous 10,000hrs of data at different testing temperatures (at least one testing
temperature shall be more than 40oC)].
Page 20-19
3. Hydrolysis Resistance Tests as per ASTM D5322 (or EN ISO 13434) at different
testing temperatures (at least one shall be 65oC or more) and exposing periods. There
should be no appreciable loss of tensile strength at normal working temperature range
(20-65oC).
4. Chemical Resistance Tests (Alkali, Acid, and Oxidized Environment) at different
concentrations and testing temperatures (at least one set of the tests shall be
conducted at PH value more than 12 and at testing temperature more than 65o C) as
per ASTM D5322, (or EN ISO 13434).
5. Low Temperature Resistance Tests as per ASTM D4594 and High Temperature
Resistance Tests as per ASTM D4594 and applied ASTM D5322.
6. Installations Damage Resistance Tests in a soil similar In gradation and texture to the
material that will be used for backfill in the reinforced zone as per ASTM D5818.
7. Biological Resistance Tests (to Manufacturer's Recommended Method), Tests should
show below 3% reduction of tensile strength.
8. Water Absorption Test should be provided to the Engineer as per ASTM D570.
9. uV Oxidation Resistance tests as per ASTM D4355.
10. Pull-out tests to establish the coefficient of friction between the geosynthatic
reinforcement and a soil similar in compaction, moisture content, gradation, and
texture to the material that will be used for backfill in the reinforced zone.
g. Leveling Pad
Material for levelling pad shall consist of class C30/20mass concrete and shall be a minimum of
150mm in depth and 00mm wide.
h. Connection
For blocks, connection long term durability and strength shall be obtained in accordance with long
term connection strength test as per appendix A of FHWA NHI-00-043 over extended period of time
not less than 10,000 hours.
For panels, connection strength shall be determined by structural tests as per AASHTO LRFD
i. Drainage System
If the permeability of the MSE fill is less than 10-2 m/sec, additional drainage measures shall be
required. The MSE wall shall be protected by an impermeable membrane and surface water shall
be channelled into chimney drain located immediately behind the wall.
The drainage system consists of pervious backfill wrapped with geotextile fabric and drainage pipe.
The geotextile fabric shall be as per the requirements of Section 2.5.2.9 of Chapter 2, Earthworks,
of the Standard Specifications.
1. Pervious backfill shall be angular, clean stone or granular fill meeting the following gradation
as determined in accordance with BS 1377 and as per Table 20-9
Table 20-9: Pervious Backfill Gradation
Sieve Size Percent Passing
75 mm 100
53 mm 90 - 100
37.5 mm 35 - 70
25 mm 0 - 15
12.5 mm 0-5
Page 20-20
2. The drainage collection pipe shall be a perforated or slotted PVC, or corrugated HDPE pipe,
The drainage pipe shall be manufactured in accordance with ASTM D3034 and/or ASTM
D1248, The pipe shall be a minimum of 100mm in diameter.
j. Reinforced (Infill) Soil

The reinforced soil material should be well graded crushed and angular not sub-rounded, and should
conform to the following:
1. Maximum particle size 75mm
2. Uniformity coefficient greater than or equal to 10
3. Maximum 10% by mass passing the 75μm sieve
4. Well graded material not gap graded
5. Granular, Inorganic and non-plastic material
6. Minimum angle of friction (Ø) of 36 degree
7. Minimum permeability coefficient of 10-4 m/sec
k. Joint Filler
Filler for horizontal joints between panels to be elastomeric pads with shore A hardness 80±5.
Filler for vertical joints shall be flexible open cell polyethylene foam strips unless otherwise noted on
approved shop drawings.
20.6.4.6 Construction
a. Excavation
The Contractor shall excavate to the lines and grades shown on the project grading plans. The
Contractor shall take precautions to minimize over excavation. Over-excavation shall be filled with
compacted material, or as directed by the Engineer.
The Contractor shall verify location of existing structures and utilities prior to excavation. The
Contractor shall ensure all surrounding structures are protected from the effects of wall excavation.
Excavation support, if required, is the responsibility of the Contractor.
The Contractor shall report immediately to the Engineer any sub-soil conditions which he encounters
during excavation which are likely to result in the bearing capacity required as shown on the Contract
plans not being achieved. The foundation of the structure shall be graded level for a width equal to
or exceeding the width of the strip footing plus a working space.
Prior to wall construction, except where constructed on rock, the sub-soil shall be compacted with a
smooth wheel vibratory roller.
b. Foundation Preparation
Following the excavation, the foundation soil shall be examined by the Engineer to assure actual
foundation soil strength meets or exceeds the design bearing strength. Soils not meeting the required
strength shall be removed and replaced with reinforced (infill) soils, as directed by the Engineer.
The foundation soils supporting the structure should be graded for a width equal to or exceeding the
length of the soil geosynthetic reinforcement. Prior to wall construction, the foundation should be
compacted with a smooth wheel vibratory roller to 95% of Modified Proctor density. Any foundation
soils found to be unsuitable should be removed and replaced, as per the wall supplier
recommendations and as accepted by the Engineer/Owner.
The strip footing shall be of class C30/20 concrete, to the dimensions indicated in the Contract plans.
c. Leveling Pad
Leveling pad shall be placed as shown on the construction drawings with a minimum thickness of
150mm to within a tolerance of 2mm of the top level shown on the drawings.
Page 20-21
The levelling pad should extend laterally at least a distance of 100mm from the toe and heel of the
lower most block unit.
d. Erection of Panels
During the specified backfill placement to install MSE panels, the Contractor shall keep the backfill
at just above the geosynthetic reinforcement connection to panel, prior to making the connection.
The Contractor shall remove and replace any face panel that does not meet the construction
tolerances.
It is recommended to use the geotextile filter cloth across the panel joints. It should be either a non-
woven needle punch polyester or polypropylene or a woven monofilament polypropylene with a
minimum width of 300mm and a minimum non-sewn lap of 150mm where necessary.
For aesthetic considerations and differential settlement concerns, the panels should be erected in
such a pattern that the horizontal panel joint line is discontinuous at every other panel. This should
be accomplished by alternating standard height and half height panel placement along the leveling
pad. Panels above the lowest level should be standard size except as required to satisfy the top of
exposed panel line shown on the Contract plans.
At locations where the plans specify a change of panel alignment creating an included angle of 150o
or less, precast corner joint elements will be required. This element should separate the adjacent
panels by creating a vertical joint secured by means of separate soil geosynthetic reinforcement.
Isolation or slip joints, which are similar to corner joints in design and function, may be required to
assist in differential settlements at locations indicated on the plans or as recommended by the wall
supplier. Wall panels with areas greater than 2.8m' may require additional slip joints to account for
differential settlements. The maximum standard panel area should not exceed 4.6m2.
As fill material is placed behind a panel, the panel should be maintained in its proper inclined position
according to the supplier specifications and as approved by the Engineer.
Vertical tolerances and horizontal alignment tolerances should not exceed 20mm when measured
along a 3.0m straight edge. The maximum allowable offset in any panel joint should be 20mm. The
overall vertical tolerance of the wall, (plumbness from top to bottom) should not exceed 10mm per
3.0m of wall height. The precast face panels should be erected to insure that they are located within
25mm from the contract plan offset at any location to insure proper wall location at the top of the
wall. Failure to meet this tolerance may cause the Engineer to require the Contractor to disassemble
and re-erect the affected portions of the wall. A 20mm joint separation (± 5mm) should be provided
between all adjacent face panels to prevent direct concrete to concrete contact.
The fill and embankment placement should closely follow the erection of each lift of panels. At each
soil geosynthetic reinforcement level, the fill material should be roughly levelled and compacted
before placing and attaching the soil reinforcing system. The soli geosynthetlc reinforcement and the
maximum lift thickness shouid be placed according to the supplier's recommended procedures
except, the lifts should not exceed 250mm loose measurement or as approved by the Engineer.
At the end of each day's operations, the Contractor should shape the last level of select fill to permit
runoff of rainwater away from the wall face. Fill should be compacted according to the requirements
of Chapter 2 of the Standard Specifications, Earthworks. Select fill compaction should be
accomplished without disturbance or distortion of soil geosynthetic reinforcing system and panels.
Compaction in a strip 1.5m wide adjacent to the backside of the panels should be achieved using a
light weight mechanical tamper, roller or vibratory system as required to achieve the specified in –
situ density.
e. Erection of Modular Blocks Facing Units

The modular block facing units shall be erected in successive horizontal lifts in the sequence
recommended in the Supplier’s construction manual, and in conjunction with the placing of the fill.
They shall be placed in the required plane and level.
Page 20-22
Unused voids shall be filled with concrete as determined by the designer of the wall.
No height greater than that equivalent to the distance between successive levels of reinforcement
shall have fill placed behind them until the fill has been inspected and approved in position in the
wall by the Engineer.
Particular care shall be taken to protect the blocks from damage throughout all construction
operations, any blocks damaged during construction shall be removed.
All modular block walls shall be capped with a purpose made precast coping unit.
f. Construction Tolerances of Modular Blocks Facing Units

The finished wall shall have an alignment such that there is no point which is out of line by more than
25 mm on a 3 metre straight edge and  50mm on the overall height of the wall. The horizontal
alignment of the wall shall be within a tolerance of  50mm. The maximum allowable offset at any
block joint shall be 5mm. Deviation in the position along the length of the wall shall be not more than
 50mm for any one block from the true position as determined from the Contract Plans, except when
split face profile blocks are used in which case the datum should be taken from a nominal face line.
Any block or group of blocks which is found to be outside these tolerances shall be removed from
the wall and realigned unless agreed otherwise by the Supplier and the Engineer. The Contractor
shall carry out regular alignment checks on the wall by reference to a fixed datum line and level at
foundation level. Where the alignment is found to be out of tolerance the advice of the Supplier shall
be sought immediately.
g. Placing of Fill
The placing of the fill shall closely follow the erection of each lift of blocks, where lift is the distance
between successive layers of reinforcement, in compacted layers in accordance with the
requirements of Section 2.5.3.4 of Chapter 2, Earthworks, of the Standard Specifications. At each
level of reinforcement the fill shall be graded and compacted.
Filling and compaction shall be carried out in a direction parallel to the wall. The area within the two
metres nearest to the wall shall be compacted with a light, manually controlled machine.
The maximum weight of any equipment within two metres of the wall shall not exceed 1.5 tonnes.
Generally, filling and compaction shall be carried out in level planes unless agreed otherwise with
the Engineer and to the requirements of the Specifications for fill. Where it is necessary to create
slopes, these shall not be greater than a slope of 1:1 or such lesser slope as is agreed with the
Engineer, according to the actual fill material being used.
In the case of soil reinforced structures, unless otherwise directed by the Engineer, each layer of fill
material shall be satisfactorily placed and compacted throughout the reinforcement soil wall extent
and the adjacent embankment prior to commencing the next layer of fill material.
h. Placing Reinforcement
Reinforcement shall be continuously placed to the alignment shown in the Contract Plans in
horizontal layers on a compacted layer of approved fill. Each level of reinforcement shall be pulled
taut and approved by the Engineer prior to the next layer of fill being placed and shall be complete
to the full extent of the structure to the approval of the Engineer prior to placing the next layer of fill
material.
Every effort must be made by the Contractor to ensure that no damage is caused to the
reinforcement. If these materials are damaged such that the Engineer considers that the structural
integrity or durability will be affected, the damaged elements shall be removed and replaced.
Page 20-23
i. Drainage System
Pervious backfill wrapped in geotextile shall be installed to the line, grades, and sections shown on
the final plans. Pervious backfill fill shall be placed to the minimum thickness shown on the
construction plans between and behind units.
j. Construction Adjacent to Completed Wall

The Contractor is responsible for ensuring that construction adjacent to the wall by others does not
disturb the wall or place temporary construction loads on the wall that exceed design loads, including
loads such as water pressure, temporary grades, or equipment loading. Heavy paving or grading
equipment shall be kept a minimum of 1m behind the back of the wall face. Equipment with wheel
loads in excess of 15kN/m² live load shall not be operated within 3m of the face of the retaining wall
during construction adjacent to the wall. Care should be taken by the Contractor to ensure water
runoff is directed away from the wall structure until final grading and surface drainage collection
systems and erosion protection measures are completed.
20.6.4.7 Tests and Inspection

An independent testing agency shall be retained by the Contractor to visually inspect and certify the
stability of MSE Walls.
20.6.4.8 Letter of Guarantee:

The supplier of the MSE panels shall submit Letters of Guarantee and BBA (or similar) Certificate
showing that both his global system and the cast-in dowels have properly considered the potential
degradative effects of elevated temperature and alkalinity. FBEC applicator qualifications per ASTM
A775/A775M.
20.6.4.9 Quality Assurance:

Quality Assurance should be as per BS EN ISO 9001/2015; "Quality systems-Model for Quality
Assurance in Production, Design and Development Installation and Servicing".
Page 20-24
INDEX
allowable offset, 20-23, 20-24 Masonry concrete blocks, 20-3

bearing capacity, 20-5, 20-12, 20-17, 20-22 mechanically stabilised earth, 20-4
cast-in-place, 20-7, 20-12 minimum compressive strength, 20-3
cellular, 20-4 Modified Proctor density, 20-5, 20-22
Chlorides, 20-5 Modular Block Facing Units, 20-15, 20-19
cleanout pipes, 20-6 monolithic cell walls, 20-14
collector pipes, 20-6 non-proprietary, 20-2
Compaction method, 20-2 outlet pipes, 20-6
Concrete gutters, 20-6 Pervious backfill, 20-4, 20-21, 20-24
crib, 20-4, 20-14, 20-15 polyethylene foam strips, 20-22
design calculations, 20-2, 20-18 precast concrete, 20-6, 20-7, 20-8, 20-9, 20-
design criteria, 20-17 11, 20-12, 20-14, 20-16, 20-18
design parameters, 20-2 Premoulded joint, 20-9
Drainage blankets, 20-6 proprietary, 20-2, 20-15, 20-16, 20-18
Drainage elements, 20-3 proprietary reinforced soil wall, 20-15
drainage system, 20-2, 20-21 Resistivity, 20-5
durability testing, 20-20 secant pile, 20-10
Earthwork requirements, 20-2 sheet pile, 20-10
expansion joints, 20-9 Shotcrete, 20-3, 20-6, 20-11
exposed face, 20-7 Soil bearing pressure, 20-9
factor of safety, 20-17 soldier-pile, 20-10, 20-11, 20-12, 20-13
filter fabric, 20-6 soundness, 20-4, 20-5
Filter fabric, 20-3 Standard Direct Shear Test, 20-5
Formwork, 20-8, 20-9 stretcher members, 20-14, 20-15
four-sided cells, 20-14 structure backfill, 20-5, 20-6, 20-15
Geocomposite drainage, 20-4, 20-7 Subgrade, 20-6
geosynthetic friction reinforcement, 20-20 Sulphates, 20-5
ground anchors, 20-10, 20-11, 20-13, 20-14 tie-back, 20-10
ground elevations, 20-2 Timber, 20-3, 20-11, 20-12, 20-14, 20-15
horizontal joints, 20-22 timber headers, 20-14
independent testing, 20-25 vertical joints, 20-22
internal friction, 20-4, 20-5 Wales, 20-13
internal friction angle, 20-4 wall-facing elements, 20-3
Joints, 20-6 Weep holes, 20-6
Leveling pad, 20-22 weepholes, 20-10
masonry, 20-7
Page 20-25
PART 2
ROAD STRUCTURES
CHAPTER 21 - CONCRETE STRUCTURES
DOCUMENT NO: TR-

FIRST EDITION
JANUARY 2018
Chapter 21: Concrete Structures

TABLE OF CONTENTS
Table of Contents............................................................................................................................. i
List of Figures ................................................................................................................................ vii
List of Tables ................................................................................................................................. vii
21 Concrete Structures ........................................................................................................ 21-1
21.1 General ........................................................................................................................ 21-1
21.1.1 Work Related to Concrete Structures.................................................................... 21-1
21.1.2 Construction Methods for Concrete Structures ..................................................... 21-1
21.1.3 Reference Standards and Codes .......................................................................... 21-2
21.2 Classes of Concrete..................................................................................................... 21-9
21.2.1 Normal-weight Concrete ....................................................................................... 21-9
21.2.2 Lightweight Concrete ............................................................................................ 21-9
21.3 Materials Used for Concrete Structures ....................................................................... 21-9
21.3.1 Blended Aggregates ............................................................................................. 21-9
21.3.2 Lightweight Aggregates ...................................................................................... 21-10
21.3.3 Concrete Durability Parameters .......................................................................... 21-10
21.3.4 Precast and Prestressed Concrete ..................................................................... 21-10
21.3.4.1 Cement ........................................................................................................ 21-10
21.3.4.2 Aggregates .................................................................................................. 21-10
21.3.4.3 Admixtures................................................................................................... 21-11
21.3.4.4 Concrete-Bonding Agent.............................................................................. 21-11
21.3.5 Steel ................................................................................................................... 21-11
21.3.5.1 Steel Plates, Studs and Anchor Bars in Precast Concrete ........................... 21-11
21.3.5.2 Metal Accessories in Prestressed Concrete Members ................................. 21-11
21.3.5.3 Pipe Sleeves in Prestressed Concrete Members ......................................... 21-11
21.3.5.4 Threaded Inserts and Lifting Devices in Precast Concrete ........................... 21-11
21.3.5.5 Built-in Materials in Prestressed Concrete Members .................................... 21-12
21.3.5.6 Welding Electrodes ...................................................................................... 21-12
21.4 Proportioning of Concrete .......................................................................................... 21-12
21.4.1 Concrete Mixing .................................................................................................. 21-12
21.4.1.1 Responsibility and Criteria for Concrete Mixing ............................................ 21-12
21.4.1.2 Trial Batch Testing for Concrete Mixing ....................................................... 21-12
21.4.1.3 Approval for Concrete Mixing ....................................................................... 21-14
21.4.2 Concrete Mixing Water Content .......................................................................... 21-14
21.4.3 Cement Control for Concrete Mixing ................................................................... 21-15
21.4.4 Concrete Admixtures .......................................................................................... 21-15
21.4.5 Mineral Admixtures ............................................................................................. 21-15
21.4.6 Chemical Admixtures .......................................................................................... 21-16
21.4.7 Corrosion Inhibitor for Structural Concrete Works ............................................... 21-16
21.5 Manufacture of Concrete ........................................................................................... 21-16
21.5.1 Delivery of Concrete ........................................................................................... 21-16
21.5.2 Concrete Sampling and Testing .......................................................................... 21-16
21.5.2.1 Concrete Sampling ...................................................................................... 21-17
21.5.2.2 Frequency of Testing for Concrete Aggregates ............................................ 21-17
21.5.3 Evaluation of Concrete Strength ......................................................................... 21-18
21.5.3.1 Concrete Strength Tests .............................................................................. 21-18
21.5.3.2 Requirements for Controlling Construction Operations ................................ 21-19
21.5.3.3 Requirements for the Acceptance of Concrete ............................................. 21-19
21.5.3.4 Requirements for the Control of Mix Design................................................. 21-19
21.6 Protection of Concrete during Placing and Curing...................................................... 21-20
21.6.1 Rain Protection ................................................................................................... 21-20
21.6.2 Hot-weather Protection ....................................................................................... 21-20
Page i
CHAPTER 21: CONCRETE STRUCTURES First Edition -January 2018
21.6.3 Special Requirements for Bridge Decks .............................................................. 21-20

21.6.4 Concrete Exposed to Salt Water ......................................................................... 21-21
21.6.5 Concrete Exposed to Sulphate Soils or Sulphate Water ..................................... 21-22
21.7 Handling and Placing Concrete.................................................................................. 21-22
21.7.1 Placement Sequences ........................................................................................ 21-22
21.7.1.1 Vertical Members ......................................................................................... 21-22
21.7.1.2 Superstructures ........................................................................................... 21-23
21.7.1.3 Arches ......................................................................................................... 21-23
21.7.1.4 Box Culverts ................................................................................................ 21-24
21.7.1.5 Tunnels and Underpasses ........................................................................... 21-24
21.7.1.6 Tunnels and Underpasses on Rock Surfaces .............................................. 21-24
21.7.1.7 Precast Elements......................................................................................... 21-24
21.7.2 Concrete Placing Methods .................................................................................. 21-24
21.7.2.1 Concrete Placing Equipment ....................................................................... 21-24
21.7.3 Consolidation Methods ....................................................................................... 21-25
21.7.4 Underwater Placement ....................................................................................... 21-25
21.7.4.1 Underwater Concrete Placement Equipment ............................................... 21-26
21.7.4.2 Underwater Concrete Placement Cleanup ................................................... 21-26
21.7.5 Reinforced-concrete Bridge Slabs ...................................................................... 21-26
21.7.5.1 Construction of Reinforced-concrete Bridge Slabs ....................................... 21-27
21.7.6 Approach Slabs .................................................................................................. 21-27
21.7.6.1 Approach Slab Construction ........................................................................ 21-27
21.7.7 Blinding Concrete ............................................................................................... 21-27
21.7.7.1 Blinding Concrete Construction.................................................................... 21-28
21.7.8 Screed Concrete ................................................................................................. 21-28
21.7.8.1 Crack Control Additive ................................................................................. 21-28
21.7.9 Mass Concrete - Thermal Control ....................................................................... 21-28
21.7.10 Removal of Falsework and Forms....................................................................... 21-29
21.7.10.1 Time of Removal.......................................................................................... 21-30
21.7.10.2 Extent of Removal ....................................................................................... 21-31
21.8 Construction Joints .................................................................................................... 21-31
21.8.1 Horizontal Joints ................................................................................................. 21-31
21.8.2 Vertical Joints ..................................................................................................... 21-31
21.8.3 Bonding .............................................................................................................. 21-31
21.8.4 Bonding and Dowelling to Existing Structures ..................................................... 21-32
21.8.5 Forms at Construction Joints .............................................................................. 21-32
21.8.6 Waterstops at Construction Joints ...................................................................... 21-32
21.9 Expansion and Contraction Joints .............................................................................. 21-32
21.9.1 Expansion and Contraction Joint Materials ......................................................... 21-32
21.9.1.1 Pre-moulded Expansion Joint Fillers ............................................................ 21-32
21.9.1.2 Polystyrene Board Fillers ............................................................................. 21-33
21.9.1.3 Contraction Joint Material ............................................................................ 21-33
21.9.1.4 Pourable Joint Sealants ............................................................................... 21-33
21.9.1.5 Metal Armour ............................................................................................... 21-33
21.9.1.6 External and Internal Waterstops ................................................................. 21-33
21.9.2 Expansion and Contraction Joint Installation....................................................... 21-35
21.9.2.1 Open Joints ................................................................................................. 21-35
21.9.2.2 Filled Joints.................................................................................................. 21-35
21.9.2.3 Sealed Joints ............................................................................................... 21-35
21.9.2.4 Waterstops .................................................................................................. 21-35
21.9.2.5 Expansion Joint Armour Assemblies ............................................................ 21-36
21.9.2.6 Sheet Packing, Preformed Pads, and Board Fillers ..................................... 21-36
21.9.3 Injection of Expansion and Construction Joints ................................................... 21-36
21.9.3.1 Construction Joints ...................................................................................... 21-37
21.9.3.2 Expansion Joints.......................................................................................... 21-37
21.9.3.3 Injection of Leaking Joints ............................................................................ 21-37
Page ii
21.10 Finishing Plastic Concrete ......................................................................................... 21-37

21.10.1 Roadway Concrete Surface Finish ...................................................................... 21-37
21.10.1.1 Striking off and Floating ............................................................................... 21-37
21.10.1.2 Straight Edging ............................................................................................ 21-40
21.10.1.3 Texturing ..................................................................................................... 21-40
21.10.1.4 Surface Testing and Correction ................................................................... 21-41
21.10.2 Pedestrian Walkway Surface Finish .................................................................... 21-41
21.10.3 Trowelled and Brushed Finish............................................................................. 21-41
21.10.4 Surfaces under Bearings .................................................................................... 21-41
21.11 Curing Concrete......................................................................................................... 21-41
21.11.1 Curing Concrete Materials .................................................................................. 21-42
21.11.1.1 Water ........................................................................................................... 21-42
21.11.1.2 Liquid Membranes ....................................................................................... 21-42
21.11.1.3 Waterproof Sheet Materials ......................................................................... 21-42
21.11.2 Curing Concrete Methods ................................................................................... 21-42
21.11.2.1 Forms-in-place Method ................................................................................ 21-42
21.11.2.2 Water Method .............................................................................................. 21-42
21.11.2.3 Liquid-membrane Curing Compound Method .............................................. 21-42
21.11.2.4 Waterproof Cover Method............................................................................ 21-43
21.11.2.5 Steam or Radiant-heat Curing Method......................................................... 21-43
21.11.2.6 Insulated Curing Method .............................................................................. 21-44
21.11.3 Bridge Decks ...................................................................................................... 21-44
21.12 Finishing Formed Concrete Surfaces ......................................................................... 21-44
21.12.1 Class 1: Ordinary Surface Finish ........................................................................ 21-45
21.12.2 Class 2: Rubbed Finish ....................................................................................... 21-45
21.12.3 Class 3: Tooled Finish ........................................................................................ 21-45
21.12.4 Class 4: Sandblasted Finish................................................................................ 21-46
21.12.5 Class 5: Wire-brushed or Scrubbed Finish .......................................................... 21-46
21.12.6 Concrete Architectural Rustication ...................................................................... 21-46
21.12.6.1 Materials ...................................................................................................... 21-46
21.12.6.2 Formwork..................................................................................................... 21-46
21.12.6.3 Sample ........................................................................................................ 21-46
21.12.6.4 Construction ................................................................................................ 21-46
21.13 Precast Concrete Structural Members ....................................................................... 21-47
21.13.1 Quality Assurance............................................................................................... 21-47
21.13.1.1 Reference Codes and Standards ................................................................. 21-47
21.13.1.2 Qualifications of Precast Prestressed Concrete Subcontractor .................... 21-47
21.13.1.3 Welder Qualifications ................................................................................... 21-47
21.13.2 Precast Concrete Submittals............................................................................... 21-47
21.13.2.1 Working Drawings........................................................................................ 21-47
21.13.2.2 Shop Drawings ............................................................................................ 21-47
21.13.2.3 Samples ...................................................................................................... 21-48
21.13.2.4 Full Size Sample .......................................................................................... 21-48
21.13.3 Precast Concrete Materials and Manufacture ..................................................... 21-48
21.13.3.1 Formwork for Precast Prestressed Members ............................................... 21-49
21.13.3.2 Precast Prestressed Concrete Deck Panels ................................................ 21-50
21.13.4 Sampling and Testing of Precast Concrete Structural Members ......................... 21-51
21.13.5 Curing Precast Concrete..................................................................................... 21-51
21.13.6 Precast Concrete Storage and Handling ............................................................. 21-52
21.13.7 Precast Concrete Erection .................................................................................. 21-52
21.13.7.1 Precast Prestressed Concrete Girders......................................................... 21-53
21.13.8 Precast Concrete Finish...................................................................................... 21-54
21.13.8.1 Concrete Fascia Elements ........................................................................... 21-55
21.13.8.2 Precast Prestressed Concrete Girders......................................................... 21-55
Page iii
21.13.9 Precast Products ................................................................................................ 21-55

21.13.10 Epoxy-bonding Agents for Precast Segmental Box Girders ................................ 21-55
21.13.10.1 Epoxy-bonding Agent Materials ................................................................... 21-55
21.13.10.2 Mixing and Installation of Epoxy................................................................... 21-59
21.14 Pre-tensioned Concrete Works .................................................................................. 21-59
21.14.1 Placing of Reinforcement Steel and Inserts ........................................................ 21-60
21.14.2 Mixing and Placing Concrete .............................................................................. 21-60
21.14.3 Placing and Compacting ..................................................................................... 21-60
21.14.4 Inspection of Completed Prestressed Members .................................................. 21-61
21.14.4.1 Tolerances ................................................................................................... 21-61
21.14.5 Rejection of Prestressed Members ..................................................................... 21-66
21.15 Post-tensioned Concrete Works ................................................................................ 21-66
21.15.1 Standards and Codes ......................................................................................... 21-66
21.15.2 Submittals ........................................................................................................... 21-66
21.15.2.1 Shop Drawings ............................................................................................ 21-66
21.15.2.2 Certificates................................................................................................... 21-67
21.15.2.3 Test Reports ................................................................................................ 21-67
21.15.3 Scheduling of Post-tensioned Concrete Works ................................................... 21-67
21.15.4 Material ............................................................................................................... 21-67
21.15.4.1 Concrete ...................................................................................................... 21-67
21.15.4.2 Post-tensioning Systems ............................................................................. 21-67
21.15.4.3 Reinforcement Steel .................................................................................... 21-67
21.15.4.4 Built-in Materials .......................................................................................... 21-67
21.15.5 Formwork............................................................................................................ 21-68
21.15.6 Placing Post-tensioning Systems ........................................................................ 21-68
21.15.7 Mixing and Placing Concrete .............................................................................. 21-69
21.15.8 Stressing Operations .......................................................................................... 21-69
21.15.9 Grouting of Tendons ........................................................................................... 21-70
21.15.10 Protection of End Anchorages ............................................................................ 21-70
21.15.11 Access Doors ..................................................................................................... 21-70
21.15.12 Vent Pipes .......................................................................................................... 21-70
21.15.13 Opening Bridges to Traffic .................................................................................. 21-71
21.16 Precast Concrete Fascia Panels ................................................................................ 21-71
21.16.1 Materials ............................................................................................................. 21-71
21.16.2 Moulds ................................................................................................................ 21-71
21.16.3 Shop Drawings and Method Statement ............................................................... 21-71
21.16.4 Sample Panel ..................................................................................................... 21-71
21.16.5 Fabrication .......................................................................................................... 21-72
21.16.6 Surface Finish ..................................................................................................... 21-72
21.16.7 Installation .......................................................................................................... 21-73
21.17 Cast-in-place Concrete Works for Bridge, Tunnel & Underpass Structures ................ 21-73
21.17.1 Materials ............................................................................................................. 21-73
21.17.2 Shop Drawings ................................................................................................... 21-73
21.17.3 Construction ....................................................................................................... 21-73
21.17.4 Formwork............................................................................................................ 21-73
21.17.5 Expanded Polystyrene Board.............................................................................. 21-73
21.18 Mortar and Grout ....................................................................................................... 21-74
21.18.1 Mortar and Grout Materials and Mixing ............................................................... 21-74
21.18.2 Placing and Curing of Mortar and Grout .............................................................. 21-74
21.18.3 Grout in Precast Works ....................................................................................... 21-75
21.19 Application of Loads .................................................................................................. 21-75
21.19.1 Earth Loads ........................................................................................................ 21-75
21.19.2 Construction Loads ............................................................................................. 21-75
21.19.3 Traffic Loads ....................................................................................................... 21-76
21.20 Special Requirements for Segmental Bridges ............................................................ 21-76
21.20.1 Geometry Control ............................................................................................... 21-76
Page iv
21.20.1.1 Deflection and Camber Data ........................................................................ 21-76

21.20.1.2 Geometry Control ........................................................................................ 21-76
21.20.2 Segmental Bridge Tolerances ............................................................................. 21-76
21.20.3 Shop Drawings and Design Calculation for Construction Procedures ................. 21-77
21.20.3.1 Design Calculation for Construction Procedures .......................................... 21-78
21.20.3.2 Shop Drawings ............................................................................................ 21-78
21.20.4 Forms ................................................................................................................. 21-79
21.20.4.1 Forms for Precast Segmental Construction.................................................. 21-79
21.20.5 Permanent Bearings ........................................................................................... 21-80
21.20.6 Special Provisions for cast-in-place Segmental Construction .............................. 21-80
21.20.6.1 Forming System........................................................................................... 21-80
21.20.6.2 Superstructure Construction ........................................................................ 21-80
21.20.7 Special Provisions for Precast Concrete Segmental Construction ...................... 21-82
21.20.7.1 Fabrication ................................................................................................... 21-83
21.20.7.2 Separation of Match-cast Segments ............................................................ 21-83
21.20.7.3 Handling and Erection of Segments ............................................................. 21-83
21.20.8 Special Provisions for Incremental Launching ..................................................... 21-83
21.20.8.1 Casting of Segments ................................................................................... 21-83
21.20.8.2 Geometric Tolerances ................................................................................. 21-84
21.20.8.3 Launching Force .......................................................................................... 21-84
21.20.8.4 Pier Monitoring ............................................................................................ 21-84
21.20.9 Defects and Breakage ........................................................................................ 21-84
21.21 Architectural Surface Treatment for Tunnel and Underpass Walls ............................. 21-84
21.21.1 Types of Surface Treatment................................................................................ 21-85
21.21.1.1 Ceramic Wall Tiles ....................................................................................... 21-85
21.21.1.2 Textured Concrete Finish............................................................................. 21-88
21.21.1.3 Painting of Exposed Concrete...................................................................... 21-88
21.21.1.4 Fire Protection Boards ................................................................................. 21-89
21.21.2 Miscellaneous Materials...................................................................................... 21-90
21.22 Scarifying Concrete Bridge Slabs............................................................................... 21-92
21.22.1 Scarifying Equipment .......................................................................................... 21-92
21.22.2 Concrete Bridge Slab Construction ..................................................................... 21-92
21.23 Extending Concrete Structures .................................................................................. 21-92
21.23.1 Concrete Structure Construction ......................................................................... 21-93
21.23.1.1 Removal of the Existing Structure ................................................................ 21-93
21.23.1.2 Reuse of Removed Portions of the Structure ............................................... 21-93
21.23.1.3 Breaking Back Bridge Slabs ........................................................................ 21-93
21.23.1.4 Splicing Reinforcing Steel ............................................................................ 21-93
21.23.1.5 Concrete Preparation ................................................................................... 21-94
21.24 Raising Existing Structures ........................................................................................ 21-94
21.24.1 Construction While Raising Existing Structures .................................................. 21-94
21.24.1.1 Preparation of Plans .................................................................................... 21-94
21.24.1.2 Raising of Spans.......................................................................................... 21-94
21.25 Spread Footings ........................................................................................................ 21-95
21.25.1 General Requirements for Spread Footings ........................................................ 21-95
21.25.2 Protection of Existing Structures ......................................................................... 21-95
21.25.3 Dewatering ......................................................................................................... 21-96
21.25.4 Excavations ........................................................................................................ 21-96
21.25.4.1 Dry Excavations ........................................................................................... 21-96
21.25.4.2 Dewatered Excavations ............................................................................... 21-96
21.25.4.3 Wet Excavations .......................................................................................... 21-97
21.25.5 Fill or Backfill ...................................................................................................... 21-97
21.25.6 Compaction and Density Requirements .............................................................. 21-97
21.25.7 Forming .............................................................................................................. 21-97
21.25.8 Reinforcing Steel Placement ............................................................................... 21-98
21.25.9 Concrete Placement ........................................................................................... 21-98
Page v
21.25.9.1 Placement.................................................................................................... 21-98

21.25.9.2 Finish ........................................................................................................... 21-98
21.25.9.3 Curing .......................................................................................................... 21-98
21.26 Steps ......................................................................................................................... 21-98
21.26.1 Materials for Steps .............................................................................................. 21-98
21.26.2 Steps Construction ............................................................................................. 21-99
21.27 Concrete for Minor Structures .................................................................................... 21-99
21.27.1 Materials for Minor Structures ............................................................................. 21-99
21.27.2 Composition of Concrete for Minor Structures .................................................... 21-99
21.27.3 Placing of Concrete .......................................................................................... 21-100
21.27.4 Curing of Concrete............................................................................................ 21-100
21.27.5 Acceptance ....................................................................................................... 21-100
Index ...................................................................................................................................... 21-101
Page vi
LIST OF FIGURES
Figure 21-1: Evaporation rate nomograph from ACI 308 .......................................................... 21-21
LIST OF TABLES
Table 21-1: Designations and titles for AASHTO and ASTM standards that apply to concrete
structures works ......................................................................................................................... 21-4
Table 21-2: Designations and titles for BS, BS EN, and DIN standards that apply to concrete
structures works ......................................................................................................................... 21-8
Table 21-3: Normal-weight concrete slump test limits at the time of placement ........................ 21-15
Table 21-4: Rates of sampling and testing from same plant ..................................................... 21-17
Table 21-5: Frequency of aggregate testing ............................................................................. 21-17
Table 21-6: Time of removal .................................................................................................... 21-30
Table 21-7: ASTM test method requirements for PVC materials .............................................. 21-34
Table 21-8: Concrete aggregate size for deck panels .............................................................. 21-50
Table 21-9: Maximum dimensional tolerances for deck panels ................................................ 21-51
Table 21-10: Sag flow test for mixed epoxy-bonding agent ...................................................... 21-56
Table 21-11: Gel time test for epoxy-bonding agent ................................................................. 21-56
Table 21-12: Open time test for epoxy-bonding agent .............................................................. 21-57
Table 21-13: Three-point tensile bending test for epoxy-bonding agent ................................... 21-57
Table 21-14: Compression strength test for cured epoxy-bonding agent .................................. 21-58
Table 21-15: Temperature deflection test for epoxy-bonding agent .......................................... 21-58
Table 21-16: Compression and shear strength test for cured epoxy-bonding agent ................. 21-58
Table 21-17: Maximum allowable dimensional tolerances for precast prestressed concrete members
(General) ................................................................................................................................. 21-61
Table 21-18: Maximum dimensional tolerances for AASHTO girders and bulb-tees................. 21-63
Table 21-19: Maximum dimensional tolerances for double-tees ............................................... 21-64
Table 21-20: Maximum dimensional tolerances for prestressed concrete piling ....................... 21-65
Table 21-21: Maximum dimensional tolerances for prestressed concrete stay-in-place forms.. 21-65
Table 21-22: Tolerances on effective depth and minimum cover.............................................. 21-76
Table 21-23: Completed segment tolerance for segmental box girder bridge construction ....... 21-77
Page vii
21 CONCRETE STRUCTURES
21.1 General
This work consists of furnishing, placing, finishing, and curing concrete in bridges, tunnels,
underpasses, culverts, and miscellaneous roadway structures in accordance with these
specifications and conforming to the lines, grades, and dimensions shown in the Contract
documents. Work includes elements of structures constructed by cast-in-place and precast methods
using either plain, or unreinforced; reinforced; or prestressed concrete — or any combination thereof.
All exposed items or surfaces not in contact with soil throughout concrete structures, except as
otherwise indicated on the Contract plans, shall be painted in accordance with Section 24.7 of
Chapter 24, Painting, of these standard specifications. Surfaces of concrete structures in contact
with soil, concrete structures that require water-tightness, and roadway surfaces of bridge decks,
underpasses, and tunnels shall be protected and waterproofed in accordance with Sections 28.2,
28.3, and 28.5 of Chapter 28, Waterproofing, of these standard specifications, as applicable. All
exposed surfaces for concrete structures indicated on the Contract plans not to be painted or
waterproofed shall be sealed as per the requirements of Section 29.6 of Chapter 29, Miscellaneous
Items for Structures, of these standard specifications.
Fabricating, furnishing, and installing tunnels shall conform to the requirements of this chapter and
Chapter 34, Road Tunnels, of these standard specifications.
21.1.1 Work Related to Concrete Structures

Other works involved in the construction of concrete structures shall be as specified in the applicable
chapters of these specifications, especially in the following:
Chapter 1: General Requirements, of these Standard Specifications;
Chapter 4: Concrete Works, of these Standard Specifications;
Chapter 5: Reinforcing Steel, of these Standard Specifications;
Chapter 22: Prestressing Systems, of these Standard Specifications;
Chapter 24: Painting, of these Standard Specifications;
Chapter 28: Waterproofing, of these Standard Specifications;
Chapter 29: Miscellaneous Items for Structures, of these Standard Specifications; and
Chapter 34: Road Tunnels, of these Standard Specifications.
Where there is a conflict in the requirements of Chapter 4 with that of Chapter 21, the requirements
as set forth in Chapter 21 shall take precedence and shall govern for all concrete works in bridges,
tunnels, underpasses, and culverts.
21.1.2 Construction Methods for Concrete Structures

Whenever the Contract documents permit the Contractor to select the method or equipment to be
used for any operation, it shall be the Contractor's responsibility to employ methods and equipment
that will produce satisfactory work under the conditions encountered such that no damage is
imparted on completed or partially completed work.
The Contractor shall construct concrete road tunnels based on one of the construction methods
specified in Chapter 34, Road Tunnels, unless otherwise indicated in the Contract documents.
Falsework and forms shall conform to the requirements of Section 1.20.8 of Chapter 01, General
Requirements, of these standard specifications.
Page 21-1
Generally, all concrete shall be fully supported until the required strength and age has been reached.
However, the slip form method may be permitted for the construction of pier shafts and railing,
providing the Contractor's plan assures the following:
a. Results will be equal in all respect to those obtained by the use of fixed forms.
b. Adequate arrangements will be provided for curing, finishing, and protecting the concrete.
21.1.3 Reference Standards and Codes

Standards and codes shall be as specified in these specifications, in the Contract documents, if any,
and the following, in their latest edition:
AASHTO LRFD American Association of State Highway and Transportation Officials - Load
and Resistance Factor Design, Bridge Construction Specifications;
and Resistance Factor Design, Bridge Design Specifications;
AASHTO Standard Specifications for Transportation Materials and Methods of
ACI American Concrete Institute;
ACI 207.4R-05 Cooling and Insulating Systems for Mass Concrete;
ACI 207.1R-05 Guide to Mass Concrete;
ACI 207.2R-07 Report on Thermal and Volume Change Effects on Cracking of Mass
Concrete;
ACI 301-10 Specifications for Structural Concrete”;
ACI 305R-10 American Concrete Institute Standard "Guide to Hot Weather Concreting";
ACI 308R-01 Guide to Curing Concrete;
ACI 318-08 Building Code Requirements for Structural Concrete and Commentary;
ADQCC (TR-516) Road Structures Design Manual;
ANSI American National Standards Institute;
ANSI A108.1B Installation of ceramic tile on a cured Portland Cement Mortar setting bed-
1999 with DRY-SET or latex Portland Cement Mortar;
ANSI A108.5 Ceramic tile installed with DRY-SET Portland Cement Mortar or latex – 1999
Portland Cement Mortar;
ANSI A108.10 Specifications for Installation of Grout in Tilework; -1999
ANSI A108/A118/ Specifications for the Installation of Ceramic Tile; A136.1-2012
ANSI A135.4 American National Standards Institute – Basic Hardboard Standard;
ANSI A137.1: American National Standards Specifications for Ceramic Tile;2008
ANSI/AWS D1.1/ American National Standards Institute, Structural welding code—Steel;
D1.1M:2010
ASTM American Society for Testing and Materials;
AWS - D1.1/ American Welding Society - Structural Welding Code – Steel; D1.1M:2010
AWS - D1.4/ American Welding Society - Structural Welding Code – Reinforcing Steel;
D1.4M:2011
BS British Standards;
BS EN European Standards;
Page 21-2
BRS Digest British Building Research Station; No 35, 1968

CRD-C-566-64 Corps of Engineers - Specifications for Grout Fluidifier - Handbook for
Concrete and Cement, U.S. Army Engineer Waterways Experiment Station,
Vicksburg, MS;
CRD-C 572-74 Corps of Engineers Specifications for Polyvinylchloride Water stop;
CRSI Concrete Reinforcing Steel Institute 1990;
DIN German Institute for Standardization;
FS Army MMM- Federal Specification - Grout, Adhesive, Epoxy Resin, Flexible, Filled; G-650B
CANC
FS TT - S-1543 Federal Specification - Class A- Sealing Compound, Silicone Rubber Base,
(For Caulking, Sealing and Glazing in Buildings and Other Structures);
FS LLL-B-810 Federal Specification - Building board (Hardboard) Hard Pressed Vegetable
Fiber;
FS MMM-G-650A Federal Specifications - Epoxy Bonding Agent;
FS SS-A-701 Federal Specifications - Bituminous Protective Coating;
FS TT-S-230 Federal Specifications - Sealing Compound, Synthetic-Rubber Base, Single
Component Chemically Curing (For Calking, and Glazing In Building
Construction);
FS-FF-P-395 Federal Specifications - Drive Pins (Power Actuated and Hand Driven);
FS QQ-Z-325 Federal Specifications - Zinc Coating, Electrodeposited
ISO International Organization for Standardization;
ISO 9000 Quality management;
ISO 9001:2015 Quality management systems – Requirements;
ISO 14001 Environmental management systems -- Requirements with guidance for use;
NFPA National Fire Protection Association;
NFPA 502 Standard for Road Tunnels, Bridges, and Other Limited Access Highways;
PCI Precast/ Prestressed Concrete Institute - Architectural Precast Concrete Color
& Texture Selection Guide, 2nd Edition;
PCI MNL-116-99 Precast Concrete Institute - Manual for Quality Control for plants and
production of Structural Precast Concrete Products;
PCI MNL-117-77 Precast Concrete Institute - Manual for Quality Control for Plants and
Production of Architectural Precast Concrete Products (1977);
PCI MNL-120-14 Precast Concrete Institute - PCI Design Handbook – Precast and prestressed
Concrete, 7th Edition;
PCI MNL 127-99 Precast Concrete Institute - Erectors’ Manual: Standards and Guidelines for
the Erection of Precast Concrete Products;
PCI Certification PCI’s Plant Certification Program;
SAE AMS-QQ- Society of Automotive Engineers - Steel, Corrosion Resistant, Bars, Wire,
S-763 Shapes, and Forgings;
TCA Tile Council of America - Installation Guide Handbook.
Table 21-1 and Table 21-2 presents American Association of State Highway and Transportation
Officials (AASHTO), American Society for Testing and Materials (ASTM), British (BS), European (BS
Page 21-3
EN), and German (DIN) Standards that are related to materials for concrete structures works. It also
includes designations and titles.
Table 21-1: Designations and titles for AASHTO and ASTM standards that apply to concrete
structures works
AASHTO ASTM
Title
Designation Designation
AASHTO M85- ASTM C150 /

Standard Specification for Portland Cement
12 C150M - 12
ASTM C845 - 04 Standard Specification for Expansive Hydraulic Cement
Standard Specification for Fine Aggregate for Hydraulic

AASHTO M6-08
Cement Concrete
ASTM C33 /
Standard Specification for Concrete Aggregates
C33M - 11a
AASHTO M195- ASTM C330 / Standard Specification for Lightweight Aggregates for
11 C330M - 09 Structural Concrete.
AASHTO M ASTM C494 / Standard Specification for Chemical Admixtures for

194M/M 194-12 C494M - 12 Concrete
AASHTO T152- ASTM C231 / Standard Test Method for Air Content of Freshly Mixed
12 C231M - 10 Concrete by the Pressure Method
Standard Test Method for Compressive Strength of

ASTM C109 /
Hydraulic Cement Mortars (Using 2-in. or [50-mm] Cube
C109M - 11b
Specimens)
ASTM C192 / Method of Making and Curing Concrete Test Specimens

AASHTO T126
C192M - 07 in the Laboratory
ASTM C457 / Standard Test Method for Microscopical Determination of

C457M - 11 Parameters of the Air-Void System in Hardened Concrete
ASTM C94 /
AASHTO M157 Standard Specification for Ready-Mixed Concrete
C94M - 12
AASHTO R 60- ASTM C172 /

Standard Practice for Sampling Freshly Mixed Concrete
12 C172M - 10
AASHTO T ASTM C138 / Standard Test Method for Density (Unit Weight), Yield,
121M/T 121-12 C138M - 12 and Air Content (Gravimetric) of Concrete
Standard Test Method for Sieve Analysis of Fine and

AASHTO T27-11 ASTM C136 - 06
Coarse Aggregates
AASHTO T ASTM C143 / Standard Test Method for Slump of Hydraulic-Cement

119M/T 119-11 C143M - 10a Concrete
AASHTO T 84- Standard Test Method for Density, Relative Density

ASTM C128 - 12
10 (Specific Gravity), and Absorption of Fine Aggregate
Page 21-4
AASHTO ASTM
Title
AASHTO T 85- Standard Test Method for Density, Relative Density

ASTM C127 - 12
10 (Specific Gravity), and Absorption of Coarse Aggregate
ASTM C567 / Standard Test Method for Determining Density of

C567M - 11 Structural Lightweight Concrete
AASHTO T 23- ASTM C31 / Standard Practice for Making and Curing Concrete Test
08 C31M - 12 Specimens in the Field
AASHTO T 22- ASTM C39 / Standard Test Method for Compressive Strength of
10 (2011) C39M - 12 Cylindrical Concrete Specimens
Standard Specification for Preformed Expansion Joint

AASHTO M 213- ASTM D1751 -
Filler for Concrete Paving and Structural Construction
01 (2010) 04(2008)
(Nonextruding and Resilient Bituminous Types)
Standard Specification for Preformed Sponge Rubber

Cork and Recycled PVC Expansion Joint Fillers for
06 (R2011) 04a(2008)
Concrete Paving and Structural Construction
AASHTO M 33- ASTM D994 / Standard Specification for Preformed Expansion Joint
99 (2012) D994M - 11 Filler for Concrete (Bituminous Type)
ASTM C203 - Standard Test Methods for Breaking Load and Flexural
05a(2012) Properties of Block-Type Thermal Insulation
Standard Specification for Joint Sealant, Hot-Applied,

Elastomeric-Type, for Portland Cement Concrete
99 (2012) 95(2006)
Pavements
AASHTO M301- Joint Sealants, Hot Poured, for Concrete and Asphalt
01 Pavements
Standard Test Methods for Density and Specific Gravity

ASTM D792 - 08
(Relative Density) of Plastics by Displacement
ASTM D2240 - Standard Test Method for Rubber Property — Durometer

05(2010) Hardness
ASTM D638 - 10 Standard Test Method for Tensile Properties of Plastics
Standard Test Method for Brittleness Temperature of

ASTM D746 - 07
Plastics and Elastomers by Impact
Standard Test Method for Apparent Bending Modulus of

ASTM D747 - 10
Plastics by Means of a Cantilever Beam
AASHTO M ASTM B152 / Standard Specification for Copper Sheet, Strip, Plate, and
138M/M 138-08 B152M - 09 Rolled Bar
AASHTO M 148- Standard Specification for Liquid Membrane-Forming

ASTM C309 - 11
05 Compounds for Curing Concrete
Page 21-5
AASHTO ASTM
Title
AASHTO M 171- Standard Specification for Sheet Materials for Curing

ASTM C171 - 07
05 Concrete
AASHTO T ASTM C403 / Standard Test Method for Time of Setting of Concrete
197M/T 197-11 C403M - 08 Mixtures by Penetration Resistance
AASHTO
Standard Specification for Epoxy Resin Adhesives
M235M/ M235
Standard Test Method for Gel Time and Peak Exothermic

ASTM D2471-99 Temperature of Reacting Thermosetting Resins
(Withdrawn 2008)
AASHTO T 97- ASTM C78 / Standard Test Method for Flexural Strength of Concrete
10 C78M - 10 (Using Simple Beam with Third-Point Loading)
Standard Test Method for Compressive Properties of

ASTM D695 - 10
Rigid Plastics
Standard Test Method for Deflection Temperature of

ASTM D648 - 07
Plastics under Flexural Load in the Edgewise Position
Standard Test Method for Determining Effects of

Chemical Admixtures on Corrosion of Embedded Steel
ASTM G109 - 07
Reinforcement in Concrete Exposed to Chloride
Environments
AASHTO T 277- Standard Test Method for Electrical Indication of

ASTM C1202 - 12
07 (2011) Concrete's Ability to Resist Chloride Ion Penetration
ASTM A36 /
A36M - 08
Standard Specification for Steel Bar, Carbon and Alloy,

ASTM A108 - 07
Cold-Finished
ASTM A706 / Standard Specification for Low-Alloy Steel Deformed and

A706M - 09b Plain Bars for Concrete Reinforcement
ASTM A153 / Standard Specification for Zinc Coating (Hot-Dip) on Iron

A153M - 09 and Steel Hardware
ASTM A123 / Standard Specification for Zinc (Hot-Dip Galvanized)

A123M - 12 Coatings on Iron and Steel Products
Standard Specification for Annealed or Cold-Worked

ASTM A666 - 10
Austenitic Stainless Steel Sheet, Strip, Plate, and Flat Bar
Standard Specification for High-Temperature Bolting, with

ASTM A453 /
Expansion Coefficients Comparable to Austenitic
A453M - 12
Stainless Steels
Page 21-6
AASHTO ASTM
Title
ASTM A510 / Standard Specification for General Requirements for Wire

A510M - 11 Rods and Coarse Round Wire, Carbon Steel
Standard Specification for Electrodeposited Coatings of

ASTM B633 - 11
Zinc on Iron and Steel
ASTM C827 / Standard Test Method for Change in Height at Early Ages
C827M - 10 of Cylindrical Specimens of Cementitious Mixtures
ASTM C207 - Standard Specification for Hydrated Lime for Masonry

06(2011) Purposes
ASTM C778 - 12 Standard Specification for Standard Sand
Standard Specification for Ceramic Glazed Structural Clay

ASTM C126 - 12
Facing Tile, Facing Brick, and Solid Masonry Units
Standard Test Method for Facial Dimensions and

ASTM C499 - 09 Thickness of Flat, Rectangular Ceramic Wall and Floor
Tile
Standard Test Method for Evaluating Ceramic Floor Tile

ASTM C627 - 10 Installation Systems Using the Robinson-Type Floor
Tester
Standard Test Method for Behavior of Materials in a

ASTM E136 - 12
Vertical Tube Furnace at 750°C
Standard Test Method for Surface Burning Characteristics

ASTM E84 - 12b
of Building Materials
ASTM D751 -
Standard Test Methods for Coated Fabrics
06(2011)
ASTM C144 - 11 Standard Specification for Aggregate for Masonry Mortar
ASTM A421 / Standard Specification for Uncoated Stress-Relieved

A421M - 10 Steel Wire for Prestressed Concrete
Standard Method of Test for Moisture-Density Relations of

AASHTO T180 Soils Using a 4.54-kg (10-lb) Rammer and a 457-mm (18-
in.) Drop
ASTM C920 - 11 Standard Specification for Elastomeric Joint Sealants
Standard Test Methods for Physical Dimensions of Solid

ASTM D5947 - 11
Plastics Specimens
ASTM D570 -
Standard Test Method for Water Absorption of Plastics
98(2010)e1
Page 21-7
AASHTO ASTM
Title
ASTM D624 - Standard Test Method for Tear Strength of Conventional

00(2012) Vulcanized Rubber and Thermoplastic Elastomers
Standard Practices for Evaluating the Resistance of

ASTM D543 - 06
Plastics to Chemical Reagents
Standard Test Method for Compressive Properties Of

ASTM D1621 - 10
Rigid Cellular Plastics
Standard Test Method for Apparent Density of Rigid

ASTM D1622 - 08
Cellular Plastics
ASTM E96/ Standard Test Methods for Water Vapor Transmission of

E96M-10 Materials, 2010
ASTM C1116 /
Standard Specification for Fiber-Reinforced Concrete
C1116M - 10a
AASHTO M ASTM C 685/C Standard Specification for Concrete Made by Volumetric

241M/M 241-11 685M-07 Batching and Continuous Mixing
AASHTO M 145- Standard Specification for Classification of Soils and Soil-

91 (2008) Aggregate Mixtures for Highway Construction Purposes
ASTM C1582 / Standard Specification for Admixtures to Inhibit Chloride-

C1582M - 11 Induced Corrosion of Reinforcing Steel in Concrete
Table 21-2: Designations and titles for BS, BS EN, and DIN standards that apply to concrete
structures works
BS DIN
BS EN Designation Title
BS 1881- Testing concrete. Method for

122:2011 determination of water absorption
Testing hardened concrete. Shape,

BS EN 12390-1:2000 dimensions and other requirements
for specimens and moulds
Testing hardened concrete. Making

BS EN 12390-2:2009 and curing specimens for strength
tests
Quality management systems.

BS EN ISO 9001:2015
Requirements
BS EN
Aggregates for concrete
12620:2002+A1:2008
Fire classification of construction

EN 13501
products and building elements
Page 21-8
BS DIN
BS EN 12350-2:2009 Testing Fresh Concrete. Slump-Test
Testing hardened concrete.

BS EN 12390-3:2009 Compressive strength of test
specimens
Testing concrete; testing of hardened

DIN 1048-
concrete (specimens prepared in
5:1991-06
mould)
Testing concrete. Recommendations

BS 1881-
for the determination of the initial
208:1996
surface absorption of concrete
Admixtures for concrete, mortar and

BS EN 480-2:1997 grout. Test methods. Determination of
setting time
BS 4370- Methods of test for rigid cellular

2:1993 materials. Methods 7 to 9
21.2 Classes of Concrete

Concrete classes used in each part of the structure shall be as specified herein or as shown in the
Contract documents. If not shown or specified, the Engineer will designate the class of concrete to
be used.
21.2.1 Normal-weight Concrete

Normal-weight concrete used in bridges, tunnels, underpasses, culverts, and miscellaneous
roadway structures shall be defined as per concrete classes provided in Section 4.3.9, Chapter 4,
Concrete Works, of these Standard Specifications.
21.2.2 Lightweight Concrete

Lightweight, or low-density, concrete shall conform to the requirements 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 the American Association of State Highway and
Transportation Officials (AASHTO) M6-08.
21.3 Materials Used for Concrete Structures

Cementitious materials, water, aggregates, mineral admixtures, and chemical admixtures — the five
major constituent materials of concrete — shall conform to the requirements of Section 4.3 of
Chapter 4, Concrete Works, of these Standard Specifications.
Other Materials for concrete structures shall comply with the standards and requirements outlined in
this section.
21.3.1 Blended Aggregates

Where suitable lightweight aggregates are available, a common practice is to blend light- with
normal-weight aggregates to achieve a desired concrete unit weight. This is done to control beam,
or other product, weights to satisfy shipping limitations, and jobsite conditions — such as crane size,
Page 21-9
reach limits, plant, or erection equipment capacities. Blends of fine and coarse aggregates shall
conform to the requirements of AASHTO T27-11 and approved by the Engineer.
21.3.2 Lightweight Aggregates

Lightweight aggregates for concrete shall conform to the requirements of AASHTO M195-11 (ASTM
C330 / C330M - 09).
21.3.3 Concrete Durability Parameters

For all structural concrete having a required cubical strength of 40MPa or greater the following
durability parameters shall apply:
1. Water absorption of ≤ 1.5 % (as tested according to BS 1881-122:2011).
2. Rapid Chloride Penetration value of ≤ 700 coulombs at 28 days (as tested according to
AASHTO T 277-07 (2011) (ASTM C1202 – 12)).
3. Water permeability of the concrete shall be tested in accordance with DIN 1048-5:1991-06
and the maximum penetration at 28 days shall be < 10 mm.
4. Initial surface absorption (ISAT) shall be tested in accordance with BS 1881-208:1996 and
the ISAT value at 28 days shall be < 0.15 ml/m²/s (10 minute test).
5. Shrinkage test at 28 days shall be in compliance with the British Building Research Station
(BRS) Digest No 35, 1968.
Tests shall be conducted at an independent laboratory as approved by the Engineer.
For the above tests, the frequency should be a minimum of one (1) set of specimens (3 cores taken
from test cubes) for every 500m³ of each class of concrete, as approved by the Engineer. For every
500m³ of each class of concrete cast, a minimum of one (1) set of specimens (3 cores) shall be
taken from the structure(s) or portions of the structure(s), as designated by the Engineer. All test
specimens should comply with the limits stated above. The Engineer may require additional testing,
as deemed necessary, at no extra cost to the Owner. All core holes in the structures should be filled
/ repaired with suitable non-shrink mortar or grout, as approved by the Engineer.
The Contractors’ proposed mix designs shall be submitted for the Engineer’s testing and approval.
21.3.4 Precast and Prestressed Concrete

All precast and prestressed concrete materials shall be as specified in Section 4.3 of Chapter 4,
Concrete Works, of these Standard Specifications — and as specified herein.
21.3.4.1 Cement
Cement for typical prestressed members, precast and fascia members shall be ASTM C150 / C150M
- 12 Type II Portland cement or of Cementitious materials as defined in Section 4.3 of Chapter 4,
Concrete Works, of these Standard Specifications, and as approved by the Engineer. All cement
shall be Manufacturer's standard grey cement, unless otherwise indicated on the Contract drawings
or specified in the Contract documents.
21.3.4.2 Aggregates
Aggregates for typical prestressed members, precast and fascia members shall conform to the
requirements of Section 4.3.7 of Chapter 4, Concrete Works, of these Standard Specifications —
and as follows:
• Fine Aggregates. Fine aggregate shall consist of natural sand conforming to the gradations
of ASTM C33 / C33M - 11a, except that not more than 1 percent shall pass a No. 200 sieve.
• Coarse Aggregates. Coarse aggregate shall consist of gravel or crushed stone. Nominal
sizes of coarse aggregates shall measure 20 mm to a No. 4 sieve and shall conform to the
grading requirements for size No. 67 aggregates of the ASTM C33 / C33M - 11a.
Page 21-10
21.3.4.3 Admixtures
Admixtures may be used only with written approval of the Engineer and as defined in Section 4.3.6
of Chapter 4, Concrete Works, of these Standard Specifications. Calcium chloride, or admixtures
containing calcium chloride, shall not be permitted.
21.3.4.4 Concrete-Bonding Agent

Concrete-bonding agents shall comply with the Federal Specification Army MMM-G-650B CANC.
The application of the concrete-bonding agent shall be strictly in accordance with manufacturer’s
recommendations to avoid any de-bonding.
21.3.5 Steel
Materials and installation of reinforcing and prestressing steel shall conform to the requirements of
Chapter 5, Reinforcing Steel; and Chapter 22, Prestressing Systems — respectively. All steel plates,
metal accessories, sleeves, inserts, and built-in materials in precast and prestresses concrete
members shall conform to the following:
21.3.5.1 Steel Plates, Studs and Anchor Bars in Precast Concrete

All steel shapes and plates embedded or cast in precast concrete shall be structural steel complying
with ASTM A36 / A36M - 08. Welded headed studs shall be in conformance with ASTM A108 - 07
and compatible with ANSI/AWS D1.1/D1.1M:2010 Type B. Deformed bar anchors shall conform to
ASTM A706 / A706M - 09b.
All steel shape and plate assemblies along with the studs and welded bars and anchors shall be hot
dipped galvanized per ASTM A153 / A153M - 09 and ASTM A123 / A123M - 12 and as approved by
the Engineer.
Any embedded items proposed by the Contractor to suit his method of operations, shall be subject
to the approval of the Engineer relative to their effect upon the strength, appearance, or properties
of the concrete, strand, or reinforcement steel.
21.3.5.2 Metal Accessories in Prestressed Concrete Members

Spacers, chairs, ties, hold-down devices, supports, and other devices for properly assembling,
placing, spacing, and supporting the reinforcement steel and the prestressing in place, shall be high-
strength, low-alloy carbon steel as approved by the Engineer. When coated reinforcement is
specified, spacers, chairs, and ties shall be epoxy-coated. Care shall be taken not to have dissimilar
metals in contact with each other in order to prevent galvanic corrosion. Hold-down devices shall be
coated with a suitable elastomeric (polyurethene) barrier coating of at least 125 µ DFT.
Accessories that are exposed on concrete surfaces may be hot-dipped galvanized per ASTM A153
/ A153M - 09 or stainless steel as specified in the Contract documents; otherwise, they shall be
stainless steel. Stainless steel shall be ASTM A666 - 10, Type 304 or 316 as directed and approved
by the Engineer, or as specified herein. Stainless steel bolts, nuts, and washers shall conform to
ASTM A453 / A453M - 12, Grade 651, Class B, 3510 kilograms per square centimetre. All stainless-
steel surfaces in contact with dissimilar metals shall be provided with 1.5 mm thick neoprene gasket
between contact faces or as directed by the Engineer.
21.3.5.3 Pipe Sleeves in Prestressed Concrete Members

Embedded pipe sleeves shall be as hot-dipped, galvanized pipe complying with ASTM A153 / A153M
- 09, Type S, Grade A.
21.3.5.4 Threaded Inserts and Lifting Devices in Precast Concrete

Embedded lifting devices, ferrule inserts and coil inserts, including loop inserts, and the
corresponding threaded and coil bolts and bars shall be manufactured of steel corresponding to the
following:
Page 21-11
For wire: ASTM A510 / A510M - 11, Grade No. 1017

For rods: ASTM A108 - 07, Grade No. 1018 or ASTM A36 / A36M - 08
All components shall be galvanized as per ASTM B633 - 11, SC-4.
Anchor bolts, where provided, shall be as per Section 30.3 of Chapter 30, Miscellaneous Metals.
21.3.5.5 Built-in Materials in Prestressed Concrete Members

The Contractor shall furnish and install all built-in materials and items as specified herein, and as
directed by the Engineer.
21.3.5.6 Welding Electrodes

Welding electrodes shall comply with AWS Standards and requirements of Article 23.4.11.1 of
Chapter 23, Steel Structures.
21.4 Proportioning of Concrete

Proportions of constituent materials for all concrete used in bridges, culverts, and miscellaneous
roadway structures shall be established to provide the following:
• Workability and consistency to permit concrete to be easily worked into forms and around
reinforcement under conditions of placement to be employed, without segregation or
excessive bleeding;
• Resistance to special exposures;
• Conformance with strength test requirements;
• Acceptable colour and texture, including aesthetics.
21.4.1 Concrete Mixing

21.4.1.1 Responsibility and Criteria for Concrete Mixing
Performance of all concrete mixes used in the bridge and culvert structures, and other roadway
structures, shall be designed by — and be the responsibility of — the Contractor. Selected mix
proportions shall produce concrete that is sufficiently workable and finishable for all uses intended
and shall conform to the requirements of Section 4.3.10 of Chapter 4, Concrete Works, of these
Standard Specifications, and all other requirements of this chapter.
The mix design shall be based on the specified properties. When strength is specified, an average
concrete strength shall be selected sufficiently above the specified 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 specified strength.
21.4.1.2 Trial Batch Testing for Concrete Mixing

Laboratory tests on trial and plant batches shall verify the performance of the proposed mix design
for all classes of concrete; precast concrete; lightweight, or low-density, concrete. Test results shall
be furnished to the Engineer by the Contractor, or the Manufacturer of precast elements, at the time
the proposed mix design is submitted.
The average values obtained from trial batches for the specified properties, such as strength, shall
exceed design values by a certain amount based on variability. For compressive strength, the
required average strength used as a basis for selection of concrete proportions shall be determined
in accordance with AASHTO M 241M/M 241-11 (ASTM C 685/C 685M-07).
Control charts shall be applied by the Manufacturer to monitor product characteristics (e.g. cube
strength, consistence, w/c ratio), constituent materials (aggregate grading, cement strengths etc.) or
production (batching accuracy).
The Manufacturer shall continuously assess the compressive strength results in order to:
Page 21-12
• check whether target strengths are being achieved;

• measure the variations from target;
• identify magnitude of any variation;
• objectively define action required (e.g. change w/c ratio) to get the process
back on target;
• identify periods and concretes where the strength was less than specified, so
that investigations can be carried out and corrective action taken.
The use of control charts should not be treated in isolation from the rest of production control. For
example routine checking and maintenance of weigh equipment will minimise the risk of a weigh-
scale failure. All the information available to the Manufacturer should be used to interpret the
information provided by the control charts and make informed decisions. Such information leads to
the cause of the change in quality being identified and appropriate action being taken. For example
a loss of accuracy in the weigh-scales should lead to repair, maintenance and re-calibration and not
a change in mix proportions. Where a change in mix proportions is required, the use of control charts
can lead to objectively defined changes in proportions.
a. Initial Standard Deviation

The initial standard deviation can be determined through a range of pairs approach where:
Initial standard deviation = 0.886 x mean range of successive pairs of results
The range is the numerical difference between successive results and the difference is always taken
as a positive number. Minimum 40 results are required to calculate the initial standard deviation.
Once the initial population standard deviation has been estimated, two methods will be permitted for
verifying the initial estimate. The first method involves checking that the standard deviation of the
most recent 15 results does not deviate significantly from the adopted value. The second method
involves the use of continuous control systems.
The target mean strength shall be selected by the Manufacturer, but the Manufacturer shall have to
comply with certain minimum values. The target strength should never be lower than:
Target mean strength ≥ characteristic compressive strength + 1.64 x initial standard deviation
b. Current Margin
The current margin for a concrete mix shall be determined by the Contractor and shall be taken as
the lesser of:
1. 1.64 times the standard deviation of cube tests on at least 100 separate batches of concrete
of nominally similar proportions and materials and produced over a period not exceeding 12
months by the same plant under similar supervision but not less than one sixth of the
characteristic strength for concretes class up to 15 MPa or 3.75 MPa for concretes of class
20 MPa or above;
2. 1.64 times the standard deviation of cube tests on at least 40 separate batches of concrete
of nominally similar proportions and materials and produced over a period exceeding 5 days
but not exceeding 6 months by the same plant and under similar supervision but not less
than one third of the characteristic strength for concrete class up to 15 MPa or 7.5 MPa for
concretes class of 20 MPa or above.
Where there is insufficient data to satisfy items (1) or (2) above the margin for the initial mix design
it shall be taken as two thirds of the characteristic strength for concrete class up to 15 MPa or 15.0
MPa for concrete class of 20 MPa or above. This margin shall be used as the current margin only
until sufficient data is available to adopt items (1) or (2) above. However, subject to the Engineer's
approval, when the specified characteristic strength approaches the maximum possible strength of
concrete made with a particular aggregate, a smaller margin of not less than one third of the
characteristic strength up to class 15 MPa or 7.5 MPa for concretes of class 20 MPa or above may
be used for the initial mix design.
Page 21-13
c. Trial Mixes
At least 8 weeks before commencing any concreting in the Works, the Contractor shall propose the
mix proportions to the Engineer and shall make trial mixes using samples of materials typical of those
proposed for the Works. Trial mixes shall be carried out for cool weather (winter) conditions and
again for hot weather (summer) conditions. The personnel, the concrete plant and the means of
transport to be used in the Works shall be employed to make the trial mixes and to transport them a
representative distance and time.
A clean, dry mixer shall be used and the first concrete batch discarded.
The workability of each batch shall be determined both at the mixer and after the representative
transport distance as described above.
Preliminary standard test cubes shall be made and tested from each class of concrete. For non-
prestressed concrete, 12 cubes shall be made from one sample from each of three consecutive
batches, and from each set of 12 cubes 3 shall be tested at an age of 7 days, 3 at an age of 28 days,
3 at an age of 56 days and 3 at an age of 90 days. For prestressed concrete, 12 cubes shall be
made from one sample from each of three consecutive batches and from each set of 12 cubes, 3
shall be tested at an age of 3 days, 3 at an age of 7 days, 3 at an age of 28 days, and 3 at an age
of 90 days. All cubes shall be made, cured, stored, transported and tested in accordance with BS
EN 12390-1:2000 and BS EN 12390-2:2009.
The average strength of the nine cubes tested at 28 days shall not be less than the initial target
mean strength minus 3.5 MPa.
As soon as the preliminary tests have been completed, the Contractor shall submit to the Engineer
full details of all trial mixes and tests made.
Before commencing any concreting of the Works, the Contractor shall submit to the Engineer full
details, including details of the aggregate type and grading and an assessment of the target mean
strength.
Prior to approval of the mixes for concrete above pilecap level, satisfactory trial panels shall have
been constructed as agreed with the Engineer.
When a mix has been approved, no variations shall be made without the consent of the Engineer.
Any such consent will be dependent upon the satisfactory outcome of further trial mixes and tests
carried out fully in accordance with the above requirements. These further requirements may include
new trial panels if deemed necessary by the Engineer.
The Contractor shall give the Engineer a minimum of three days notice of all trial mix operations and
ascertain whether the Engineer wishes to witness each operation. If so, the Contractor shall make
arrangements with him accordingly.
21.4.1.3 Approval for Concrete Mixing

All mix designs and any modifications thereto shall be 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 metre of concrete.
21.4.2 Concrete Mixing Water Content

Water amounts used shall not exceed the limits provided in Table 4-16 of Chapter 4, Concrete
Works, of these Standard Specifications for water to cement (W/C) ratios, and shall be as per the
approved mix design as per laboratory or plant trials; and shall be further reduced, as necessary, to
produce concrete of the consistencies listed in
Table 21-3. Water for concrete shall be from an approved source only.
Page 21-14
Table 21-3: Normal-weight concrete slump test limits at the time of placement
Type of Work Nominal Slump (mm) Maximum Slump (mm)
Formed Elements:
Sections more than 300 mm thick 25 – 75 125*
Sections 300 mm thick or less 25 – 100 125*
Cast-in-place piles and drilled shafts not vibrated 125 – 200 225
Concrete placed under water 125 – 200 225
Filling for riprap 75 – 175 200
• *When GGBS is used the maximum slump may increase to 180.
When Type F or G high-range, water-reducing admixtures are used, the Contractor may exceed the
slump limits in
Table 21-3, as permitted by the Engineer.

When the consistency of the concrete is found to exceed the nominal slump, the Contractor shall
adjust the mixture of subsequent batches to reduce the slump to a value 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
and WC ratio allowed, adjustment shall be made with an approved admixture, and the WC ratio shall
be maintained as low as possible as per approved concrete mix design.
21.4.3 Cement Control for Concrete Mixing

Cement content minimums shall conform to the requirements of Table 4-16 of Chapter 4, Concrete
Works, of these Standard Specifications; or as otherwise specified in the Contract documents. Actual
cement content used shall sufficiently produce concrete of the required strength, consistency, and
performance.
21.4.4 Concrete Admixtures

Concrete admixtures shall comply with ASTM C494 / C494M – 12 or BS EN 480-2:1997, and shall
be added to the concrete mix at the time of batching the concrete and in accordance with the
Manufacturer’s written procedure, and as approved by the Engineer. Copies of the Manufacturer’s
written procedure shall be furnished to the Engineer prior to use of any admixture. Any deviations
from these written procedures shall be submitted to the Engineer for approval. Admixtures shall not
be added to the concrete with the modified procedure until the Engineer has approved them in
writing.
When the Contractor proposes to use admixtures from different admixture manufacturers, the
Contractor shall provide evidence from the Manufacturers to the Engineer that the admixture will be
compatible and does not adversely affect the air-void system, strength, durability, and performance
of the hardened concrete. Test results complying with ASTM C457 / C457M - 11 shall serve as
evidence to satisfy this requirement.
Concrete admixtures shall not be used at site.
Page 21-15
21.4.5 Mineral Admixtures

Mineral admixtures shall be used in the amounts specified in the Contract documents. When mineral
admixtures are neither specified in the Contract documents nor prohibited, they shall be comparable
to the specified type of cement, and the Contractor shall comply with the requirements of Section
4.3.6 of Chapter 4, Concrete Works, of these Standard Specifications.
21.4.6 Chemical Admixtures

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, and when permitted by the
Engineer, to increase the workability or alter the time-of-set of the concrete. Using calcium chloride
shall not be permitted. Chemical admixtures for concrete shall be tested in accordance with ASTM
C494 / C494M – 12.
Methods and equipment for measuring and adding additives shall be approved by the Engineer.
Equipment at the batching plant that does not accurately dispense the correct amount of additive in
an acceptable manner shall not be approved.
21.4.7 Corrosion Inhibitor for Structural Concrete Works

Liquid concrete admixture shall be provided by the Contractor as required by the Contract documents
to protect the steel reinforcement from corrosion induced by carbonation, chloride and atmospheric
attack as specified herein and directed by the Engineer. The Contractor shall add to all Cast-In-Place
(CIP) structural concrete works a corrosion inhibitor as recommended by the Manufacturer, as
specified in Table 4.7 of Chapter 4, Concrete Works, of these Standard Specifications, and as
approved by the Engineer. The corrosion Inhibitor shall possess the following properties:
1. Proven effective when tested in accordance to ASTM G109 - 07 for a testing period not less
than 10 years
2. Complies to requirements of ASTM C494 / C494M – 12
3. Complies to the requirements of ASTM C1582 / C1582M - 11
4. Proven effective in modified cracked beam testing
5. Established international and regional track-record in excess of 20 years
6. Protects both anodic and cathodic components of the corrosion cell
7. Homogeneous; settlement should not be observed with time
8. The Manufacturer shall be ISO 9001 and ISO 14001 certified for the design and
manufacturing of corrosion protection systems and concrete protection products with a valid
(up-to-date) certificate.
9. Approved and certified by BBA, MPA Stuttgart or equivalent.
21.5 Manufacture of Concrete

Ready-mixed concrete production and concrete produced by stationary plant shall conform to the
requirements of AASHTO M157 and the requirements of Section 4.3 of Chapter 4, Concrete Works,
of these Standard Specifications.
21.5.1 Delivery of Concrete

To ensure continuous delivery, at the rate required for the Project, the company supplying concrete
shall have sufficient plant capacity and transporting apparatuses. Concrete delivery rates during
concreting operations shall be such as to provide for the proper handling, placing, and finishing of
the concrete. These rates shall ensure that the interval between batches does not exceed 20 minutes
and shall sufficiently prevent joints within a monolithic pour caused by placing fresh concrete against
concrete in which the initial set has already occurred. Delivery and handling methods shall facilitate
concrete placing with minimal re-handling and without damaging the structure or the concrete.
Page 21-16
21.5.2 Concrete Sampling and Testing

In addition to the requirements and standard methods provided in Section 4.3 of Chapter 4, Concrete
Works, of these Standard Specifications, compliance with the requirements indicated in this section
shall be determined in accordance with the following standard methods of the AASHTO, ASTM, or
BS EN:
• Sampling Fresh Concrete, AASHTO R 60-12 (ASTM C172 / C172M - 10)
• Weight per Cubic Metre, Yield, and Air Content (Gravimetric) of Concrete, AASHTO T
121M/T 121-12 (ASTM C138 / C138M - 12)
• Sieve Analysis of Fine and Coarse Aggregate, AASHTO T27-11 (ASTM C136 - 06)
• Slump of Portland Cement Concrete, AASHTO T 119M/T 119-11 (ASTM C143 / C143M -
10a)
• Testing Fresh Concrete, Slump-Test, BS EN 12350-2:2009
• Air Content of Freshly Mixed Concrete by the Pressure Method, AASHTO T 152-12 (ASTM
C231 / C231M - 10)
• Specific Gravity and Absorption of Fine Aggregate, AASHTO T 84-10 (ASTM C128 - 12)
• Specific Gravity and Absorption of Coarse Aggregate, AASHTO T 85-10 (ASTM C127 - 12)
• Determining Density of Structural Lightweight (Low-Density) Concrete, ASTM C567 / C567M
- 11
• Making and Curing Concrete Test Specimens in the Laboratory, AASHTO T 126 (ASTM
C192 / C192M - 07)
• Making and Curing Concrete Test Specimens in the Field, AASHTO T 23-08 (ASTM C31 /
C31M - 12)
• Testing Hardened Concrete, Compressive Strength of Test Specimens, BS EN 12390-
3:2009
21.5.2.1 Concrete Sampling

One set consisting of nine (9) cubes (15cm) shall be made in accordance with BS EN 12390-1:2000
and BS EN 12390-2:2009 from a sample taken from each randomly selected batch of concrete.
Samples shall be taken at the point of discharge from the delivery truck. Unless otherwise instructed
by the Engineer the rate of sampling of randomly selected batches from same plant shall be as given
in Table 21-4, but not less than one sample shall be taken on each day that concrete of that class is
used.
The nine cubes shall be numbered consecutively and marked with the date, the section of work from
which it was taken and any other information required and dispatched to the approved laboratory for
testing for compressive strength.
Table 21-4: Rates of sampling and testing from same plant
Number of trucks Rate
(1) Truck (1) set
(2-4) Trucks (2) sets
> 40 One set for each 100 m3
21.5.2.2 Frequency of Testing for Concrete Aggregates

Unless otherwise instructed by the Engineer, the aggregates in use shall be regularly tested in a
laboratory acceptable to the Engineer at a frequency not less than that indicated in Table 21-5:
Page 21-17
Table 21-5: Frequency of aggregate testing
Test Frequency Remarks
Particle size distribution by sieve analysis Weekly More frequently at start of production
Clay, fine silt, et. Weekly
Sand equivalent of fine aggregate Bi-weekly
Fineness modulus of fine aggregate Bi-weekly
Clay lumps Bi-weekly
Flakiness index Bi-weekly Reducing to weekly when stable.
Elongation index Bi-weekly Reducing to weekly when stable.
Specific Gravity of coarse and fine Weekly Reducing to bi-weekly when stable.
aggregates
Water absorption Weekly Reducing to bi-weekly when stable.
Bulk density and voids of aggregate Weekly
Organic impurities Weekly
Aggregate crushing value Weekly
10% fines Weekly
Aggregate Impact Value Weekly
Los Angeles abrasion resistance Bi-weekly
Sulfate content Bi-weekly
Chloride content Bi-weekly
Voided Shell Content Bi-weekly Reducing to monthly when stable
Cement – Aggregate Reactivity Initially for each source and as directed by the
Engineer
Sulfate soundness Monthly
Drying Shrinkage Initially for each source and as directed by the

Engineer
Others As required by the Engineer
Page 21-18
21.5.3 Evaluation of Concrete Strength

21.5.3.1 Concrete Strength Tests
Cubes Nos. 1, 5 and 9 shall be tested after 7 days. If the average of the three 7-day test cubes is
below the minimum requirement, the Contractor must immediately stop all concreting until checks
are made on the material and equipment and immediately rectify any defect which has become
apparent as the result of such checking. If the Contractor elects to remove and replace the defective
concrete without waiting for the results of the 28-day test, concreting can then continue entirely at
the responsibility of the Contractor. Cubes Nos. 2 and 8, 3 and 7, and 4 and 6 will be considered
three individual samples or sets and after 28 days of curing shall be tested as specified above. If
either of the cubes in any set shows definite evidence, other than low strength, of improper sampling,
molding, handling, curing or testing, said cube shall be discarded and the strength test shall consist
of the strength of the remaining cubes.
21.5.3.2 Requirements 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 cubes shall be cured at the structure site under conditions that
are not more favourable than the most unfavourable conditions for the portions of the structure that
they represent, as described in AASHTO T 23-08 (ASTM C31 / C31M - 12), Article 9.4. Sufficient
test cubes, as specified in Article 21.5.2.1, shall be made and tested at the appropriate ages to
determine when operations, such as release of falsework, application of prestressing forces, or
placing the structure in service, can occur.
21.5.3.3 Requirements for the Acceptance of Concrete

All concrete shall be accepted based on adherence to the requirements of this chapter and Section
4.3.12 of Chapter 4, Concrete Works, of these standard specifications.
When determining compliance of concrete with a specified strength, test cubes shall be cured under
controlled conditions, as described in Article 9.3 of AASHTO T 23-08 (ASTM C31 / C31M - 12); and
shall be tested at the specified age.
Final acceptance of the concrete works is based on 28 days' testing on the three sets of two cubes
each. The work is considered in compliance if the average of the three sets of cubes equals or
exceeds the minimum specified for the class of concrete being placed, and if the average of the two
cubes in any one set does not fall below the specified minimum strength by more than 3.4 MPa. If
the results of the 28-day testing are unsatisfactory, the Contractor, in accordance with the
instructions of the Engineer, shall conduct tests in the suspect parts of the structure. The concrete
may be test loaded in-situ or cylindrical test cores may be drilled out and tested in accordance with
BS EN 12390-3:2009. Should the tests prove that the concrete is unsatisfactory or below the
standards specified, the Engineer may order the concrete to be removed and replaced with concrete
of the specified quality. All the above shall be at the expense and responsibility of the Contractor.
21.5.3.4 Requirements for the Control of Mix Design

Whenever the average of three consecutive strength tests that were made to determine acceptability
of the concrete falls to less than 1.03 MPa below the specified strength, or any single strength test
falls more than 1.38 MPa below the specified strength, the Contractor shall, at the Contractor's
expense, make corrective changes in the materials, mix proportions, or concrete manufacturing
procedures before placing additional concrete from that class. Such changes shall be approved by
the Engineer prior to use.
a. Precast Concrete Cured by Waterproof Cover Method, Steam, or Radiant Heat

When a precast concrete member is cured by the waterproof cover method, steam, or radiant heat,
the compressive strength test cubes made for any of the above purposes shall be cured under
conditions similar to the member. Such concrete shall be considered acceptable whenever a test
Page 21-19
indicates that the concrete has reached the specified compressive strength if such strength is
reached no later than the specified age for the compressive strength.
Test cubes shall be cured by only one of the following methods:
• For concrete with specified design compressive strengths less than or equal to 41.4 MPa,
test cubes shall be stored next to the member and under the same covers so that the cubes
are exposed to the same temperature conditions as the member.
• For all specified concrete strengths, test cubes shall be match-cured in chambers in which
the temperature of the chamber is correlated with the temperature in the member prior to
release of the prestressing strands. Temperatures of the chamber and member shall be
verified by use of temperature sensors in the chamber and member. Unless specified
otherwise, temperature sensors in I-beams shall be located at the centre of gravity of the
bottom flange. For other members, the temperature sensors shall be located at the centre of
the thickest section. Locations shall be specified in the Contract documents. After release of
the prestressing strands, cubes shall be stored in a similar temperature and humidity
environment as the member.
21.6 Protection of Concrete during Placing and Curing

Precautions shall be taken as needed to protect concrete from damage due to weather or other
environmental conditions during placing and curing periods. Concrete damaged by weather
conditions shall be either repaired to an acceptable condition or removed and replaced.
21.6.1 Rain Protection

Under conditions of rain, the placing of concrete shall not commence, or shall stop, unless adequate
protection is provided to prevent damage to the surface mortar or damaging flow or wash of the
concrete surface.
21.6.2 Hot-weather Protection

The recommendations of the American Concrete Institute Standard "Guide to Hot Weather
Concreting", ACI 305R-10, and “Cooling and Insulating Systems for Mass Concrete”, ACI 207.4R-
05, shall be followed. Proposals for hot weather concreting shall be included with the submissions
for trial mixes.
Concrete mixture temperatures immediately before placement shall be between 10 degrees Celsius
and 32 degrees Celsius, except as otherwise provided herein.
When the ambient temperature is above 32 degrees Celsius, the forms, reinforcing steel, steel-beam
flanges, and other surfaces that will come in contact with the mix shall be cooled to below 32 degrees
Celsius by means of a water spray — or other approved methods.
Concrete temperatures at time of placement shall be maintained within the specified temperature
range by any combination of the following:
• Shading the materials storage areas or the production equipment;
• Cooling the aggregates by sprinkling with water that conforms to the requirements of Article
4.4.1.3 of Chapter 4, Concrete Works, of these Standard Specifications;
• Shading the steel reinforcement;
• White painting the transit mixer and covering it with hasin;
• Reducing the time between placing of concrete and start of curing to minimum possible;
• Using chilled water of a temperature below 4˚ C;
• Cooling the aggregates or water by refrigeration or replacing a portion of the mix water with
ice that is flaked or crushed to the extent that the ice will completely melt while mixing of the
concrete; and,
• Injecting liquid nitrogen.
Page 21-20
21.6.3 Special Requirements for Bridge Decks

When placing concrete in bridge decks or other exposed slabs, the Contractor shall ensure that the
evaporation rate does not exceed the bleeding rate. In no case the evaporation rate shall be more
than 0.5 kg per square metre per hour. The evaporation rate maybe estimated from ACI 308R-01
chart shown in Figure 21-1.
When necessary, the Contractor shall take one or more of the following actions to reduce the
evaporation rate:
• Construct windbreaks or enclosures to effectively reduce the wind velocity throughout the
area of placement;
• Use fog sprayers upwind of the placement operation to effectively increase the relative
humidity; and,
• Reduce the temperature of the concrete according to Section 21.6.3.
Figure 21-1: Evaporation rate nomograph from ACI 308

During periods of low humidity, wind, or high temperatures, and prior to the application of curing
materials, the Contractor shall protect concrete being placed and finished for bridge decks from
damage due to rapid evaporation. Such protection shall prevent premature crusting of the surface
or an increase in drying cracking. Such protection shall be provided by raising the humidity of the
surrounding air with fog sprayers operated upwind of the deck, by employing wind-breaks or sun-
Page 21-21
shades, additionally reducing the temperature of the concrete, scheduling placement during the
cooler times of days or nights, or any combination thereof.
For bridge decks that are located over or adjacent to salt water or when specified in the Contract
documents, the maximum temperature of the concrete at the time of placement shall be 27 degrees
Celsius.
21.6.4 Concrete Exposed to Salt Water

Unless otherwise specified in the Contract documents, concrete for structures exposed to salt or
brackish water shall comply with the requirements of Class C40/20 concrete. Such concrete shall be
mixed for a period of not less than two minutes and the water content of the mixture shall be carefully
controlled and regulated so as to produce concrete of maximum impermeability. To produce
maximum density and a complete lack of rock pockets, the concrete shall be thoroughly
consolidated, as necessary. Unless otherwise indicated in the Contract documents, the clear
distance from the face of the concrete to the reinforcing steel shall be not less than 100 mm. No
construction joints shall be formed between levels of extreme low and high water, or the upper limit
of wave action, as determined by the Engineer. Between these levels, the forms shall not be
removed, or other means provided, to prevent salt water from coming in direct contact with the
concrete for a period of not less than 30 days after placement. Except for the repair of any rock
pockets and the plugging of form-tie holes, the original surface — as the concrete comes from the
forms — shall be left undisturbed. Special handling shall be provided for precast members to avoid
even slight deformation cracks.
21.6.5 Concrete Exposed to Sulphate Soils or Sulphate Water

When the Contract documents identify the area as containing sulphate soils or sulphate water, the
concrete that will come in contact with such soil or water shall be Class C40/20 and shall be mixed,
placed, and protected from contact with soil or water, as required for concrete exposed to salt water;
however, the protection period shall be not less than 72 hours.
21.7 Handling and Placing Concrete

Concrete shall be handled, placed, and consolidated by methods that shall not cause segregation of
the mix and will result in a dense homogeneous concrete that is free of voids and rock pockets. The
Contractor-selected methods shall not cause the displacement of reinforcing steel, or other
materials, to become embedded in the concrete. Concrete shall be placed and consolidated prior to
initial set and in no case more than 1.5 hours after the cement was added to the mix. This time limit
maybe increased to 2.0 hours when plasticizer type F, G, or D is used. Concrete shall not be re-
tempered.
Concrete shall not be placed until the Engineer has inspected and approved the forms, all materials
to be embedded, and the adequacy of the foundation material for spread footings. Prior to
commencing placement, the Contractor shall remove all mortar from pervious placements, debris,
and foreign material from the forms and steel. Immediately before placing the concrete against the
forms and subgrade, it shall be thoroughly moistened with water. Temporary form spreader devices
may be left in place until concrete placement precludes their need, after which they shall be removed.
Placement of concrete for each section of the structure shall be done continuously without
interruption between planned construction or expansion joints. Delivery rates, placing sequences,
and methods shall be such that fresh concrete is always placed and consolidated against previously
placed concrete before its initial set has occurred.
During and after the placement of concrete, care shall be taken not to injure the concrete or break
the bond with reinforcing steel. Workers shall not walk in fresh concrete. Platforms for workers and
equipment shall not be supported directly on any reinforcing steel. Once the concrete is set, forces
shall not be applied to the forms or to reinforcing bars that project from the concrete until the concrete
is of sufficient strength to resist damage.
Page 21-22
21.7.1 Placement Sequences

Whenever a concrete placement plan or schedule is specified or approved, the sequence of
placement shall conform to the approved plan. Unless otherwise specifically permitted by the
Contract documents, the requirements of the following specifications shall apply.
21.7.1.1 Vertical Members

Concrete for columns, substructure and culvert walls, and other similar vertical members shall be
placed and allowed to set and settle for a period of time before placing concrete for integral horizontal
members — such as caps, slabs, or footings. Settling periods shall adequately allow the completion
of settlement due to loss of bleed water and shall be not less than 12 hours for vertical members
measuring more than 4.5 m in height and not less than 30 minutes for members measuring more
than 1.5 m, but not more than 4.5 m in height. When friction collars or falsework brackets are
mounted on vertical members, and unless otherwise approved, the vertical member shall have been
in place at least seven days and shall have attained its specified strength before loads from horizontal
members are applied.
21.7.1.2 Superstructures
Unless otherwise permitted, no concrete shall be placed in the superstructure until substructure
forms have been stripped sufficiently to determine the character of the supporting substructure
concrete.
d. T-beams and Deck Girder Spans

Concrete for T-beam or deck girder spans whose depth measures less than 1.2 m may be placed in
one continuous operation or may be placed in two separate operations; first, to the top of the girder
stems; and second, to completion. For T-beam or deck girder spans whose depth measures 1.2 m
or more, and unless the falsework is non-yielding, such concrete shall be placed in two operations,
and at least five days shall elapse after placement of stems before the top deck slab is placed.
e. Concrete Box Girders

Concrete for box girders may be placed in two or three separate operations consisting of bottom
slabs, girder stems, and top slabs. In either case, the bottom slab shall be placed first and, unless
otherwise permitted by the Engineer, the top slab shall not be placed until the girder stems have
been in place for at least five days.
Concrete sequence placement for the cast-in-place, multiple-cell box girders at bridges shall be as
follows:
The bottom slab, the exterior and interior web portions and the diaphragm portions shall be placed
monolithically, as indicated on the Contract drawings, and as specified herein.
Placement of the top slab shall occur. Top slabs shall not be placed until the girder webs have been
in place for at least five days.
Vertical construction joints in all portions of the multiple cell box girders shall be minimized and,
where proposed, shall preferably be placed at 0.2 of the span length on either side of a supporting
pier. Positive moment areas shall be placed first followed by the placement of concrete for the
negative moment area over the pier. Dependent upon the volume of concrete, additional vertical
construction joints may be used — subject to the Engineer’s approval.
A concrete pour sequence plan shall be prepared by the Contractor for each superstructure and
submitted to the Engineer for approval prior to commencing any bridge superstructure work. Pour
sequence plans shall show the locations of all construction joints that shall be bonded joints, as
specified herein. Concrete pours within each element shall be alternated to eliminate shrinkage to
the greatest extent possible.
Concrete placement in each pour shall start at the low point and shall continue upgrade, unless
otherwise permitted by the Engineer.
Page 21-23
Joints created due to the stopping of work shall be avoided as far as possible. Such joints shall be
constructed as directed by the Engineer, when necessary.
At deck median locations indicated on the Contract drawings, the Contractor shall apply a
commercial quality, bond-breaking compound to construction joint surfaces.
21.7.1.3 Arches
Arch ring concrete shall be placed in such a manner as to load the centring uniformly and
symmetrically. Arch rings shall be cast in transverse sections of such size that each section can be
cast in a continuous operation. Section arrangements and placement sequences shall be as
approved and shall avoid the creation of initial stress in the reinforcement. These sections shall be
bonded together by suitable keys or dowels. Arch barrels for culverts and, unless prohibited by the
Contract documents, other arches may be cast in a single, continuous operation.
21.7.1.4 Box Culverts

In general, the base slab or footings of box culverts shall be placed and allowed to set before the
remainder of the culvert is constructed. For culverts whose wall height measures 1.5 m or less, the
sidewalls and top slabs may be placed in one continuous operation. For higher culvert walls, the
requirements for vertical members shall apply.
21.7.1.5 Tunnels and Underpasses

Tunnel and underpass concrete shall be placed by pumping and shall be discharged into the work
through a pipe inserted into the formed space. Discharge lines shall be graduated to indicate the
depth of filling at any time. Special care shall be taken to force concrete into all irregularities in work
surfaces and to completely fill tunnel/underpass walls and crown. Only experienced operators shall
operate placing equipment. Pumped concrete shall be vibrated by the Contractor. Concrete shall not
be pumped through aluminium alloy pipe.
21.7.1.6 Tunnels and Underpasses on Rock Surfaces

Rock surfaces against or upon which concrete is to be placed shall be clean; free of oil and other
objectionable coatings, water, mud, debris, dummy rock, and loose semidetached or unsound
fragments; and shall be sufficiently rough to assure satisfactory bond with the concrete.
Discontinuities shall be cleaned to hard rock on the sides, and to a depth that is approved by the
Engineer. All overbreak beyond the excavation limit shown in the Contract documents shall be
backfilled with shotcrete or concrete at the Contractor's expense.
21.7.1.7 Precast Elements

The sequence of placement for concrete in precast elements shall be such that sound, well
consolidated concrete that is free of settlement or shrinkage cracks is produced throughout the
member. Placing and compacting prestressed concrete members shall conform to Section 21.7.2,
Section 21.7.3, and Section 21.14.3
21.7.2 Concrete Placing Methods

Concrete shall be placed in its final position, as nearly as possible, and the Contractor shall not use
vibrators for extensive shifting of the weight of fresh concrete.
Concrete shall be placed in horizontal layers of a thickness not exceeding the capacity of the vibrator
to consolidate the concrete and merge it with the previous lift. In no case shall the depth of a lift
exceed 600 mm. Concrete placement rates shall not exceed those rates assumed for the design of
the forms — as corrected for the actual temperature of the concrete being placed.
When placing operations involve dropping the concrete more than 1.5 m, the concrete shall be
dropped through a tube fitted with a hopper head — or through other approved devices — to prevent
segregation of the mix and spattering of mortar on steel and forms above the elevation of the lift
Page 21-24
being placed. This requirement shall not apply to cast-in-place piling when concrete placement is
completed before initial set occurs in the first placed concrete.
21.7.2.1 Concrete Placing Equipment

All equipment used to place concrete shall be of adequate capacity and designed and operated so
as to prevent segregation of the mix or loss of mortar. Such equipment shall not cause vibrations
that might damage freshly placed concrete. Aluminium parts of the equipment shall not come in
contact with the concrete. Between uses, the Contractor shall clean the mortar coating inside placing
equipment that has set or dried out before its use is resumed.
Chutes shall be lined with smooth watertight material and, when steep slopes are involved, shall be
equipped with baffles or reverses.
Operation of concrete pumps shall product a continuous stream of concrete without air pockets.
When pumping is completed, the concrete remaining in the pipeline, if it is to be used, shall be
ejected in such a manner that there will be no contamination of the concrete or separation of the
ingredients.
Conveyor belt systems shall be as approved by the Engineer, and shall not exceed a total length of
168 m, measured from end to end of the total assembly. Belt assemblies shall be arranged so that
each section discharges into a vertical hopper arrangement to the next section. To keep segregation
to a minimum, scrapers shall be situated over the hopper of each section so as to remove mortar
adhering to the belt and to deposit it into the hopper. Conveyor belt system discharge ends shall be
equipped with a hopper and a chute — or suitable deflectors — which shall allow the concrete to
drop vertically into the deposit area.
21.7.3 Consolidation Methods

All concrete, except concrete placed underwater and concrete otherwise exempt, shall be
consolidated by mechanical vibration immediately after placement.
Except as noted herein, vibration shall be internal. External form vibrators may be used for thin
sections when the forms have been designed for external vibration.
Vibrators shall be of approved type, design, and of a size appropriate for the work. They shall be
capable of transmitting vibration to the concrete at frequencies of not less than 75 Hz.
A sufficient number of vibrators shall be provided by the Contractor to properly compact each batch
of concrete immediately after it is placed in the forms. Additionally, the Contractor shall have at least
one spare vibrator immediately available in case of breakdown.
To thoroughly work the concrete around the reinforcement and embedded fixtures and into the
corners and angles of the forms, the Contractor shall manipulate the vibrators. Vibration shall be
applied at the point of deposit and in the area of freshly deposited concrete; and the Contractor shall
insert vibrators into and withdraw them from the concrete slowly. Finally, vibration shall be of
sufficient duration and intensity to thoroughly consolidate the concrete but shall not be continued so
as to cause segregation.
Shall localized areas of grout form, vibration shall be halted. Vibrators applications shall be uniformly
spaced and not farther apart than 1.5 times the radius over which the vibration is visibly effective.
Vibration shall not be applied directly to, or through the reinforcement to, sections or layers of
concrete that have hardened to the degree that the concrete ceases to be plastic under vibration.
Vibrators shall not be used to transport concrete in the forms.
Where immersion-type vibrators are used to consolidate concrete around epoxy-coated reinforcing
steel, the vibrators shall be equipped with rubber or another non-metallic coating.
Vibration shall be supplemented by such spading as is necessary to ensure smooth surfaces and
dense concrete along form surfaces and in corners and locations impossible to reach with the
vibrators.
Page 21-25
When approved by the Engineer, the Contractor may consolidate small noncritical elements by using
suitable rods and spades.
21.7.4 Underwater Placement

Generally, the Engineer shall not permit the placement of concrete in/or underwater. Where the
Engineer specifically approves the placement of concrete in/or underwater, the Contractor shall
submit its proposed construction procedure for placing the concrete for the Engineer’s approval
before proceeding with the work.
Methods for placing concrete in/or underwater shall keep as much of the concrete out of direct
content with the water as possible to avoid any rapid movement or agitation of the exposed surface.
Underwater concrete placement shall be continuous from start to finish. Concrete surfaces shall be
kept as nearly horizontal as practicable. To ensure thorough bonding, each succeeding layer of seal
shall be placed before the preceding layer has taken initial set. For large pours, more than one tremie
or pump shall be used to ensure compliance with this requirement.
To prevent segregation, concrete placed underwater shall be carefully placed in a compact mass, in
its final position, by means of a tremie, concrete pump, or other approved method; and shall not be
disturbed after being deposited. Still water shall be maintained at the point of deposit and the forms
underwater shall be watertight. Cofferdams shall be vented during placement and while curing the
concrete to equalize the hydrostatic pressure and thus prevent water from flowing through the
concrete.
21.7.4.1 Underwater Concrete Placement Equipment

Tremies shall consist of a watertight tube with a diameter measuring not less than 250 mm and fitted
with a hopper at the top. Aluminium pipes shall not be used. Tremies shall be supported so as to
permit free movement of the discharge end over the entire top surface of the work and so as to
permit rapid lowering, when necessary, to retard or stop the flow of concrete. To prevent water from
entering the tube before it is filled with concrete, the Contractor shall seal the discharge ends closed
at the start of work. After placement begins, the tremie tube shall be kept full of concrete to the
bottom of the hopper. If water enters the tube after placement has begun, the tremie shall be
withdrawn, the discharge end resealed, and the placement restarted. When a batch is dumped into
the hopper, the flow of concrete shall be induced by slightly raising the discharge end, always
keeping it in the deposited concrete. Flows shall be continuous until the work is completed. When
cofferdam struts prevent the tremie's lateral movement, the Contractor shall use one tremie in each
bay.
Concrete pumps used to place concrete underwater shall include a device at the end of the discharge
tube to seal out water while the tube is first being filled with concrete. Once the flow of concrete has
begun, the Contractor shall keep the end of the discharge tube full of concrete and below the surface
of the deposited concrete until placement is completed.
Detailed proposals for concreting shall be submitted by the Contractor for the Engineer’s approval.
Where concrete is to be placed in/or underwater, the actual mix proportions and selection of
aggregates shall ensure a resulting concrete with good flow and cohesion characteristics.
Underwater cement content shall be 25 percent greater than for a comparable mix for use in dry
conditions; and, the Engineer shall approve the minimum works cube strength for all concrete for the
comparable mixes used in dry conditions.
21.7.4.2 Underwater Concrete Placement Cleanup

Dewatering may proceed after test specimens cured under similar conditions indicate that the
concrete has sufficient strength to resist the expected loads. All laitance, or other unsatisfactory
materials, shall be removed from the exposed surface by scraping, chipping, or other means that
shall not injure the concrete surface before placing foundation concrete.
Page 21-26
21.7.5 Reinforced-concrete Bridge Slabs

This work shall form and construct reinforced-concrete bridge slabs in accordance with this chapter,
the requirements of this section, and the Contract documents.
Unless otherwise shown in the Contract drawings, all cast-in-place reinforced-concrete bridge slabs
shall be Class C40/20.
21.7.5.1 Construction of Reinforced-concrete Bridge Slabs

a. Cast-in-place Slabs
Conventional forms, permanent metal deck forms, or prestressed concrete panels shall be used by
the Contractor as indicated in the Contract plans and in accordance with Article 1.20.8.2 of Chapter
1, General Requirements, and as approved by the Engineer. Permanent metal deck or conventional
forms shall be used by the Contractor for thickened slabs, diaphragms, or other regions — as shown
in the Contract plans where prestressed concrete panels are not used.
Slabs shall be constructed as shown in the Contract plans and in accordance with the following
pertinent requirements:
• Chapter 4, Concrete Works, of these Standard Specifications;
• Chapter 5, Reinforcing Steel, of these Standard Specifications;
• Chapter 21, Concrete Structures, of these Standard Specifications; and,
• Chapter 22, Prestressing Systems, of these Standard Specifications.
Surface evenness, the method of testing, and finishing of the surface shall comply with the
requirements specified in Section 21.10, Finishing Plastic Concrete.
b. Extending Existing Slabs

Existing slabs shall be extended by the Contractor in accordance with Section 21.23, Extending
Concrete Structures.
c. Prestressed Concrete Deck Panels

Where the Project requires the use of prestressed concrete deck panels, the Contractor shall profile
each beam to determine the actual camber, or sag, of the beams before placing the panels. To
obtain the required cover over the slab reinforcement, and the required slab thickness, the profile
grade line, panel elevation, and bearing seat elevations shall be adjusted, as needed. When a profile
grade line adjustment is necessary, the Contractor shall make adjustments over suitable increments,
depending on span lengths, so that the revised grade line will produce a uniform profile and good
riding qualities. Grade adjustments shall be approved by the Engineer prior to placement by the
Contractor. When adjusting the grade line, the actual beam camber shall be considered in adjacent
spans or slab placements. Abutment back- and wing wall portions shall be placed after the
Contractor adjusts the profile grade line.
21.7.6 Approach Slabs

Approach slabs consisting of cast-in-place concrete shall be furnished and installed by the
Contractor, as indicated in the Contract drawings and as directed by the Engineer. Concrete placed
at approach slabs shall consist of Class C40/20 concrete — unless otherwise specified in the
Contract documents. All materials for the concrete in approach slabs shall comply with the
requirements of this chapter.
21.7.6.1 Approach Slab Construction

Concrete approach slabs shall be placed on an aggregate base course, as specified in Section 3.2.2
of Chapter 3, Pavement, of these Standard Specifications.
Page 21-27
All approach slab concrete shall be placed in accordance with the applicable clauses under this
chapter. Surface evenness and methods for testing and finishing the surface shall comply with the
requirements specified in Section 21.10, Finishing Plastic Concrete.
21.7.7 Blinding Concrete

Blinding concrete shall be furnished and installed by the Contractor, as indicated in the Contract
drawings, as specified herein, and as directed by the Engineer.
Blinding concrete shall be constructed with Class C15/20 concrete and shall comply with all
requirements of this chapter.
21.7.7.1 Blinding Concrete Construction

Construction of all blinding concrete shall comply with the requirements of this chapter, or as directed
by the Engineer.
21.7.8 Screed Concrete

Screed concrete shall be furnished and installed by the Contractor, as indicated in the Contract
drawings, as specified herein, and as directed by the Engineer.
The screed concrete shall consist of one part Sulfate Resistant Portland Cement (SRC) to three
parts sand by volume. The ingredients shall conform to and be mixed as specified for Class C40/20
concrete in Section 4.3 of Chapter 4, Concrete Works, of these Standard Specifications. The
concrete substrate onto which the screed is to be applied shall be broom-finished, cleaned, and
coated with proper bonding agent prior to application as specified in this chapter and Chapter 4,
21.7.8.1 Crack Control Additive

The screed concrete shall be mixed with a crack controlling additive of high performance
micropolypropylene fiber complying with ASTM C1116 / C1116M - 10a Type II at a mixing rate of
1.0 kg per 1 cubic meter of screed mix or as recommended by the Manufacturer and approved by
the Engineer. Mixing shall be in accordance with the Manufacturer’s recommendation and as
21.7.9 Mass Concrete - Thermal Control

Mass concrete placement shall be defined as any pour in which the concrete being cast has
dimensions of 1.00 metre or greater in all three directions (x, y, and z). For all mass concrete pours,
the mix temperature shall not exceed 25o C as measured immediately prior to placement of the
concrete into the forms. Further, the Contractor shall be required to maintain a core temperature of
68o C or less and a temperature differential of 20 degrees or less between the interior and exterior
of all mass pour elements during curing.
Mass concrete construction shall conform to the requirement and recommendation specified in ACI
Publication 207.1R-05 “Guide to Mass Concrete” and ACI 207.2R-07” Report on Thermal and
Volume Change Effects on Cracking of Mass Concrete”.
The Contractor shall provide temperature monitoring devices to record temperature development
between the interior and exterior of the element at points approved by the Engineer and shall monitor
the mass pours to measure temperature differential. Temperature monitoring shall continue until the
interior temperature is within a differential of 20o C with the lowest ambient temperature for a
maximum of two weeks.
A proper thermal control plan shall be submitted by the Contractor describing the procedures to be
used to minimize the temperature differentials and to be approved by the Engineer. The independent
thermal control plan shall be submitted during the concrete mix design stage, and shall include the
following:
Page 21-28
a. Concrete Mix: The mix design shall be optimized with supplementary cementitious
materials like GGBS, PFA, etc. to reduce the heat of hydration.
b. Mass Concrete: Placing methods and time of placement at hot & cold weather ,
control of concrete delivery and placement temperatures , monitoring the core and
ambient temperatures by sensing probes placed at appropriate locations, curing
methods to control temperature differentials, use of insulation, placing of concrete lifts
along with successive timings, water cooling or water retention methods etc.
c. Formwork: Wooden forms shall be used, delayed form removal, protruding steel bars
to be utilized as heat sinks to draw heat out of core concrete, etc.
d. Corrective Measures: Corrective measures shall be proposed in case of failure to
comply with the methodology and revised thermal control reports.
The Engineer shall be provided with a copy of each set of readings as they are taken and a
temperature chart for each mass pour element showing temperature readings vs. time. Prior to
placing any mass concrete on the Project, the Contractor shall submit for approval:
a. An analysis of the anticipated thermal developments within mass pour placements
using the proposed materials and casting methods.
b. A plan outlining specific measures to be taken to control the temperature differential
within the limits noted above.
c. Their proposed monitoring system.
d. If the Contractor is proposing a special concrete mix design as part of the temperature
control plan, this mix design shall also be submitted for the Engineer’s review and
approval.
If monitoring indicates that the proposed measures are not controlling the concrete core temperature
below 68o C and the concrete temperature differential within the 20 degrees specified, the Contractor
shall make the necessary revisions to the plan and submit the revised plan for approval.
The Contractor shall assume all risks connected with the placing of mass pour concrete and approval
of the Contractor’s plan will in no way relieve the Contractor of the responsibility for satisfactory
results. Should any mass concrete placed under this specification proves unsatisfactory, the
Contractor will be required to make the necessary repairs or remove and replace the material at the
Contractor’s expense.
Accumulation of water on the surface due to any cause during compaction shall be prevented as far
as possible and any such water shall be removed before further concrete is placed.
All costs associated with special temperature controls for mass concrete placement shall be included
at the Contractor's expense, and shall be without additional specific compensation. Requirements
for control of temperatures in mass concrete pours included in this article shall be in addition to any
other applicable requirements found in the Contract plans and Contract documents.
21.7.10 Removal of Falsework and Forms

Falsework and forms are temporary works that shall comply with the requirements of Section 1.20,
Chapter 1, General Requirements of these standard specifications.
The Contractor shall not remove falsework or forms without the Engineer’s approval. Any implicit or
explicit permission in these specifications to remove falsework or forms shall not relieve the
Contractor of responsibilities regarding damages to the concrete works that result from the
Contractor’s removal of the falsework or forms.
To determine when to remove falsework and forms, the Contractor shall consider conditions that
influence the early strength of concrete, including the location and character of work structures,
weather, and materials used in concrete mixes.
To remove falsework and forms, the Contractor shall not use any methods that are likely to
overstress the concrete or damage concrete surfaces. The Contractor shall remove supports in a
way that uniformly and gradually applies stresses to a concrete work.
Page 21-29
After removing formwork, the Contractor shall promptly request the Engineer’s inspection of concrete
works and surfaces. The Contractor shall carry out any remedial treatment to surfaces that the
Engineer requests without delay. The Engineer may reject any concrete surface that the Contractor
treats before such inspection.
The following defects and conditions may require repair or cleaning:
1. Crazing
2. Cracks
3. Spalls
4. Pop outs
5. Air Bubbles
6. Honeycombing
7. Holes left by rods and bolts
8. Surface deficiencies that penetrate to the reinforcement
9. Fins and other objectionable projections on the surface
10. Stains and discolorations that cannot be removed by cleaning
The Engineer may require the Contractor to remove and replace entire portions of defective concrete
that cannot be easily repaired or cleaned.
The Contractor shall remove falsework for arch bridges uniformly and gradually, beginning at the
crown and working toward the springing. At the same time, the Contractor shall remove the falsework
for adjacent arch spans.
Forms that support decks for box girders and forms in hollow abutments may remain in place when
no permanent access into such cells is available. Before reusing formwork, the Contractor shall
thoroughly clean it and make it ready to the satisfaction of the Engineer.
The Contractor shall remove forms that do not support the dead load of concrete members and forms
for railings and barriers 24 hours after the placement of concrete. Exposed concrete surfaces shall
be protected from damage.
After use and removal, forms and falsework shall remain the property of the Contractor. Work areas
shall be restored to their original or planned conditions and cleaned of all debris.
For structures of two or more spans, the sequence of falsework removal shall be as specified or
approved in Contract documents.
21.7.10.1 Time of Removal

The Contractor shall time the removal of formwork to best suit curing and to prevent elastic
shortening, shrinkage, or creep.
The Contractor shall not remove forms and supports until sufficient time has passed after concrete
placement, as indicated in Table 21-6.
Table 21-6: Time of removal
Structural member Time of

Removal
Forms and falsework that provide support for the following structures:
• Spans over than 4.3 metres (slab spans, pan girders, reinforced concrete 14 days
box (RCB) decks, or pier caps)
• Spans of 4.3 metres or less (bridges decks on girders, RCB decks, and 10 days
diaphragms)
• Pile bent pier caps that are not yet supporting girders 10 days
Page 21-30
Structural member Time of

Removal
Forms that do not support the dead weight of concrete:
• Side forms for abutments and pier caps, sides of beams, slabs,
24 hours
walls, and columns (unloaded)
• Interior cells of box girders, railings, and barriers 12 hours
Special notes on project plans that detail the removal of forms and falsework under arches,
continuous spans, and other special structures including pre-stressed concrete beams shall have
precedence over the time limits for removal of forms and falsework shown in Table 21-6.
The Engineer may accelerate the removal for supporting forms or falsework (except those for
columns, walls, side forms for abutment, pier caps, railing and barriers), requesting such removal as
soon as concrete has attained 80 % of its specified strength.
Time of removal for forms and falsework must meet the following additional requirements:
1. Forms shall not be removed until concrete has sufficient strength to prevent damage to the
surface.
2. Falsework for post-tensioned portions of structures shall not be released until the prestressing
steel has been tensioned.
3. Falsework that supports any span of a continuous or rigid frame bridge shall not be released until
the aforementioned requirements have been satisfied for all 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 for which falsework is to be released.
4. Unless other specifications or approvals apply, falsework shall be released before the placement
of railings, copings, or barriers for all types of bridges. For arch bridges, the time of falsework
release relative to the construction of elements of the bridge above the arch shall be as shown
on the plans or as directed by the Engineer.
21.7.10.2 Extent of Removal

The Contractor shall remove all falsework and forms except under the following conditions:
1. If portions of driven falsework piles are more than 300 mm below the subgrade within roadbeds,
more than 600 mm below the original ground or finished grade outside of roadbeds, or more than
600 mm below the established limits of any navigation channel
2. If the removal of footing forms would endanger the safety of cofferdams or other work
3. If forms support enclosed cells where access is not provided
4. If deck forms in the cells of box girder bridges do not interfere with the future installation of utilities
shown in Contract documents
21.8 Construction Joints

Construction joints shall be made only where specified in the Contract documents, or shown in the
pouring schedule, unless otherwise approved. All planned reinforcing steel shall extend
uninterrupted through joints. In the case of emergencies, the Contractor shall place the construction
joints as directed by the Engineer; and, if directed, additional reinforcing steel dowels shall be placed
across the joint. Such additional steel shall be furnished and placed at the Contractor's expense.
Injection of construction joints shall be carried out in accordance with Section 21.9.3.
21.8.1 Horizontal Joints

Generally, horizontal joints shall be made by pouring the concrete slightly above the grade of the
construction joint, and after the surface has reached its final set, the surface shall be prepared as
Page 21-31
outlined in Section 21.8.421.8.3, Bonding. Insert formwork shall be used to obtain neat, horizontal
lines.
21.8.2 Vertical Joints

Vertical joints shall be formed with substantial bulkheads or headers, as required. Feather-edged
joints shall not be permitted.
21.8.3 Bonding
Unless otherwise specified in the Contract documents, horizontal joints may be made without keys,
and vertical joints shall be constructed with shear keys. Surfaces of fresh concrete at horizontal
construction joints shall be rough-floated sufficiently to thoroughly consolidate the surface and left
intentionally in a roughened condition. Shear keys shall consist of formed depressions in the surface
covering approximately one-third of the contact surface. Key forms shall be bevelled so that removal
shall not damage the concrete.
All construction joints shall be cleaned of surface laitance, curing compounds, and other foreign
materials before fresh concrete is placed against the surface of the joint. Abrasive blast or other
approved methods shall be used to clean horizontal construction joints to the extent that clean
aggregate is exposed. All construction joints shall be flushed with water and allowed to dry to a
surface-dry condition immediately prior to placing concrete.
21.8.4 Bonding and Dowelling to Existing Structures

When the Contract documents specify that new concrete be bonded to existing concrete structures,
the existing concrete shall be cleaned and flushed, as specified in Section 21.8.3, Bonding. When
the Contract documents show reinforcing dowels grouted into holes drilled in the existing concrete
at such construction joints, the holes shall be drilled by methods that shall not shatter or damage the
concrete adjacent to the holes. Drilled-hole diameters shall measure 6 mm larger than the nominal
diameter of the dowels, unless shown otherwise in the Contract documents. Grout shall consist of a
neat, cement paste created from Portland cement and water, with water content that shall not
measure more than 0.36 litre/kg of cement. Re-tempering of the grout shall not be permitted.
Immediately prior to placing the dowels, the Contractor shall clean the holes of dust and other
deleterious materials, and thoroughly saturate them with water and remove all free water, then the
holes shall be dried to a saturated surface-dry condition. Sufficient grout shall be placed in the holes
so that no voids remain after the dowels are inserted. Grout shall be cured for a period of at least
three days, or until dowels are encased in concrete.
When specified in the Contract documents, or approved by the Engineer, epoxy may be used in lieu
of Portland cement grout for the bonding of dowels in existing concrete. When used, epoxy shall be
mixed and placed in accordance with the Manufacturer's recommendations.
21.8.5 Forms at Construction Joints

When forms at construction joints overlap previously placed concrete, they shall be retightened
before depositing new concrete. Straight bulkheads or grade stripes shall be the Contractor’s tool
for neatly forming the face edges of all joints that are exposed to view. If straight bulkheads or grade
stripes are not available, the Contractor may otherwise carefully finish the face edges true to line
and elevation.
21.8.6 Waterstops at Construction Joints

Waterstops shall be installed at all construction joints in accordance with Article 21.9.1.6 and Article
21.9.2.4.
21.9 Expansion and Contraction Joints

Expansion and contraction joints shall be constructed at the locations, and in accordance with the
details, specified in the Contract documents; and include open joints, filled joints, joints sealed with
Page 21-32
sealants or water stops, joints reinforced with steel armour plates or shapes, and joints with
combinations of each of these features.
When preformed elastomeric compression joint seals or bridge deck joint seal assemblies are
required, they shall conform to the requirements of Chapter 26, Bridge Deck Joint Systems.
21.9.1 Expansion and Contraction Joint Materials

21.9.1.1 Pre-moulded Expansion Joint Fillers
Pre-moulded fillers shall conform to one of the following specifications:
• Specification for Preformed Expansion Joint Fillers for Concrete Paving and Structural
Construction, AASHTO M 213-01 (2010) (ASTM D1751 - 04(2008)).
• Specification for Preformed Sponge Rubber and Cork Expansion Joint Fillers for Concrete
Paving and Structural Construction, AASHTO M 153-06 (R2011) (ASTM D1752 - 04a(2008)).
Type II (cork) shall not be used when resiliency is required.
• Specification for Preformed Expansion Joint Filler for Concrete, AASHTO M 33-99 (2012)
(ASTM D994 / D994M - 11).
21.9.1.2 Polystyrene Board Fillers

Board fillers shall be expanded polystyrene with a minimum flexural strength of 0.24 MPa, as
determined by ASTM C203 - 05a(2012) and compressive yield strengths measuring between 0.1
MPa to 0.3 MPa at five percent compression. When specified in the Contract documents, or where
required to prevent damage during concrete placement, the surface of polystyrene board shall be
faced with 3-mm thick hardboard conforming to American National Standards Institute (ANSI)
A135.4. Density of the polystyrene board shall be as specified in the Contract documents.
21.9.1.3 Contraction Joint Material

Material placed in contraction joints shall consist of asphalt-saturated felt paper or another approved
bond-breaking material.
21.9.1.4 Pourable Joint Sealants

Pourable sealants placed along the top edges of contraction or filled expansion joints shall conform
to one of the following:
• Hot-poured sealants shall conform to AASHTO M 282-99 (2012) (ASTM D3406 - 95(2006));
except when the sealant comes in contact with asphaltic material, then it shall conform to
AASHTO M301-01.
• Cold-poured sealant shall be silicone-type, conforming to Federal Specification TT - S-1543,
Class A. Sealants shall be a one-part, low-modulus silicone rubber-type with an ultimate
elongation of 1,200%.
• Polyethylene foam strips used when shown in the Contract documents shall consist of
commercial quality with a continuous, impervious, glazed top surface, suitable for retaining
the liquid sealant at the proper elevation in the joint while hardening.
21.9.1.5 Metal Armour

Expansion joint armour assemblies shall be fabricated from steel in conformance with the
requirements of Section 30.5 of Chapter 30, Miscellaneous Metal. Assemblies shall be accurately
fabricated and straightened at the shop after fabrication and galvanizing, as necessary, to conform
to the concrete section.
Page 21-33
21.9.1.6 External and Internal Waterstops

Waterstops shall consist of the type, size, and shape specified in the Contract documents. They shall
be dense, homogeneous, and without holes or other defects. Waterstops shall be furnished by a
manufacturer with a minimum of ten years experience in the Middle East.
Shop drawings for the waterstops network shall be submitted by the Contractor for the approval of
the Engineer. Samples of the proposed materials shall be submitted. Technical backup services and
supervision on site during the application of the waterstops shall be provided by the Manufacturer.
External waterstops in base slab expansion joints shall be minimum 350mm wide with four bulbs
and ten parallel lines of fins. The Centre box section shall be 25mm wide and flat to accept a filler
board. The waterstop shall have an outer nailing flange with reinforced and profiled edge to resist
tear when fixed to shuttering with double headed nails, and provide additional key when cast into the
concrete.
External waterstops in base slab construction and contraction joints shall be minimum 350mm wide
with four bulbs and ten parallel lines of fins. The waterstop shall incorporate a central fin, 22mm high,
as shutter stop. The waterstop shall have an outer nailing flange with a reinforced and profiled edge
to resist tear when fixed to shuttering with double headed nails, and provide additional key when
cast into the concrete.
Internal waterstops in wall and roof expansion joints shall have a centre box to accommodate
movement, be minimum 350mm wide with four bulbs and ten parallel lines of fins. The centre box
section shall be flat to accept a filler board. The web shall have a thickened central section to transfer
stresses to the centre bulbs. The waterstop shall have a reinforced eyeleted outer flange for secure
fixing of the waterstop into position.
Internal waterstops in wall and roof construction and contraction joints shall be minimum 350mm
wide with four bulbs and ten parallel lines of fins. The web shall have a thickened central section to
transfer stresses to the centre bulbs. The waterstop shall have a reinforced eyeleted outer flange for
secure fixing of the waterstop into position.
Waterstops shall only be supplied by manufacturers operating a BS EN ISO 9001 quality assurance
scheme.
a. Rubber Waterstops
Rubber waterstops shall be formed from synthetic rubber made exclusively from neoprene,
reinforcing carbon black, zinc oxide, polymerization agents, and softeners. This compound shall
contain not less than 70% by volume of neoprene. Tensile strengths shall not be less than 19 MPa
with an elongation at breaking of 600%. Shore durometer indication, or hardness, shall be between
50 and 60. Tensile strengths shall not be less than 65% of the original after seven days in air at a
temperature of 70 degrees Celsius, ±1 degree — or after four days in oxygen at 70 degrees Celsius,
±1 degree, and 2 MPa pressure.
To ensure the production of a uniform section with a permissible variation in dimension of ±0.8 mm,
the Manufacturer shall form the rubber waterstops with an integral cross section in suitable moulds.
No splices will be permitted in straight strips. Additionally, strips and special connection pieces shall
be well cured in a manner that creates dense, homogeneous cross sections that are free from all
porosity. Junctions in the special connection pieces shall be full moulded. During the vulcanizing
period, the joints shall be securely held by suitable clamps. Materials at the splices shall be dense
and homogeneous throughout the cross section.
b. Polyvinyl Chloride Waterstops

Polyvinyl chloride (PVC) waterstops shall be manufactured by the extrusion process from an
elastomeric plastic compound, the basic resin that consists of PVC. These compounds shall contain
any additional resins, plasticizers, stabilizers, or other materials needed to ensure that, when the
material is compounded, it will meet the performance requirements given in this specification. No
reclaimed PVC or other material shall be used.
Page 21-34
Materials shall comply with the physical requirements presented in Table 21-7, when tested under
the indicated ASTM test method.
Table 21-7: ASTM test method requirements for PVC materials
Size ASTM D5947 - 11 -
ASTM D570 -
Water Absorption 0.02
98(2010)e1
Tear Resistance ASTM D624 - 00(2012) 39.40 N/mm
Specific Gravity ASTM D792 - 08 1.40 maximum
Durometer Hardness ASTM D2240 - 05(2010) 75 ± 5
13.80 MPa
Tensile Strength ASTM D638 - 10
mini
Elongation ASTM D638 - 10 350%
Cold Brittleness ASTM D746 - 07 -37oC
Stiffness in Flexure ASTM D747 - 10 4.8 MPa
Effect on Alkali after 7 days (Weight Change & Hardness + 0.10%
ASTM D543 - 06
Change) + 1 Point
Tensile strength after Accelerated Extraction CRD-C 572-74 12.75 MPa
Elongation after Accelerated Extraction CRD-C 572-74 350%
a. Copper Waterstops
Sheet copper shall conform to the specifications for copper sheet, strip, plate, and rolled bar;
AASHTO M 138M/M 138-08 (ASTM B152 / B152M - 09); and shall meet the embrittlement test of
Section 10 of AASHTO M 138M/M 138-08 (ASTM B152 / B152M - 09).
b. Testing of Waterstops Material

All waterstop materials shall be tested by the Manufacturer, either in company-owned or affiliated
laboratories — or in a recognized commercial laboratory — and shall submit three certified copies
of the test results to the Engineer.
21.9.2 Expansion and Contraction Joint Installation

21.9.2.1 Open Joints
Open joints shall be constructed by the insertion and subsequent removal of a wood strip, metal
plate, or other approved material. Template insertion and removal shall be accomplished without
chipping or breaking concrete corners. When not protected by metal armour, open joints in decks
and sidewalks shall be finished with an edging tool. Upon completion of concrete finishing work, all
mortar and other debris shall be removed from open joints.
21.9.2.2 Filled Joints

When filled joints are specified in the Contract documents, pre-moulded-type fillers shall be used
unless polystyrene board is specifically called for. Filler for each joint shall consist of as few pieces
of material as possible. Abutting edges of filler material shall be accurately held in alignment with
each other and tightly fitted or taped, as necessary, to prevent the intrusion of grout. Joint filler
material shall be anchored to one side of the joint by waterproof adhesive or other methods so as to
prevent it from working out of the joint, but not interfere with the compression of the material.
21.9.2.3 Sealed Joints

Prior to the installation of pourable joint sealants, the Contractor shall remove all foreign material
from the joint, shall cut back the filler material to the depth shown or approved, and clean the surface
of the concrete that will be in contact with the sealant with light sandblasting. When required, a
polyethylene foam strip shall be placed in the joint to retain the sealant and isolate it from the filler
material. Sealant materials shall then be mixed and installed in accordance with the Manufacturer's
directions; and any material that fails to bond to the sides of the joint within 24 hours after placement
shall be removed and replaced by the Contractor.
Page 21-35
21.9.2.4 Waterstops
Waterstops shall be furnished and installed in accordance with the details indicated on the Contract
drawings, the provisions of this section, and as directed by the Engineer.
Waterstops shall conform to the cross section and to the minimum dimensions indicated on the
Contract drawings.
Adequate water stops of metal, rubber, or plastic shall be placed as specified in the Contract
documents. Where movement at the joint is provided for, the waterstops shall be of a type permitting
such movement without damage. They shall be spliced, welded, or soldered to form continuous
watertight joints.
No site welding of waterstops and no splices will be permitted in straight strips. Additionally, strips
and special connection pieces shall be well cured in a manner that creates dense, homogeneous
cross sections that are free from all porosity. All junctions in the special connection pieces shall be
fully moulded. During the vulcanizing period, the Contractor shall secure the joint with suitable
clasps. Materials at the splices shall be dense and homogeneous throughout the cross sections.
Field splices for rubber waterstops shall be either vulcanized, mechanical, using stainless steel parts;
or made with a splicing union of the same stock as the waterstop, at the option of the Contractor.
Field splices for PVC waterstops shall be performed by heat sealing the adjacent surfaces in
accordance with the Manufacturer's recommendations. A thermostatically controlled electric source
of heat shall be used to make all splices and shall sufficiently melt, but not char, the plastic.
The waterstop network shall provide an integral four bulb system with constant width throughout.
Standard intersections shall be used to accommodate changes in direction. On site jointing shall be
carried out using metal jigs provided by the Manufacturer to ensure alignment and continuity of
section.
To avoid bucking or distortion of the web or flange during waterstop installation, the Contractor shall
cut and splice them at changes in directions, as may be necessary.
Field splices shall develop water tightness equal to that of the unspliced material and have a tensile
strength of not less than 50 percent of the unspliced material.
Precautions shall be taken so that the waterstops shall be neither displaced nor damaged by
construction operations, or other means. While the waterstop is being embedded in concrete, the
Contractor shall keep all surfaces free from oil, grease, dried mortar — or any other foreign matter.
Means shall be used to ensure that all portions of the waterstop designed for embedment shall be
tightly enclosed by dense concrete.
Waterstops shall be properly placed and tensioned prior to start concrete work. If, after placing the
concrete the waterstops are materially out of position or shape, the Contractor shall remove the
surrounding concrete, rest the waterstop, and replace the concrete — at its own expense.
21.9.2.5 Expansion Joint Armour Assemblies

Armour assemblies shall be installed so the top surface matches the plane of the adjacent finished
concrete surface throughout the length of the assembly. Positive methods shall be employed in
placing the assemblies to keep them in correct position during the placing of the concrete. Openings
at expansion joints shall be that designated in the Contract documents at normal temperature, or as
directed by the Engineer for other temperatures; and, the Contractor shall take care to avoid
impairment of the clearance in any manner.
21.9.2.6 Sheet Packing, Preformed Pads, and Board Fillers

Tempered hardboard shall conform to Federal Specification LLL-B-810, Type II; and shall be smooth
on one side and plain. Hardboards shall measure at a minimum thickness of 3 mm, unless shown or
specified otherwise.
Page 21-36
Expanded polystyrene shall be a commercially available polystyrene board. Expanded polystyrene

shall have a flexural strength of 240 kPa, minimum, determined in conformance with the
requirements in ASTM C203 - 05a(2012) and compressive yield strengths of between 110 kPa and
275 kPa, at 5% compression.
When shown in the Contract documents, surfaces of expanded polystyrene shall be faced with
hardboard, which shall measure at a minimum thickness of 3 mm, conforming to Federal
Specification LLL-B-810, any type. Other facing materials may be used, provided they furnish
equivalent protection. Boards shall be held in place by nails, waterproof adhesives, or other means
21.9.3 Injection of Expansion and Construction Joints

Re-injectable PVC hoses comprising of a hollow core and lateral openings covered by neoprene
strips and webbed nylon mesh (or equivalent) shall be installed at all horizontal and vertical
expansion and construction joints, in all structural elements exposed to water such as base slab,
walls, and all underground structures as indicated in the Contract plans.
The outside diameter of the hose shall be a minimum of 24 mm with a longitudinal internal injection
hole diameter of 10 mm and discharge openings of 5 mm diameter at a maximum spacing of 300
mm centre to centre. The hose shall be placed to the total length of expansion and construction joints
with entry port and vent ends terminating in a junction box. The re-injectable hose shall be cleanable
and re-injectable. The hose shall be clamped into position with clips spaced at 250 mm apart.
21.9.3.1 Construction Joints

The concrete substrate along the length of the construction joint shall be free of debris and from any
form of contaminants. Sharp areas shall be grinded off and loose concrete shall be removed by the
Contractor.
The Contractor shall place the re-injectable hoses between the internal and external waterstops and
fix them firmly into the substrate.
Initial injection of construction joints shall be carried out by the Contractor before demobilizing the
dewatering system and immediately after achieving the 28 days compressive strength. Approved
cementatious flowable grout shall be used for injection. Installation of hose and injection of grout
shall be carried out exactly as per the Manufacturer’s instructions. Volumes of grout injected and
pressure used to inject shall be recorded. All injection hoses shall be flushed out after the above
mentioned injection is carried out to allow future re-injection.
21.9.3.2 Expansion Joints

The Contractor shall install and fix the re-injectable hoses on both edges of internal waterstop. For
all expansions joints initial injection shall be carried out immediately after achieving the 28 days
compressive strength. Approved acrylic gel (or equivalent), having ultra low viscosity, high
expandability, strength, and accommodation of joint movements, shall be used. Installation of the
hose and injection of the resin shall be carried out as per the Manufacturer’s recommendations.
Volumes of acrylic gel injected and pressure used to inject shall be recorded. All injection hoses shall
be flushed out after the above mentioned injection is carried out to allow future re-injection.
21.9.3.3 Injection of Leaking Joints

The Contractor shall identify the leakage locations on the joints of the structure and re-inject hoses
satisfactorily in the leaking joints until all leaks have been stopped.
No additional payment will be made by the Owner for these items and they shall be placed at the
Contractor’s expense.
Page 21-37
21.10 Finishing Plastic Concrete

Unless otherwise specified in the Contract documents, after the Contractor has consolidated the
concrete — and prior to the application of cure — all surfaces of concrete that are not placed against
forms shall be struck-off to the planned elevation or slope and the surface finished by floating with a
wooden float sufficiently to seal the surface. While the concrete is still in a workable state, the
Contractor shall carefully tool all expansion and construction joints with an edger. Joint filler shall be
left exposed.
21.10.1 Roadway Concrete Surface Finish

All bridge decks, approach slabs, and other concrete surfaces used by traffic shall be finished to a
smooth skid-resistant surface in accordance with this chapter. During finishing operations, the
Contractor shall provide suitable and adequate work bridges for proper performance of the work,
including the application of fog sprays and curing compound, and for inspecting the work.
21.10.1.1 Striking off and Floating

After the concrete is placed and consolidated according to the specifications in Section 21.7,
Handling and Placing Concrete, bridge decks or top slabs of structures shall be finished by the
Contractor using approved power-driven finishing machines. If the Engineer approves them, the
Contractor may use hand-finishing methods for short bridges measuring 15 m or less in length — or
for irregular areas where the use of a machine would be impractical.
All surfaces shall be struck-off by equipment supported by and travelling on rails or headers. Rails,
headers, and strike-off equipment shall be of sufficient strength and be adjusted so that the concrete
surface, after strike-off, will conform to the planned profile and cross section. Rails or headers shall
be set on non-yielding supports and shall be completely in place and firmly secured for the scheduled
length for concrete placement before placing of concrete will be permitted. Rails for finishing
machines shall extend beyond both ends of the scheduled length for concrete placement for a
sufficient distance to permit the float of the finishing machine to fully clear the concrete to be placed.
Rails or headers shall be adjustable for elevation and shall be set to allow for anticipated settlement,
camber, and deflection of falsework — as necessary — to obtain a finished surface true to the
required grade and cross section. They shall be of a type and shall be so installed that no springing
or deflection will occur under the weight of the finishing equipment and shall be so located that
finishing equipment may operate without interruption over the entire surface. Rails or headers shall
be adjusted, as necessary, to correct for unanticipated settlement or deflection that may occur during
finishing operations. If rail supports are located within the area where concrete is being placed, the
Contractor shall remove them to at least 50 mm below the finished surface, as soon as they are no
longer needed, and shall fill the void with fresh concrete.
Before the delivery of concrete, the finishing machine, or the hand-operated strike-off tool, shall be
operated over the entire area to check for excessive rail deflections and for proper deck thickness
and cover on reinforcing steel. This check will also verify operation of all equipment. Any necessary
corrections shall be made before beginning concrete placement.
Concrete finishing machine shall include, but not by way of limitation, the following:
a. Finishing machine shall be of a type approved by the Engineer, power driven and equipped
with at least two screeds, and shall be fully and accurately adjustable to produce a crowned
or flat surface. The finishing machine shall be designed and operated to strike-off, screed,
and consolidate and shall have a minimum of one reciprocating, non-vibratory screed.
Finishing machines shall have ample strength and sufficient power and be so geared as to
operate consistently, regularly, and smoothly.
b. Concrete finisher floats shall be attached to the finishing machine. They shall be equipped
with independent wheels that ride on the rails and shall be of sufficient weight as to not flex
under the pressure of the concrete. Floats shall be easily adjustable from crown to flat and
shall be a minimum of 76 cm in length with a minimum 60 cm in contact with the concrete.
Float pans shall be suspended from the frame, float freely on the concrete and shall be
Page 21-38
capable of being adjusted in both height and width. Float pans, once adjusted, shall be
equipped hydraulically, or by other suitable means so that they may be raised from the
operator's platform and when lowered shall automatically return to their pre-set positions.
c. Finishing machines shall be so constructed that the travel of the floating mechanism can be
adjusted to conform to the concrete cross section indicated in the Contract drawings or
formed by the finishing machine.
d. Concrete bridge roadway decks and approach slabs shall be struck off and screeded with a
finishing machine; the use of a vibratory screed shall not be permitted.
e. Consolidating methods for the concrete shall be as approved by the Engineer; and the use
of vibrating equipment shall be subject to the approval of the Engineer.
Finishing of concrete placed in bridge decks shall consist of striking off the surface of the concrete
as placed, floating the surface so struck off, and finishing as specified herein.
Concrete placement in bridge roadway decks shall not be permitted until the Engineer is satisfied
that the rate of producing and placing concrete will be sufficient to complete the proposed operations
within the scheduled time, that experienced finishing machine operators are employed to finish the
deck, and that fogging equipment and all necessary finishing tools and equipment are on-site and in
satisfactory condition for use. Finishing machines shall be set up sufficiently in advance of use to
permit inspection by the Engineer during the daylight hours before each pour.
All concrete on the bridge decks and approach slabs shall be formed and placed by the Contractor
to comply with all lines, levels, and profiles — as indicated in the Contract drawings. This process
shall include all depressions or notches to receive expansion joints, as indicated and as specified in
Section 21.9, Expansion and Contraction Joints.
Immediately prior to placing bridge deck concrete or approach slabs, the Contractor shall check all
forms, falsework, and wedges and shall make all necessary adjustments. Care shall be exercised to
ensure that settlement and deflection, due to the added weight of the bridge deck concrete, shall be
a minimum. Suitable means, such as telltales, shall be provided by the Contractor to readily permit
measurement by the Engineer of settlement and deflection as it occurs.
If settlement, or other unanticipated events occur, which in the opinion of the Engineer shall prevent
obtaining bridge deck or approach slabs that comply with the requirements of these Standard
Specifications, placing of deck concrete shall be discontinued until corrective measures that are
satisfactory to the Engineer are provided. If the Contractor fails to provide satisfactory measures
prior to initial set of the concrete in the affected area, the placing of concrete shall be discontinued
and a bulkhead installed at a location determined by the Engineer. All concrete in place beyond the
bulkhead shall be removed.
Concrete for bridge decks shall be placed in a uniform heading approximately normal to the structure
centreline or, in the case of screeds supported on transverse headers, parallel to the centreline —
as directed by the Engineer. Concrete placing rates shall be limited to that which can be finished
before the beginning of initial set.
Immediately after the concrete has been placed and consolidated, the surface shall be struck off with
the finishing machine until the required surface is obtained.
Finishing machines shall go over each area of the surface as many times as required to obtain the
required profile and cross section. A slight excess of concrete shall be kept in front of the cutting
edge of the screed at all times. This excess shall be carried all the way to the edge of the pour or
form and shall not be worked into the slab. It shall be wasted.
After strike-off, the surface shall be finished with a float, roller, or other approved device to remove
any local irregularities and to leave sufficient mortar at the surface of the concrete for later texturing.
During finishing operations, excess water, laitance, or foreign materials brought to the surface during
the course of the finishing operations shall not be reworked into the slab, but shall be removed
immediately upon appearance by means of a squeegee or straightedge drawn from the centre of the
slab toward either edge.
Page 21-39
Adding water to the concrete surface to assist in finishing operations shall not be permitted to avoid
shrinkage cracks.
Prior to their use, the strike-off method and equipment shall be subject to approval by the Engineer,
who can withdraw his approval if performance is not satisfactory. Selected equipment shall be
capable of finishing roadway decks within the surface tolerances set forth in these standard
specifications. Improper adjustment and operation that results in unsatisfactory consolidation and
smoothness shall be corrected immediately. Unsatisfactory performance may be cause for rejection
of the equipment and removal of the in-place concrete.
In areas inaccessible to a finishing machine — and where permitted by the Engineer — the
Contractor may float the roadway or approach slab surfaces to a smooth, uniform surface following
the completion of the strike-off by hand methods by means of floats measuring 3 m or more in length.
When a finishing machine is used, the finished surface shall be floated in a similar manner — unless
otherwise directed by the Engineer. Adequate floats shall be used to remove roughness and minor
irregularities left by the strike board or finishing machine and to seal the concrete surface. Excessive
working of the concrete surface shall not be permitted by the Engineer. All floats shall be used in
such a manner that each transverse pass overlaps the previous pass by a distance of at least one-
half the length of the float.
When hand-operated float boards are used, they shall measure 3.5 m to 4.5 m long, and shall be
ribbed and trussed to provide a rigid float. They shall also be equipped with adjustable handles at
each end. Float shall consist of wood not less than 25 mm thick and a minimum of 200 mm wide.
Adjusting screws spaced at no more than 600 mm on centres shall be provided between the float
and the rib. Float boards shall be maintained free of twist and true at all times.
Hand-operated float boards shall be operated from transverse finishing bridges, which shall
completely span the bridge roadway deck or approach slab area being floated, and a sufficient
number of finishing bridges shall be provided to permit operation of the floats without undue delay.
Not less than two transverse finishing bridges shall be provided when hand-operated float boards
are used. When a finishing machine is used for longitudinal floating, one finishing bridge equivalent
to the transverse finishing bridge specified herein shall be furnished for use by the Engineer.
All finishing bridges shall be of rigid construction and shall be free of wobble and spring when used
by the operators of longitudinal floats. They shall also be easily moved.
21.10.1.2 Straight Edging

After the floating has been completed, but while the concrete is still plastic, the slab surface shall be
tested with a 3-m metal straightedge, which shall be held in contact with the surface in successive
positions parallel to the bridge roadway deck or approach slab centreline and then at right-angles.
Testing shall occur throughout the whole area, from one side of the deck or slab to the other. These
tests shall be in successive stages of not more than one-half the length of the straightedge. Any
depressions found shall be filled at once with freshly mixed concrete, struck off, consolidated, and
refinished. High areas shall be cut down and refinished. Testing and refinishing shall continue until
the entire surface is found to be free from deviations of more than 3 mm from the testing edge of the
straightedge. For deck surfaces that are to be overlaid with 25 mm or more of another material, such
deviation shall not exceed 10 mm in 3 m. Deviations in excess of these requirements shall be
corrected before the concrete sets.
Allowances shall be made for crown, camber, and vertical curvature. Any straight-edging and
corrective work performed on the plastic concrete shall not relieve the Contractor of testing the
smoothness requirements on the hardened concrete, as outlined hereinafter.
21.10.1.3 Texturing
Surfaces shall be given a skid-resistant texture by either burlap or carpet dragging, brooming, tinning,
or by a combination of these methods. Such equipment required to produce the final surface texture
shall be secured to the finishing machine. Texturing operations shall be so executed that the surface
is uniform in appearance and free from rough and porous spots, irregularities, and depressions.
Page 21-40
Employed methods shall be as specified in the Contract documents, or as approved by the Engineer.
Surfaces that are to be covered with a waterproofing membrane deck seal shall not be coarse
textured, but rather finished to a smooth surface, free of mortar ridges and other projections.
This operation shall be done after floating and at such time, and in such manner, that the desired
texture will be achieved while minimizing displacement of the larger aggregate particles.
a. Dragged
If the surface texture is to be a drag finish, the surface shall be finished by dragging a seamless strip
of damp burlap over the full width of the surface. Sufficient layers of burlap made up of sufficient
lengths shall create the burlap drag that will connect with the concrete to slighting groove the surface.
It shall be moved forward with a minimum bow of the lead edge. Drags shall be kept damp, clean,
and free of particles of hardened concrete. As an alternative to burlap, the Engineer may approve or
direct that carpet or artificial turf of an approved type and size be substituted.
b. Broomed
If the Contract documents require the surface texture to consist of a broom finish, the surface shall
be broomed when the concrete has hardened sufficiently. Brooms shall be of an approved type and
strokes shall be square across the slab, from edge to edge, with adjacent strokes slightly overlapped.
Strokes shall be made by drawing the broom without tearing the concrete but producing regular
corrugations not more than 3 mm in depth. Surfaces, as thus finished, shall be free from porous
spots, irregularities, depressions, and small pockets or rough spots that may be caused by
accidentally disturbing particles of coarse aggregate embedded near the surface during the final
brooming operation.
c. Tined
If the surface is to be tined, the tinning shall be in a transverse direction using a wire broom, comb,
or finned-float having a single row of tines or fins. Tinning grooves shall be between 1.5 mm and 5
mm wide and between 3 mm and 5 mm deep, spaced 12 mm to 20 mm on centres. Tinning shall be
discontinued 300 mm from the curb line on bridge decks. Areas adjacent to the curbs shall be given
a light broom finish longitudinally. As an alternative, tinning may be achieved using an approved
machine designed specifically for tinning or grooving concrete pavements.
21.10.1.4 Surface Testing and Correction

After the concrete has hardened, the Engineer will inspect finished deck roadway surfaces that shall
not be overlain with a wearing surface. Any variations in the surface that exceed 3 mm from a 3 m
straightedge will be marked and corrected by the Contractor by the use of concrete planning or
grooving equipment that produces a textured surface equal in roughness to the surrounding
unground concrete without shattering or otherwise damaging the remaining concrete.
21.10.2 Pedestrian Walkway Surface Finish

After placement of the concrete for sidewalks and decks of pedestrian structures, it shall be
consolidated and the surface shall be struck off by means of a strike board and floated with wooden
or cork float. If directed, the surface shall then be lightly broomed in a transverse direction. An edging
tool shall be used on edges and expansion joints. Surfaces shall not vary more than 3 mm under a
1.5 m straightedge and shall have a granular or matte texture that shall not be slippery when wet.
Sidewalk surfaces shall be laid out in blocks with an approved grooving tool, as specified in the
Contract documents — or as directed by the Engineer.
21.10.3 Trowelled and Brushed Finish

Surfaces that are specified in the Contract documents to be trowelled shall first be finished as
specified under Section 21.10, Finishing Plastic Concrete. Then, after the concrete is partially set,
Page 21-41
the surface shall be finished to a smooth surface by trowelling with a steel trowel until a slick surface
that is free of bleed water is produced and then brushed with a fine brush using parallel strokes.
21.10.4 Surfaces under Bearings

When metallic masonry plates are placed directly on the concrete, or on filler material less than 3
mm thick, the surface shall first be finished with a float finish. After the concrete has set, the area
that will be in contact with the masonry plate shall be ground to provide full and even bearing. When
such plates are set on filler material between 3 mm and 12 mm thick, the concrete surface shall be
steel-trowel finished without brushing and the flatness of the finished surface shall not vary from a
straightedge laid on the surface in any direction within the limits of the masonry plate by more than
1.5 mm. Surfaces that fail to conform to the required flatness shall be ground until acceptable.
Surfaces under elastomeric bearings and under metallic masonry plates that are supported on
mortar or filler pads measuring 12 mm or greater in thickness shall be finished by wood floating to a
flat and even surface free of ridges.
21.11 Curing Concrete

All newly placed concrete shall be cured so as to prevent loss of water by use of one or more of the
methods specified herein. Except for high-performance concrete (HPC) used in cast-in-place
construction — where performance criteria in addition to concrete compressive strengths are
specified — curing shall commence immediately after the free water has left the surface and finishing
operations are completed. For HPC, water curing shall commence immediately after finishing
operations are complete. If the surface of the concrete begins to dry before the selected cure method
can be applied, the surface of the concrete shall be kept moist by a fog spray applied so as not to
damage the surface.
Curing by other than waterproof cover, steam, or radiant-heat methods with precast concrete shall
continue uninterrupted for seven days — except for when pozzolans in excess of 10 percent, by
weight, of the Portland cement are used in the mix. When such pozzolans are used, the curing period
shall be 10 days with an appropriate curing suitable for pozzolans such as the insulated curing, all
as per approved thermal control plan. For other than top slabs of structures serving as finished
pavements and HPC concrete, the above curing periods may be reduced and curing terminated
when test cubes cured under the same conditions as the structure indicate that concrete strengths
of at least 70% of that specified have been reached.
When deemed necessary by the Engineer during periods of hot weather, water shall be applied to
concrete surfaces being cured by the liquid membrane method or by the forms-in-place method, until
the Engineer determines that a cooling effect is no longer required. Such application of water shall
be at no cost to the Owner.
21.11.1 Curing Concrete Materials

21.11.1.1 Water
Water shall conform to the requirements of Section 4.3.8 of Chapter 4, Concrete Works, of these
21.11.1.2 Liquid Membranes

Liquid membrane-forming compounds for curing concrete shall conform to the requirements of
AASHTO M 148-05 (ASTM C309 - 11).
21.11.1.3 Waterproof Sheet Materials

Waterproof paper, polyethylene film, and white burlap polyethylene sheets shall conform to the
requirements of AASHTO M 171-05 (ASTM C171 - 07).
Page 21-42
21.11.2 Curing Concrete Methods

21.11.2.1 Forms-in-place Method
Formed surfaces of concrete may be cured by retaining the forms in place without loosening for the
required time.
21.11.2.2 Water Method

For this method, concrete surfaces shall be kept continuously wet by ponding, spraying, or covering
with materials that are kept continuously and thoroughly wet. Such materials may consist of cotton
mats, multiple layers of burlap, or other approved materials that do not discolour or otherwise
damage the concrete.
21.11.2.3 Liquid-membrane Curing Compound Method

This method shall not be used on surfaces where a rubbed finish is required or on surfaces of
construction joints, unless it is removed by sand blasting prior to placement of concrete against the
joint. Type 2, white pigmented, liquid membranes may be used only on the surfaces of bridge decks,
on surfaces that shall not be exposed to view in the completed work, or on surfaces where their use
has been approved by the Engineer.
When membrane curing is used, the exposed concrete shall be thoroughly sealed immediately after
the free water has left the surface. Formed surfaces shall be sealed immediately after the forms are
removed and necessary finishing has completed. These solutions shall be applied by power-
operated atomizing spray equipment in one or two separate applications. Hand-operated sprayers
may be used for coating small areas. Membrane solutions containing pigments shall be thoroughly
mixed prior to use and agitated during application. If the solution is applied in two increments, the
second application shall follow the first application within 30 minutes. To ensure a uniform coverage
at the rate of 0.27 litre/m2, the Contractor shall provide satisfactory equipment together with the
means to properly control and assure the direct application of the curing solution on the concrete
surface.
If rain falls on the newly coated concrete before the film has dried sufficiently to resist damage, or if
the film is damaged in any other manner during the curing period, a new coat of the solution shall be
applied to the affected portions equal in curing value to that specified above.
21.11.2.4 Waterproof Cover Method

This method shall cover the surface with a waterproof sheet material so as to prevent moisture loss
from the concrete. It may be used only when the covering can be secured adequately to prevent
moisture loss.
During installation, concrete shall be wet at the time the cover is installed; the sheets shall be of the
widest practicable width; adjacent sheets shall overlap a minimum of 150 mm and shall be tightly
sealed with pressure sensitive tape, mastic, glue, or other approved methods to form a complete
waterproof cover of the entire concrete surface. Waterproof sheets shall be secured so that wind
shall not displace it. Shall any portion of the sheets be broken or damaged before expiration of the
curing period, the broken or damaged portions shall be immediately repaired. Sections that have lost
their waterproof qualities shall not be used.
21.11.2.5 Steam or Radiant-heat Curing Method

This method may be used only for precast concrete members manufactured in established plants.
Steam curing or radiant-heat curing shall be done under a suitable enclosure to contain the live
steam or the heat. Steam shall be low-pressure and saturated. Temperature recording devices shall
be employed to verify that temperatures are uniform throughout the enclosure and within the limits
specified in the Contract documents. When HPC is used in prestressed concrete members — where
a concrete compressive strength greater than 41.4 MPa is specified — the Contractor shall place
Page 21-43
temperature-sensing devices within the concrete to verify that temperatures are uniform and within
the limits specified.
Initial applications of the steam, or of the heat, shall not occur prior to initial set of the concrete except
to maintain the temperature within the curing chamber above the specified minimum temperature.
Initial set times may be determined by the Standard Method of Test for Time of Setting of Concrete
Mixtures by Penetration Resistance, AASHTO T 197M/T 197-11 (ASTM C403 / C403M - 08).
During the waiting period, the temperature within the curing chamber shall not be less than 10
degrees Celsius and live steam, or radiant heat, may be used to maintain the curing chamber at the
proper minimum temperature. During this period, the concrete shall be kept wet.
Application of live steam shall not be directed on the concrete or on the forms so as to cause localized
high temperatures. During the initial application of live steam or of radiant heat, the temperature
within the concrete shall increase at an average rate not exceeding 22 degrees Celsius per hour
until the curing temperature is reached. Maximum curing temperatures within the concrete shall not
exceed 71 degrees Celsius and shall be held until the concrete has reached the desired strength. In
discontinuing the steam application, the concrete temperature shall not decrease at a rate to exceed
22 degrees Celsius per hour until a temperature of 11 degrees Celsius above the temperature of the
air to which the concrete will be exposed has been reached.
Radiant heat may be applied by means of pipes circulating steam, hot oil, or hot water — or by
electric heating elements. Radiant-heat curing shall be done under a suitable enclosure to contain
the heat, and moisture loss shall be minimized by covering all exposed concrete surfaces with plastic
sheeting or by applying an approved liquid-membrane curing compound to all exposed concrete
surfaces. Top surfaces of concrete members to be used in composite construction shall be clear of
residue of the membrane curing compound so as not to reduce bonds below design limits. Surfaces
of concrete members to which other materials will be bonded in the finished structure shall be clear
of residue of the membrane curing compound so as not to reduce bond below design limits.
For prestressed members, the transfer of the stressing force to the concrete shall be accomplished
immediately after the steam or heat curing has been discontinued.
21.11.2.6 Insulated Curing Method

The insulated curing method shall be in accordance of the requirements of Article 4.4.2.6 of Chapter
4, Concrete Works, of these standard specifications.
21.11.3 Bridge Decks

Top surfaces of bridge decks shall be cured by a combination of the liquid-membrane curing
compound method and the water method, and/or insulated curing method. Liquid membranes shall
be Type 2, as defined in AASHTO M 148-05 (ASTM C309 - 11), white pigmented, and shall be
applied from finishing bridges progressively and immediately after finishing operations are complete
on each portion of the deck. Water cures shall be applied not later than four hours after the
completion of deck finishing or for portions of the decks on which finishing is completed.
HPC, where performance criteria in addition to concrete compressive strengths are specified, tends
to have little bleed, especially when the low-water to cementitious materials ratio is used with mineral
admixtures. Additional performance criteria may include shrinkage, chloride permeability, de-icer
scaling resistance, abrasion resistance, or heat of hydration. As a result, the evaporation protection
of the bleed water on the fresh concrete is lost. Therefore, when HPC is used in cast-in-place
construction of bridge decks, water cure shall be applied immediately after the finishing of any portion
of the deck is complete and shall remain in place for a minimum period of seven days irrespective of
concrete strength. If conditions prevent immediate application of the water cure, an evaporation
retardant shall be applied immediately after completion of finishing or fogging shall be used to
maintain a high, relative humidity above the concrete to prevent drying of the concrete surface.
Following the water-cure period, liquid-membrane curing compound may be applied to extend the
curing period.
Page 21-44
21.12 Finishing Formed Concrete Surfaces

Surface finishes for formed concrete surfaces shall be classified as follows:
• Class 1: Ordinary surface finish
• Class 2: Rubbed finish
• Class 3: Tooled finish
• Class 4: Sandblast finish
• Class 5: Wire brush or scrubbed finish
All concrete shall be given a Class 1 finish and, in addition, if further finishing is required, such other
type of finish as is specified.
If not otherwise specified in the Contract documents, exposed surfaces of piers, barriers, parapets,
curbs, underside of copings, backwalls above bridge seats and such other surfaces where smooth,
uniform surfaces are specified except the soffits of superstructures and the interior faces and
bottoms of concrete girders shall be given a Class 2 finish.
Class 3, 4, or 5 finishes shall be applied only where specified in the Contract documents.
The surface finish on piers shall include all exposed surfaces below the bridge seat to 300 mm below
the finish ground line.
21.12.1 Class 1: Ordinary Surface Finish

Immediately following the removal of forms, the Contractor shall remove all fins and irregular
projections from all surfaces that are to be exposed or waterproofed. Bulges and offsets in such
surfaces shall be removed with carborundum stones or discs.
Localized, poorly bonded rock pockets or honeycombed concrete shall be removed and replaced
with sound concrete or packed mortar, as specified in Section 21.18, Mortar and Grout. If, in the
opinion of the Engineer, rock pockets are of such an extent or character as to affect the strength of
the structure materially or to endanger the life of the steel reinforcement, the Engineer may declare
the concrete defective and require the removal and replacement of the portions of the structure
affected.
On all surfaces, the cavities produced by form ties; other holes, broken corners, or edges; and other
defects shall be thoroughly cleaned and, after having been thoroughly saturated with water, shall be
carefully pointed and trued with a mortar conforming to Section 21.18. For exposed surfaces, white
cement shall be added to the mortar in an amount sufficient to result in a patch that, when dry,
matches the surrounding concrete. Mortar used in pointing shall be not more than one hour old; and
the concrete shall be rubbed, if required, or the cure continued as specified in Section 21.10,
Finishing Plastic Concrete. Construction and expansion joints in the completed work shall be left
carefully tooled and free of mortar and concrete. Joint fillers shall be left exposed for the full length
with clean and true edges.
Resulting surfaces shall be true and uniform. Appearances of repaired surfaces that are not
satisfactory shall be rubbed as specified in Section 21.12.2, Class 2: Rubbed Finish.
21.12.2 Class 2: Rubbed Finish

After the removal of forms, the rubbing of concrete shall begin as its condition will permit. Immediately
before starting this work, the concrete shall be thoroughly saturated with water. Sufficient time shall
have elapsed before the wetting down to allow the mortar used in the pointing of rod holes and
defects to thoroughly set. Surfaces to be finished shall be rubbed with a medium-coarse
carborundum stone, using a small amount of mortar, which shall be composed of cement and fine
sand, mixed in proportions used in the concrete being finished. Rubbing shall be continued until form
marks, projections, and irregularities have been removed; voids have been filled; and a uniform
surface has been obtained. Pastes produced by this rubbing shall be left in place.
Page 21-45
After the completion of additional work that could affect the surface, the final finish shall be obtained
by rubbing with a fine carborundum stone and water. This rubbing shall be continued until the entire
surface is of a smooth texture and uniform colour.
After the final rubbing is completed and the surface has dried, it shall be rubbed with burlap to remove
loose powder and shall be left free from all unsound patches, paste, powder, and objectionable
marks.
When metal, fibre, lined, or plywood forms in good condition are used, the requirement for a Class
2 finish may be waived by the Engineer when the uniformity of colour and texture obtained with Class
1 finishing are essentially equal to that which could be attained with the application of a Class 2
finishing. In such cases, grinding with powered disc grinders or light sandblasting with fine sand or
other means approved by the Engineer may be utilized in conjunction with Class 1 finishing.
21.12.3 Class 3: Tooled Finish

Finish of this character for panels and other like work may be secured by the use of a bush hammer,
pick, crandall, or other approved tool. Air tools, preferably, shall be employed. No tooling shall be
done until the concrete has set for at least 14 days and as much longer as may be necessary to
prevent the aggregate particles from being picked out of the surface.
21.12.4 Class 4: Sandblasted Finish

Thoroughly cured concrete surfaces shall be sandblasted with hard, sharp sand to produce an even,
fine-grained surface in which the mortar has been cut away, leaving the aggregate exposed.
21.12.5 Class 5: Wire-brushed or Scrubbed Finish

As soon as the forms are removed, and while the concrete is still comparatively green, the Contractor
shall thoroughly and evenly scrub the surface with stiff wire or fibre brushes, using a solution of
muriatic acid in the proportion of one-part acid to four parts water by volume until the cement film or
surface is completely removed and the aggregate particles are exposed. This process shall leave
an even, pebbled texture that presents an appearance grading from that of fine granite to course
conglomerate — depending upon the size and grading of the aggregate used. When the scrubbing
has progressed sufficiently to produce the texture desired, the entire surface shall be thoroughly
washed with water to which a small amount of ammonia has been added, to remove all traces of
acid.
21.12.6 Concrete Architectural Rustication

Concrete architectural rustication in piers, abutments, wingwalls and retaining walls shall be
constructed as indicated on the Contract plans, as specified herein, or as directed by the Engineer.
Concrete architectural rustication which shall include but not be limited to concrete form liners, rough
texture finish, or any finishes shown on the Contract plans, in piers, abutments, wingwalls and
retaining walls is a decorative treatment and as such is not designed to support any superimposed
loads during construction or upon completion of the Works.
21.12.6.1 Materials
All materials shall comply with the requirements of Section 4.3 of Chapter 4, Concrete Works, of
these Standard Specifications, and this chapter.
21.12.6.2 Formwork
Formwork for the pier, wingwall, and abutment rustication shall be constructed of fibreglass or
approved metal. The Contractor shall submit shop drawings of his proposed formwork to the
Engineer for approval in accordance with the requirements of the Contract documents. The form
release oil shall be nonstaining.
Page 21-46
21.12.6.3 Sample
Prior to the construction of the pier, wingwall, retaining walls, and abutment rustication, the
Contractor shall submit to the Engineer for approval a full-size sample of a section of each type of
rustication constructed of concrete. These samples shall be provided at the Contractor’s expense.
No loads shall be placed on the concrete architectural rustication in piers, abutments, wingwalls,
retaining Walls, at any time during or on completion of construction.
Very tight (water-sealed) shutters shall be used. A small mock-up with the approved mix shall be
demonstrated before production.
The Contractor shall submit his proposed construction method, complete with all details and written
description, to the Engineer for approval. The Contractor shall receive written approval of the
Engineer of his proposed construction method prior to the start of construction.
21.13 Precast Concrete Structural Members

Precast concrete structural members shall be constructed and placed in the work in conformance
with the details specified in the Contract documents, as specified herein, and as directed by the
Engineer.
If approved by the Engineer, the Contractor may use precasting methods for elements of the work
that are otherwise indicated to be constructed by the cast-in-place method. When such precasting
is proposed, the Contractor shall submit full design calculations and working drawings showing
construction joint details and any other information required by the Engineer.
21.13.1 Quality Assurance

21.13.1.1 Reference Codes and Standards
Codes and standards shall be as specified herein and the Contract documents.
1. ACI 301-10 “Specifications for Structural Concrete”;
2. ACI 318-08 “Building Code Requirements for Structural Concrete and Commentary;
3. Precast Concrete Institute MNL-116-99, “Manual for Quality Control for plants and production
of Structural Precast Concrete Products”;
4. Precast Concrete Institute PCI MNL-120-14, “PCI Design Handbook – Precast and
prestressed Concrete, 7th Edition”;
5. Precast Concrete Institute MNL 127-99, “Erectors’ Manual: Standards and Guidelines for the
Erection of Precast Concrete Products”;
6. American Welding Society (AWS) - D1.1/D1.1M:2010, Structural Welding Code – Steel; and
7. American Welding Society (AWS) - D1.4/D1.4M:2011, Structural Welding Code – Reinforcing
Steel.
21.13.1.2 Qualifications of Precast Prestressed Concrete

Subcontractor
The proposed organization for the performance of the prestressed concrete works under these
specifications shall be certified by the Precast/Prestressed Concrete Institute, Plant Certification
Program, prior to start of production of works.
21.13.1.3 Welder Qualifications

Welders shall be qualified in accordance with AWS D1.1/D1.1M:2010 for all weld operations on the
job.
Page 21-47
21.13.2 Precast Concrete Submittals

21.13.2.1 Working Drawings
Whenever specified in the Contract documents — or requested by the Engineer — the Contractor
shall provide working drawings for precast members. Such drawings shall include all details not
provided in the Contract documents for the construction and the erection of the members and shall
be approved before any members are cast. Such approval shall not relieve the Contractor of any
responsibility under the Contract documents for the successful completion of the work.
21.13.2.2 Shop Drawings

All shop drawings shall be submitted for review and approval in accordance with the requirements
specified in the Contract documents and these standard specifications. Prints of the final approved
shop drawings shall be furnished by the Contractor for the Engineer's use and as many other prints
shall be provided as may be needed by the Contractor to facilitate and expedite performance of the
Works.
All shop drawings shall show each member location, fabrication details, joint and openings details,
identification markings, reinforcement, connection details, dimensions, embedded items and
relationship to adjacent materials and construction in sufficient detail to facilitate manufacture,
handling, and erection. Identification markings shall include date of casting.
Reinforcement and connection designs shall be accompanied by supporting engineering data,
including all loading details, for review by the Engineer.
The shop drawing submittal shall include erection and handling procedure and sequence for all
precast members.
21.13.2.3 Samples
Samples shall be submitted in the quantity as directed by the Engineer for the following:
1. Embedded items
2. Anchorages
3. Joint materials
21.13.2.4 Full Size Sample

After the Engineer has approved the shop drawings, the precast concrete Fabricator shall produce
full-size typical members for inspection by the Engineer at the production site. If approved,
production of additional members may proceed and the approved samples may be used in the
Project after the production of other such members. If the full-size samples are rejected, required
corrections shall be performed or new full-size samples shall be produced until approval is obtained.
All criteria covered by this article on submittals and approval shall also apply to any subcontractor
conducting any of the respective precast prestressed concrete work.
21.13.3 Precast Concrete Materials and Manufacture

Unless otherwise specified in the Contract documents, all concrete for precast structural members
shall be Class C50/20 concrete, meeting the requirements of Section 4.3 of Chapter 4, Concrete
Works, of these Standard Specifications, and Section 21.3.4. Steel reinforcement shall comply with
Section 21.3.5. Grout in precast works shall comply with Section 21.18.3. The construction of precast
concrete fascia panels shall comply with the requirements of Section 21.16.
Precast concrete shall be as dense, and reach the compressive strengths, as specified herein.
Material gradations and proportions may be varied, subject to the samples submitted by the
Contractor to the Engineer for its approval. All requirements of other articles in this chapter referring
to materials and manufacturing processes for cast-in-situ and prestressed concrete shall apply to
precast concrete, except those requirements that are modified or supplemented by the provisions
Page 21-48
that follow. Additionally, the Contractor’s work shall satisfactorily ensure the Engineer that the
precast concrete units are not moved or loaded until they have attained the required strength.
When precast members are manufactured in established casting yards, the Manufacturer shall
oversee the continuous monitoring of the quality of all materials and concrete strengths. Tests shall
be performed in accordance with appropriate AASHTO or ASTM methods. All sampling and testing,
and the results of all tests, shall be made available to the Engineer, which shall be allowed to observe
sampling and testing procedures.
Established precast concrete manufacturing plants shall be certified under the Precast/ Prestressed
Concrete Institute (PCI) certification program — or an alternative equivalent program for the category
of work being manufactured.
Additionally, plant quality control (QC) personnel shall be certified in the PCI QC personnel
certification program, Level II. Plant QC managers shall be certified PCI, Level III. These
requirements may be met by alternative, equivalent experience and certification.
Precast members shall be cast on rigid beds or pallets. When casting the bearing surfaces, the
Contractor shall use special care to ensure that they will join properly with other elements of the
structure.
For prestressed precast units, several units may be cast in one continuous line and stressed at one
time. Sufficient space shall be left between unit ends to permit access cutting of the tendons after
the concrete has attained its required strength.
The consistency of the concrete will be measured by the Engineer by the slump test in accordance
with ASTM C143 / C143M - 10a or BS EN 12350-2:2009. The slump of all concrete shall be as
approved by mix design and as directed by the Engineer.
As soon as their removal shall not cause distortion of the concrete surface, the Contractor may
remove the side forms, providing that curing is not interrupted. Members shall not be lifted from
casting beds until their strength will sufficiently prevent damage.
When cast-in-place concrete will later be cast against the top surfaces of precast beams or girders,
these surfaces shall be finished to a coarse texture by brooming with a stiff, coarse broom. Prior to
shipment, such surfaces shall be cleaned of laitance or other foreign material by sandblasting, or
another approved method.
When precast members are designed to be abutted together in the finished work, each member shall
be match-cast with its adjacent segments to ensure proper fit during erection. As the segments are
match-cast, they shall be precisely aligned to achieve the final structure geometry. During the
alignment, the Contractor shall make adjustments to compensate for deflections.
21.13.3.1 Formwork for Precast Prestressed Members

Formwork for all precast, prestressed members shall comply with the requirements of Section 1.20
of Chapter 01, General Requirements, of these Standard Specifications, and as specified herein.
All forms shall be constructed and maintained mortar-tight, of sufficient strength to withstand
pressures to maintain true to the shapes and dimensions indicated on the Contract plans to provide
completed members of shapes, lines, and dimensions indicated within fabrication tolerances
specified herein. The casting bed shall have a concrete deck to which the bottom forms shall be
adequately anchored. Bottom forms shall be placed to provide for camber and to allow for automatic
cambering resulting from transfer of tendon prestress to the concrete, and shall be maintained in
true alignment and of sufficient stiffness to prevent excessive deflection under the load of wet
concrete. Self stressing moulds shall not be allowed.
Forms and all related supports shall be designed to anticipate shortening of members due to
concrete shrinkage and the transfer of pre-tensioning or post-tensioning force to the concrete. Forms
shall be constructed to compensate for this shortening so that the centre-to-centre bearing distance
of the completed beam under full dead load will be as indicated on the Contract plans.
Page 21-49
Side forms shall be of steel and shall be supported without resort to ties or spreaders within the body
of the member. They shall be braced and stiffened so that no undesirable deflection or curvature
takes place under concrete pressure. They shall be so designed that proper cleaning of the forms
between uses is facilitated.
The ends and sides of adjacent sections of forms which are butt joined shall match smoothly and
tightly and shall result in proper alignment. The side forms shall be cross-tied above the finished
surface of the member at sufficiently close spacing to maintain true cross-sectional dimensions.
All exposed outside edges shall be beveled or chamfered as indicated on the Contract plans.
Leakage of mortar will not be permitted. Joints between soffit, side forms, and bulkheads shall be
tight and, if necessary, shall be gasketed with rubber. Rubber may also be used to provide the corner
chamfers. Plugging of holes and slots in the forms shall be neatly done so that the finished members
will have a workmanlike appearance acceptable to the Engineer.
Before the concreting operations begin, the forms and casting bed shall be treated with a suitable
form lacquer or oil to prevent bonding of the concrete. The form lacquer or oil shall be of such quality
as to leave no stains or discoloration on the member faces. Extreme care shall be exercised to
prevent the coating of strands and reinforcement steel with such material and any strands or bars
so contaminated shall be satisfactorily cleaned or replaced.
Forms shall be free from paint or other protective substance that may cling to the surface of the
finished precast members. Forms not thoroughly cleaned after prior use shall not be used.
No form ties, spreaders, or forming facilities shall penetrate the body of the member, except those
necessary to provide the ultimate openings as indicated on the Contract plans. Before any forms are
removed, the concrete shall have attained sufficient strength to prevent injury due to such removal.
No forms shall be removed without the approval of the Engineer. Proper care and precautions shall
be exercised in removing forms so that no damage results to the finished surfaces.
In the event that during the casting of members it becomes apparent that forms have deteriorated to
the degree that finished precast members no longer can be constructed without approaching or
exceeding the dimensional tolerance limits, the Engineer may order production suspended with
respect to the use of the unsatisfactory forms and until they have been completely renovated or
replaced by the Contractor.
Built-in items and anchorages shall be accurately positioned and secured to form work. The
Contractor shall locate such items and anchorages where they do not affect the position of main
reinforcement or placing of concrete. Bearing plates shall not be relocated in units unless approved
by the Engineer.
All exposed corners of all precast concrete beams, columns, spandrels, and other members shall
have a 12 mm minimum, 45 degree chamfer unless otherwise indicated on the Contract plans. The
Contractor shall form all recesses, design bevels, and other requirements indicated on the Contract
plans.
21.13.3.2 Precast Prestressed Concrete Deck Panels

The fabrication, handling, storing, transporting and erecting of the precast prestressed concrete deck
panels shall be as indicated on the Contract plans, as specified herein and as directed by the
Engineer.
The Contractor shall provide and install the deck panels, complete, furnishing all materials, labor and
equipment and performing all required work as indicated on the Contract plans, as specified herein,
and as directed by the Engineer.
The precast prestressed concrete deck panel work shall include, but not by way of limitation, the
furnishing and installing of the deck panels, the steel shims, the preformed filler strips, the adhesive,
the grout and all appurtenances.
Page 21-50
a. Materials for Deck Panels

Concrete materials used in the fabrication of the precast deck panels shall comply with the
requirements of this chapter and the following requirements:
• Concrete shall consist of Class C50/20 concrete that shall meet the requirements of Section
4.3 of Chapter 4, Concrete Works, of these Standard Specifications — unless otherwise
indicated on the Contract drawings.
• Aggregates for the concrete shall be graded as shown in Table 21-8:
Table 21-8: Concrete aggregate size for deck panels
Percent Passing (%)
Sieve Size (mm)
100
12.5
95 – 100
9.5
30 – 60
4.75
0 – 15
2
0–5
1.18
• Steel shims shall be constructed of ASTM A36 / A36M - 08 Steel.
• Preformed filler strips shall be suitable, compressible material — as approved.
• Grout shall consist of an approved, flowable, non-shrink, non-metallic grout containing
sulphate-resistant cement. It shall have a minimum compressive strength of 20.6 MPa at an
age of 24 hours, when tested using applicable portions of ASTM C109 / C109M - 11b. Grout
temperature shall be ≤ 30o C.
• Grouts shall show no expansion after final set takes place, when tested in accordance with
ASTM C827 / C827M - 10. It shall have an initial setting time of not less than 45 minutes.
• Embedded, threaded inserts shall be manufactured from round or hexagonal, Type 304,
stainless-steel bar that complies with SAE AMS-QQ-S-763; or Type 304, stainless-steel
schedule-40 pipe.
a. Fabrication of Deck Panels

The fabrication of the deck panels shall comply with the applicable requirements as specified in
Section 21.13.3 and shall be as approved by the Engineer.
b. Tolerances for Deck Panels

The maximum dimensional tolerances for the deck panels are listed in Table 21-9. It is intended that
the dimensions of all deck panels shall be well within these tolerances and that the maximum values
shall be permitted to be approached or equalled only occasionally. Equipment and methods which
permit an undue proportion of dimensions approaching the tolerance limits shall not be used. Deck
panels having dimensions outside the tolerance limits will be rejected by the Engineer.
Table 21-9: Maximum dimensional tolerances for deck panels
Tolerance
Dimension
Panel depth (thickness) + 9.5 mm, -3.2 mm
± 25.4 mm
Panel length (parallel to strands)
Panel width + 3.2 mm, - 12.7 mm
Position of strands (vertical) ± 3.2 mm

± 12.7 mm
Position of strands (horizontal)
Page 21-51
21.13.4 Sampling and Testing of Precast Concrete Structural

Members
Sampling and testing shall be in general compliance with this chapter and the provisions of PCI MNL-
117-77. The Contractor shall employ the services of an independent testing laboratory approved by
the Owner to test the cement and aggregates, design the concrete mixes, and make all tests of
concrete, reinforcing steel, and prestressing steel and such other materials as directed by the
Engineer. The laboratory shall have at least five years’ experience in performing the specified tests.
21.13.5 Curing Precast Concrete

Unless otherwise permitted, precast members shall be cured by the water, waterproof cover, or the
steam or radiant-heat methods. Using insulated blankets shall be permitted with the waterproof cover
method. When the waterproof cover method is used, the air temperature beneath the cover shall not
be less than 10 degrees Celsius and live steam or radiant heat may be used to maintain the
temperature above the minimum value; the maximum concrete temperature during the curing cycle
shall not exceed 71 degrees Celsius; and, the waterproof cover shall remain in place until the
concrete’s compressive strength reaches the strength specified for de-tensioning or stripping.
The ends of prestressed concrete members shall be treated with a glass-reinforced plastic lining
(GRP) to protect the strand ends from corrosion. The Contractor shall submit a method statement
for the application of the liner for the Engineer’s approval.
21.13.6 Precast Concrete Storage and Handling

The handling of precast prestressed concrete members from the time of placing of concrete in the
forms until they are in place in the structure shall be in accordance with the standard specifications.
Failure to comply with these specifications may result in damage or destruction of the member by
the internal stresses. Any member damaged during handling, storing, transporting, or erecting shall
be replaced by the Contractor at his expense.
When handling and moving precast, prestressed concrete members, the Contractor shall exercise
extreme care. Girders shall be maintained and handled in an upright, or vertical, position at all times;
and, the directions of the reactions — with respect to the member — shall be as in the final position.
Support points during transportation and storage shall be located within 750 mm of their final
position; otherwise, their location shall be as shown on the shop drawings. During lifting, the
Contractor shall support the girders only by the inserts provided for that purpose.
Proposed methods for handling, lifting, and erecting precast concrete elements; and the details of
any inserts required to be cast into the girders for such purposes shall be included in the Contractor’s
working drawings — as required by Article 21.13.2.1.
During transportation, the ends of the girders shall not extend a distance of more than the depth of
the girder and in no case more than 1 m beyond the bolsters or other supports on the transporting
vehicle. Deck beam ends shall not extend a distance of more than 1.5 times their depth and in no
case more than 1 m beyond the supports. Precast girders shall be braced laterally to prevent buckling
during transportation and erection. This bracing shall be securely attached to the top flange of the
girders and shall be of sufficient stiffness to prevent lateral deflection of the top flange during handling
for transportation and erection.
During storage, the supports shall maintain the girders in a level position and without twisting.
Stacking girders while in storage will be permitted only with the approval of the Engineer. If such
permission is granted, the supports of all girders shall be in the same vertical planes and shall be of
adequate thickness to prevent damage to the lifting devices.
Prestressed concrete members shall not be shipped until tests on concrete cubes, manufactured of
the same concrete and cured under the same conditions as the girders, indicate that the concrete of
the particular member has attained a compressive strength equal to the specified 28-day
compressive strength — except when otherwise specified or approved by the Engineer.
Page 21-52
Precast units shall be so stored, hoisted, transported, and fixed that they shall not be overstressed
at any time or suffer any cracking or damage. Units damaged by improper storage or handling shall
be replaced at the Contractor's expense.
21.13.7 Precast Concrete Erection

During all stages of construction, the Contractor shall ensure the structural integrity of the precast
members. Lifting devices shall be used in a manner that does not cause damaging, bending, or
tensional forces. After a member has been erected, but until it is secured to the structure, the
Contractor shall provide temporary braces to resist wind or other loads and to ensure proper
alignment and safety. If accidental loading is imparted on the precast member, the Contractor shall
prepare an evaluation of the accidental loading effects, and shall share this evaluation with the
Engineer to ensure that the member has not been damaged. Elements shall be rejected by the
Engineer if the analysis is not conclusive.
When erecting girders, the Contractor shall take care to keep bridge seats and tops of bearing
devices free of foreign materials. Any shifting of girders shall be done while they are held free of the
foundation.
Placement of, or the use of, erecting equipment supported on the girders or the bridge deck shall
not be permitted by the Engineer.
Precast concrete members shall be erected level, plumb, square and true within the allowable
tolerances. They must be positioned so that cumulative dimensional error does not occur. Joints
shall be correctly aligned and uniform joint width shall be maintained as erection progresses. Each
member shall be securely fastened in place as indicated on the approved shop drawings.
Adjustments or changes in connections, which could involve additional stresses in the products or
connections, will not be permitted without approval by the Engineer.
Precast concrete members shall be lifted and supported during erection operations only at the lifting
or supporting points, or both, as shown on the approved shop drawings. After erection, exposed
locations shall be patched to match adjacent surfaces.
Unless otherwise specified in the Contract plans, installation tolerances of the erected members shall
not exceed following tolerance limits specified in PCI MNL 127-99, “Standards and Guidelines for
the Erection of Precast Concrete Products.”
• Variances from Plumb: 6 mm in 6.00 m run or story height; 12 mm total in 12.00 m or longer
run.
• Variations from level or elevation: 6 mm in 6.00 m run; 10 mm in 12.00 m run;  12.00 mm
maximum.
• Variation from position in plan: 12 mm maximum.
• Offsets in alignment or adjacent members at Joint: 6 mm in 3.0 m run; 10 mm maximum.
The Contractor shall be responsible for chipping, spalling, cracking or other damage to the members
until they are erected at the job site. After installation is completed, any further damage is the
responsibility of the Contractor.
No stresses, except for the allowed adjustment in connections indicated above, shall be introduced
into precast members or their connections in order to make connections fit.
The Contractor shall protect members from damage by field welding operations and provide
noncombustible shields as necessary during these operations.
Structural welds shall be made by certified welders in accordance with the erection drawings which
shall clearly specify type, extent, sequence and location of welds. A fire extinguisher of an approved
type and in operating condition shall be located within reach of welding operations at all times.
All work and materials of other trades shall be adequately protected by the erector at all times.
After precast concrete members have been set in place, the work shall be inspected by the Engineer.
Members found to be slightly damaged may be authorized for repair at this time. Repairs shall
conform to the Engineer's requirements and shall be structurally sound. Members that cannot be
Page 21-53
satisfactorily repaired, or that are off-colour in the opinion of the Engineer shall be replaced with new,
undamaged units at no additional cost to the Owner.
Exposed faces shall be cleaned as necessary to remove dirt and stains that may be on the members
after erection. The precast units shall be cleaned only after all installation procedures are completed.
The exposed surfaces shall be cleaned in accordance with the precast Manufacturer's
recommendations.
21.13.7.1 Precast Prestressed Concrete Girders

The Contractor shall verify building structures, anchors, devices, and openings are ready to receive
work of this section.
The Contractor shall check both line and grade in sufficient time before erection is scheduled to
permit any necessary corrections. Corrections, if any, shall be made by the Contractor before
erection begins. Proposed corrections should be submitted to the Engineer for approval.
The Contractor shall submit his proposed method of handling, lifting, erecting and details of any
inserts required to be cast into the members for such purpose shall be included in the shop drawings
required by Section 21.13.2.
Each member shall have proper identification as to number, position in the structure, and date of
casting painted on its top and on one end. Members shall not be shipped to the job site before the
28-day compressive strength data are available except as otherwise specified or approved by the
Engineer.

Precast deck form panels shall be erected and placed so that the fit of mating surfaces shall not
create excessive grout leakage. If such a fit is not provided, joints shall be dry-packed or sealed with
an acceptable caulking compound prior to placing the cast-in-place concrete. End panels for skewed
structures may be sawed to fit the skew.
Deck panels shall be fabricated and placed in such a manner that they will extend approximately
100 mm over the girders. They shall be installed by the Contractor in the following sequence:
• Shims shall be placed at 1.5 m on centres along girder flanges. Their thickness shall be
determined by the Contractor with survey equipment. These thicknesses shall vary within the
spans of the deck panels to accommodate the girder camber and the roadway profile while
maintaining the depth of the cast-in-place slab.
• Strips of preformed filler strips shall be placed along the edge of the girder flange and
preformed filler strips shall be glued to the tops of the girder flange using an approved
adhesive. Preformed joint filler heights shall be between 5 percent and 10 percent greater
than the height of the adjacent steel shims. Once installed, and after the deck panels have
been lowered into position, the preformed filler strips shall form a mortar-tight seal.
• Non-shrink grout shall be placed around and between the steel shims and along the
preformed filler strips in such a manner that there are no voids under the deck panels. Grout
may be placed by the Contractor before or after the deck panels are lowered into position.
If the grout is placed before the deck panels are lowered into position, then the height of the grout
shall be slightly greater than the heights of the nearby steel shims to ensure that the placement of
the deck panels will compact the mortar, thus forming a uniform bearing surface for the deck panels.
During this placement method, the Contractor shall ensure that no grout is forced between any steel
shims. Grout shall be mixed and placed in accordance with the grout Manufacturer’s written
instructions. Rotating drum-type concrete mixers shall not be allowed for mixing the grout.
• Deck panels shall be lowered into their final positions. If the Contractor chooses to apply the
grout after the deck panels have been lowered, grout shall be placed with a low-pressure
pumping system until all voids under the deck panels have been filled with grout. After the
deck panels have been installed and prior to placing the cast-in-place concrete slabs, the
Contractor shall remove all laitance or flakes by water blasting, which shall be performed by
Page 21-54
experienced personnel with equipment that provides a pressure adequate to ensure the
removal of all laitance and other deleterious materials. Prior to placing the cast-in-place
concrete slabs, the precast deck panels shall be moistened for a period of time approved by
the Engineer.
21.13.8 Precast Concrete Finish

Upon removal from the forms, the precast concrete units shall be examined and all surfaces that will
remain permanently visible shall have a smooth and dense finish or uniform texture that is free from
holes, fins, and shutter staining. Any precast concrete unit found to be defective in any respect will
be rejected.
Surfaces that will be exposed in the completed structure other than architectural precast elements,
will be given Class 1 "ordinary finish" consisting of the removal of fins, rough spots, stains, hardened
mortar or grout, and form lines by rubbing with a No. 16 carborundum stone or an abrasive of equal
quality without materially changing the texture of the surface. The rubbing shall be continued
sufficiently to remove all roughness and projections. When the surface of concrete that will be
exposed to view shows a film of oil left from an excess of oil on the forms, or the concrete is oil-
stained, or is otherwise not of uniform colour, the Engineer shall require the Contractor to employ a
satisfactory cleaning method.
Depressions resulting from holes left by attachments to rod or bolt anchorages shall be carefully and
neatly pointed with a non-shrinkage grout or mortar having equal or better strength than the concrete
used.
Air pockets or rough places larger than 13 mm diameter occurring in any surface shall be pointed as
specified in the foregoing paragraph. Honeycombed areas shall be chipped out by the Contractor
and inspected by the Engineer before being pointed. Pointed areas mentioned in this article shall
then be given an ordinary finish as herein specified.
21.13.8.1 Concrete Fascia Elements

All exposed surfaces of architectural precast fascia elements, shall have a finish equivalent to PCI
finish No. 280 Acid Etched Light (AE-L), as specified in PCI (Precast/Prestressed Concrete Institute)
“Architectural Precast Concrete - Color & Texture Selection Guide”, 2nd Edition.
21.13.8.2 Precast Prestressed Concrete Girders

The top surface of beams and girders shall be finished initially with a wooden hand float. Further
finishing shall be delayed until the water sheen appears, but not to the point of rendering further
manipulation ineffective. The surface then shall be finished in accordance with the Manufacturer’s
recommendations to receive the coating system and protection as approved by the Engineer.

The top surface of each deck panel shall be given a rough finish. At approximately the time of initial
set, all laitance shall be removed with a coarse wire brush or with metal tines not less than 3 mm
deep to ensure proper bond with the concrete that will be placed onto the deck panels after the deck
panels have been installed.
21.13.9 Precast Products

All precast units shall be manufactured of diverse sizes by the Contractor with materials as specified
in this chapter. These units shall be transported to the worksite by the Contractor’s own means of
transportation. These materials shall be examined by the Contractor before shipping to ensure that
they are of good quality and comply with these Standard Specifications. Any damage sustained by
this material in the course of transportation, or on the worksite, shall be the responsibility of the
Contractor, including its prices for all costs of labour, haulage, transportation, on-site offloading,
waste, and everything necessary for this work.
Page 21-55
21.13.10 Epoxy-bonding Agents for Precast Segmental Box Girders

21.13.10.1 Epoxy-bonding Agent Materials
Epoxy-bonding agents for match-cast joints shall consist of thermosetting, 100 percent solid
compositions that do not contain solvent or any nonreactive organic ingredient — except for the
pigments required for colouring. Epoxy-bonding agents shall consist of the following two
components: a resin and a hardener. Each component shall be distinctly pigmented, so that mixing
produces a third colour similar to the concrete in the segments to be joined, and shall be packaged
in proportioned, labelled, ready-to-use containers.
Epoxy-bonding agents shall be formulated to provide application temperature ranges that will permit
erection of match-cast segments at substrate temperatures from 4 degree Celsius to 46 degree
Celsius. If two surfaces to be bonded have different substrate temperatures, the adhesive applicable
at the lower temperature shall be used.
Epoxy-bonding agents shall be insensitive to damp conditions during application and, after curing,
shall exhibit high-bonding strength to cured concrete, good water resistivity, low creep
characteristics, and tensile strength greater than the concrete. Additionally, the epoxy-bonding
agents shall function as a lubricant during the joining of the match-cast segments; as a filler to
accurately match the surface of the segments being joined; and as a durable, watertight bond at the
joint.
To determine their workability, gel and open time, bond and compression strength, shear, and
working temperature range, the Contractor shall test the epoxy-bonding agents at frequencies stated
Material samples shall be furnished by the Contractor to the Engineer for quality assurance (QA)
testing with a certification from a reputable independent laboratory that indicates that the material
has passed the required tests.
Specific properties of epoxy and the test procedures to be used to measure these properties shall
be as described in the following sections.
a. Test 1: Sag Flow of Mixed Epoxy-bonding Agent

The sag flow test for mixed epoxy-bonding agent is not directly measured. Table 1 of AASHTO M
235M/M 235 specifies the properties for the various types, grades, and classes of bonding agents.
Table 21-10 presents the testing method and related specification.
Table 21-10: Sag flow test for mixed epoxy-bonding agent
Testing No testing is required.

Method:
Specification: Mixed epoxy-bonding agents must be an AASHTO M 235M/M 235 Type VI, Grade
3 (non-sagging) consistency at the designated application temperature class for
the bonding agents used.
b. Test 2: Gel Time of Mixed Epoxy-bonding Agent

Test 2 shall determine gel time on samples mixed and as specified in the testing method. It provides
a guide for the period of time the mixed bonding agent remains workable in the mixing container
during its application to the match-cast joint surfaces. Table 21-11 presents the testing method and
related specification.
Table 21-11: Gel time test for epoxy-bonding agent
Testing ASTM D2471-99*, and 1-litre and 4-litre quantities shall be tested.
Method:
Page 21-56
Specification: A 30-minute minimum testing shall occur on 1-litre and 4-litre quantities at the
maximum temperature of the designated application temperature range for gel
time. Note: Gel time is not to be confused with the open time specified in Test 3.
*It is the responsibility of the Contractor to establish appropriate safety and health practices and
determine the applicability of regulatory limitations prior to use this standard.
c. Test 3: Open Time of Bonding Agent

Open time of bonding agent test measures workability of the epoxy-bonding agent for the erection
and post-tensioning operations. As tested here, open time is defined as the minimum allowable
period of elapsed time from the application of the mixed epoxy-bonding agent to the precast
segments until the two segments have been assembled together and temporarily post-tensioned.
Table 21-12 presents the testing method and related specification.
Table 21-12: Open time test for epoxy-bonding agent
Testing Open time is determined using test specimens, as detailed in Test 4, Three-Points
Method: Tensile Bending Test. Epoxy-bonding agent, at the highest specified application
temperature, is mixed together and applied as instructed in Test 4 to the concrete
prisms, which shall also be at the highest specified application temperature.
Adhesive-coated prisms shall be maintained for 60 minutes at the highest specified
application temperature with the adhesive-coated surface or surfaces exposed and
uncovered before joining together. Assembled prisms shall then be cured and tested,
as instructed in Test 4.
The epoxy-bonding agent shall be deemed acceptable for the specified application
temperature only when essentially total fracturing of concrete paste and aggregate
occurs with no evidence of adhesive failure.
Construction situations may sometimes require application of the epoxy-bonding
agent to the precast section prior to erecting, positioning, and assembling. This
operation may require epoxy-bonding agents having prolonged open time. In general,
where the erection conditions are such that the sections to be bonded are
prepositioned prior to epoxy application, the epoxy-bonding agent shall have a
minimum open time of 60 minutes within the temperature range specified for its
application.
d. Test 4: Three-point Tensile Bending Test

The three-point tensile bending test performed on a pair of concrete prisms bonded together with
epoxy bonding agent, determines the bonding strength between the bonding agent and concrete.
Bonded concrete prisms are compared to a reference test beam of concrete that measures 150 mm
by 150 mm by 450 mm. Table 21-13 presents the testing method and related specification.
Table 21-13: Three-point tensile bending test for epoxy-bonding agent
Testing ASTM C192 / C192M - 07 150×150×225 mm concrete prisms of 41.4 MPa

Method: compressive strength at 28 days shall be sandblasted on one 150 mm by 150
mm side to remove mould release agents and laitance; and shall be submerged
in clean water at the lower temperature of the specified application temperature
range for 72 hours. Immediately on removing the concrete prisms from the
water, the sandblasted surfaces shall be air-dried for one hour at the same
temperature and 50 percent relative humidity and each shall be coated with
approximately a 1.5 mm layer of the mixed bonding agent. The adhesive-
coated faces of two prisms shall then be placed together and held with a
clamping force normal to the bonded interface of 0.35 MPa. Assemblies shall
Page 21-57
then be wrapped in a damp cloth that is kept wet during the curing period of 24
hours at the lower temperature of the specified application temperature range.
After the 24-hour curing period at the lower temperature of the application
temperature range specified for the epoxy-bonding agent, the bonded
specimens shall be unwrapped, removed from the clamping assembly, and
immediately tested. Tests shall be conducted using the standard AASHTO T
97-10 (ASTM C78 / C78M - 10) and the Contractor shall test for flexural
strength with third-point loading and the standard MR unit. At the same time,
the two prisms shall be prepared and cured and a companion test beam shall
be prepared of the same concrete, cured for the same period, and tested
following AASHTO T 97-10 (ASTM C78 / C78M - 10).
Specification: Use of epoxy-bonding agent shall be acceptable if the load on the prisms at
failure is greater than 90 percent of the load on the reference test beam at
failure.
e. Test 5: Compression Strength of Cured Epoxy-bonding Agent

Compression strength tests of the cured epoxy-bonding agent measures the compressive strength
of the epoxy-bonding agent. Table 21-14 presents the testing method and related specification.
Table 21-14: Compression strength test for cured epoxy-bonding agent
Testing ASTM D695 - 10

Method:
Specification: Compressive strength at 25 degrees Celsius shall be a minimum of 14.0 MPa

after 24 hours of curing at the minimum temperature of the designated application
temperature range and 41.5 MPa at 48 hours.
f. Test 6: Temperature Deflection of Epoxy-bonding Agent

Temperature deflection tests of epoxy-bonding agents determine the temperature at which an
arbitrary deflection occurs under arbitrary testing conditions in the cured epoxy-bonding agent. It is
a screening test to establish performance of the bonding agent throughout the erection temperature
range. Table 21-15 presents the testing method and related specification.
Table 21-15: Temperature deflection test for epoxy-bonding agent
Testing ASTM D648 - 07

Method:
Specification: A minimum deflection temperature of 50 degrees Celsius at fibre-stress loading

of 1.8 MPa is required on test specimens cured seven days at 25 degrees
Celsius.
g. Test 7: Compression and Shear Strength of Cured Epoxy-bonding Agent

Compression and shear strength test of the cured epoxy-bonding agent is a measure of the
compressive and shear strengths of the epoxy-bonding agent compared to the concrete to which it
bonds. Slant cylinder specimens with the epoxy-bonding agent are compared to a reference test
cylinder of concrete only. Table 21-16 presents the testing method and related specification.
Table 21-16: Compression and shear strength test for cured epoxy-bonding agent
Testing A test specimen of concrete is prepared in a standard 150-mm by 300-mm

Method: cylinder mould to have a height at midpoint of 150 mm and an upper surface with
a 30-degree slope from the vertical. Upper and lower portions of the specimen
Page 21-58
with the slant surfaces may be formed through the use of an elliptical insert or by
sawing a full-sized 150-mm by 300-mm cylinder. If desired, 75-mm by 50-mm or
100-mm by 200-mm specimens may be used. After the specimens have been
moist cured for 14 days, the slant surfaces shall be prepared by light sandblasting,
stoning, or acid etching; then by washing and drying the surfaces; and finally by
coating one of the surfaces with a 0.25-mm thickness of the epoxy-bonding agent
under test. Specimens shall then be pressed together and held in position for 24
hours. Assemblies shall then be wrapped in a damp cloth that shall be kept wet
during an additional curing period of 24 hours at the minimum temperature of the
designated application temperature range. Specimens shall then be tested at 25
degrees Celsius, following AASHTO T 22-10 (2011) (ASTM C39 / C39M - 12) or
BS EN 12390-3:2009 procedures. At the same time as the slant cylinder
specimens are made and cured, a companion standard test cylinder of the same
concrete shall be made, cured for the same period, and tested following AASHTO
T 22-10 (2011) (ASTM C39 / C39M - 12) or BS EN 12390-3:2009.
Specification: Use of epoxy-bonding agent is acceptable for the designated application

temperature range if the load on the slant cylinder specimen is greater than 90
percent of the load on the companion cylinder.
21.13.10.2 Mixing and Installation of Epoxy

As general instructions contained herein cannot cover all situations, specific recommendations and
instructions shall be obtained in each case from the Engineer in charge.
Instructions furnished by the Supplier for the safe storage, mixing, and handling of the epoxy-bonding
agent shall be followed. Epoxies shall be thoroughly mixed until they are of uniform colour. Use of a
proper-sized mechanical mixer operating at no more than 600 revolutions per minute, or as
recommended by the Manufacturer, shall be required. Contents of damaged or previously opened
containers shall not be used.
Surfaces to which the epoxy material is to be applied shall be at least 4 degrees Celsius and shall
be free from oil, laitance, form release agents, or any other material that prevents the epoxy from
bonding to the concrete surface. All laitance and other contaminants shall be removed by light
sandblasting or by high-pressure water blasting with a minimum pressure of 34 MPa. Wet surfaces
shall be dried before applying epoxy-bonding agents and surfaces shall be at least the equivalent of
saturated surface dry, with no visible water.
Mixing shall not start until the segment is prepared for installation. Application of the mixed epoxy-
bonding agent shall be according to the Manufacturer's instructions using trowel, rubber glove, or
brush on one or both surfaces to be joined. These coatings shall be smooth and uniform in thickness
and shall cover the entire surface with a minimum thickness of 1.5 mm applied on both surfaces. A
discernible bead line shall be observed on all exposed contact areas after temporary post-tensioning.
Erection operations shall be coordinated and conducted so as to complete the operations of applying
the epoxy-bonding agent to the segments, erection, assembling, and temporary post-tensioning of
the newly joined segment within 70 percent of the open time period of the bonding agent as
determined in Test 3.
Epoxy material shall be applied to all surfaces to be joined within the first half of the gel time, as
shown on the containers. Segments shall be joined within 45 minutes after application of the first
epoxy material placed and a minimum average temporary prestress of 0.3 MPa over the cross
section shall be applied within 70 percent of the open time of the epoxy material. At no point of the
cross section shall the temporary prestress be less than 0.2 MPa.
Joints shall be checked immediately after erection to verify uniform joint width and proper fit. Excess
epoxy from the joint shall be removed, where accessible. All tendon ducts shall be swabbed
immediately after stressing, while the epoxy is still in the non-gelled condition, to remove or smooth
out any epoxy in the conduit and to seal any pockets or air bubble holes that have formed at the
joint.
Page 21-59
If the jointing is not completed within 70 percent of the open time, the operation shall be terminated
and the epoxy-bonding agent shall be completely removed from the surfaces. Surfaces must be
prepared again and fresh epoxy shall be applied to the surface before resuming jointing operations.
21.14 Pre-tensioned Concrete Works

Pre-tensioned concrete members shall be constructed and placed in the work in conformance with
the details specified in the Contract documents, as specified in Section 21.13, as specified herein,
and as directed by the Engineer. Concrete and steel materials shall comply with the requirements
of Section 21.3.4 and Section 21.3.5.
21.14.1 Placing of Reinforcement Steel and Inserts

The reinforcement steel bars shall be accurately cut and formed to the dimensions and shapes as
indicated on the approved shop drawings and bar lists. All bars shall be accurately located and
securely anchored. The Contractor shall provide approved bolsters, chairs, supports, and wire, as
required or directed by the Engineer. The bars shall be free of all loose mill scale, rust, mud, and
other materials that reduce or destroy bonds with concrete. Embed reinforcing steel, anchors,
inserts, plates, angels, and other cast-in items as indicated on approved shop drawings.
Inserts in the concrete shall be accurately installed and secured in place. Where there is interference
with pre-tensioning strands, inserts shall be relocated or modified as directed by the Engineer. In no
case may imbedded inserts be attached to the prestressing strands and care shall be taken so as
not to move the strands out of their designed positions.
21.14.2 Mixing and Placing Concrete

The concrete shall be as specified in Section 21.3.4 and Section 21.13.3. The Contractor shall inform
the Engineer of the tentative amounts of admixtures he proposes to use, and it being understood
that the amounts of these will be adjusted during the progress of the work. The Contractor shall state
the name, source, brand, or type, or otherwise identify each of the materials as per ASTM C494 /
C494M - 12.
The Contractor shall furnish, and have available for the use of the Engineer, approved equipment
for slump and air-content determinations, and sufficient molds for making the specified number of
test specimens. The cube moulds shall be steel and shall comply with the requirements of ASTM
C31 / C31M - 12. Moulds made of cardboard or other expendable material shall not be used.
Tests of the concrete mixture for air content and slump shall be performed on each batch after
delivery to the casting site and before the concrete is incorporated into the girders. The slump of the
concrete shall be no greater than is necessary for proper placement and compaction and within the
limits specified herein.
A minimum of six test specimens shall be made from the concrete mixture entering into each
member. The test specimens shall be cast from samples taken from batches designated by the
Engineer, after delivery to the casting site and as the concrete mixture is being discharged for
incorporation into the member. The test specimens shall be compacted by standard rodding, or they
may be compacted by internal vibration, provided the Contractor furnishes suitable vibratory
equipment designed for that purpose and approved by the Engineer.
The test specimens shall be placed with and cured in the same manner as the member. The position
of the test specimens during curing shall be such that no undue advantage is given to them, as
compared to any part of the precast members, with respect to environment favorable to gain in
strength. The test specimens shall remain with the member until removed for testing or until the
prestress forces are transferred to the concrete in the member. Thereafter, the test specimens
reserved for the 28-day tests may be cured under standard moist room conditions, or they may be
cured in sand, continuously kept moist, or immersed in water, and the curing temperature shall be
maintained within the range of 18o to 30°C. If immersed in water, a saturated lime solution shall be
used. The Engineer will perform all testing in the testing laboratory. All quality decisions with respect
to the concrete shall be based on the average strength of at least two specimens.
Page 21-60
21.14.3 Placing and Compacting

The forms, pre-tensioning steel, reinforcement steel, and accessories shall be inspected and
approved by the Engineer immediately prior to the Contractor placing the concrete. No concrete shall
be placed until such inspection has been made. Approval by the Engineer shall not relieve the
Contractor of responsibility as to the results obtained. Concrete shall be placed in horizontal lifts and
consolidated by internal vibration. Internal vibrators shall have a vibrating head not more than 32
mm in diameter unless otherwise approved by the Engineer. At locations of relative massive concrete
and away from the prestressing strands, where, with the exercise of ordinary care, the reinforcing
steel will not be displaced, the Engineer may approve the use of larger vibrators. External vibration
may be used in conjunction with the internal vibration, if approved by the Engineer. Vibration shall
be performed with care to avoid the displacement of reinforcement, prestressing steel, and
accessories, and to ensure satisfactory compaction.
The concreting operations shall proceed at a rate sufficient to ensure that no seams or cold joints
will exist. Vibration of each lift shall be sufficient to eliminate honeycomb and excess water and air
pockets, and the vibrators shall be inserted completely through the lift and barely into the preceding
lift to ensure proper unification at the junctures of all lifts. The vibrator shall be inserted and removed
slowly but shall not be permitted to remain stationary in the concrete. It shall not be forced between
strands.
21.14.4 Inspection of Completed Prestressed Members

The completed prestressed members shall be inspected while they are still on the casting bed to
determine their acceptability under the standard specification requirements. They shall be inspected
again just prior to and after placement in the structure for possible damage during handling, storing,
transporting, and erecting.
Before the members are removed from the casting bed, all defects visible on the surface shall be
observed, dimensions shall be measured and checked against the shop drawings, and all other
conditions that may have a bearing upon the acceptability of the members shall be noted.
It is the intent of these standard specifications that the members will be cast without cracks or other
defects and true to the dimensions indicated on the approved shop drawings. It is recognized that
certain cracks and surface defects may not be detrimental from the standpoint of structural integrity
and may be relatively harmless if remedied by proper repair as approved by the Engineer. Further
deviations in dimensions from those indicated on the approved shop drawings and within certain
limits as specified herein shall be subject to approval by the Engineer.
The Engineer will determine the kind, type, and extent of cracks and surface defects, such as
honeycomb and chipped edges or corners, that will be tolerated. All such cracks and surface defects
shall be repaired as directed by the Engineer.
21.14.4.1 Tolerances
Members shall be produced well within the specified acceptable range. The production process shall
be corrected when members approach or equal a specified limit. If any members are out of tolerance,
the Contractor shall notify the Engineer immediately. Applicable dimensional tolerances shall be
checked before casting and after removal from the forms. Time-dependent tolerances, such as
length, camber, and sweep, shall be rechecked within three days before shipment. Camber and
sweep shall be checked at a time when thermal effects of sunlight are negligible such as on a cloudy
day or early morning. Sweep is defined as the horizontal deviation from a straight line parallel to the
centreline of the member. Camber is defined as upward deflection of the member caused by
prestress. The Contractor shall check local smoothness with a 1.5 m straightedge.
Tolerance for precast prestressed members shall be as described in PCI MNL-120-14 “Precast
Concrete Institute (PCI) Design Handbook 7th Edition (Precast and prestressed Concrete)”, except
as listed in Table 21-17. It is intended that the dimensions of all members shall be well within these
tolerances and that the maximum values shall be permitted to be approached or equaled only
occasionally. Equipment and methods which permit an undue proportion of dimensions approaching
Page 21-61
the tolerance limits shall not be used. Members having dimensions outside the tolerance limits will
be rejected.
Table 21-17: Maximum allowable dimensional tolerances for precast prestressed concrete
members (General)
Dimension Tolerance
Depth (flanges, web, and fillets)  mm
Depth (overall)  mm
Width (flanges and fillets)  mm
Width (web)  mm
Length  mm
Square Ends (deviation from square)  mm
Skew Ends (deviation from tangent offset)  mm
Side Insert (spacing between centres of inserts and from the centres
 mm
of inserts to the ends of the beams)
Bearing Plates (spacing between the centres of bearing plates)  mm
Bearing Plate (spacing from the centres of bearing plates to the

 mm
ends of the beams)
Bearing Plate or Bearing Area (variation from a true horizontal plane

 mm
or from a plane surface when tested with a straightedge)
Stirrup Bars (extension above top of the beam) + 6 mm, -9 mm
Stirrup Bars (longitudinal spacing, provided that there are not less
 mm
than the required number in a given length)
not more than 50 mm from

End Stirrup Bars
the end of the beam
Horizontal Alignment (deviation from a straight line parallel to the  mm perm
centreline of the beam) Max. ± 19 mm
Position of blockouts  mm of centreline
Position of strands  mm
Position of deflection points for deflected strands  mm
Position of plates and inserts  mm
Position of handling devices  mm
Page 21-62
The prestress losses due to creep and shrinkage of concrete, relaxation of prestressing steel and
elastic shortening shall be estimated with reference to Chapter 5 of AASHTO LRFD Bridge Design
Specifications and Road Structures Design Manual (ADQCC TR-516).
The Contractor shall comply with the maximum dimensional tolerances in Table 21-18 for AASHTO
girders and bulb-tees, Table 21-19 for double-tees, Table 21-20 for prestressed piling, and
Table 21-21 for prestressed deck panels.
Table 21-18: Maximum dimensional tolerances for AASHTO girders and bulb-tees
Dimension Tolerance
Length (±0.8 mm/m, ±25 mm maximum)
Width (overall) (+10 mm, -6 mm)
Width(web) (+10 mm, -6 mm)
Depth (overall) (+13 mm, -6 mm)
Depth (flanges) (±6 mm)
Sweep (1 mm/m)
Variation from end squareness or skew (±16 mm/m, ±25 mm maximum)
Camber variation from design camber1 (±1 mm/m)
For spans of 24 m or less (±13 mm maximum)
For spans more than 24 m (±25 mm maximum)
Differential camber between adjacent members (1 mm/m)
Position of Strands:
Individual (±6 mm)
Bundled (±13 mm)
Draped strand hold-down point (±0.5 m)
Position of plates:
Bearing plates (±16 mm)
Other plates (±25 mm)
Tipping and flushness of plates:

Bearing plates (±0.5 percent, ±3 mm maximum)
Position of Inserts including diaphragm holes (±13 mm)
Position of handling devices:

Parallel to length (±150 mm)
Transverse to length (±25 mm)
Page 21-63
Dimension Tolerance
Position of stirrups:
Longitudinal spacing (±50 mm)
Projection above top (±19 mm)
Local smoothness of any formed surface (±3 mm/1,500 mm)
Note 1: To be used when a design camber is specified.

Table 21-19: Maximum dimensional tolerances for double-tees
Dimension Tolerance
Length (±0.8 mm/m, ±25 mm maximum)
Width (overall) (±6 mm)
Width (webs) (±3 mm)
Depth (overall) (±6 mm)
Thickness (flanges) (±6 mm, -3 mm)
Flange Overhang (flange edge to web edge) (±6 mm)
Distance between Webs (±6 mm)
Sweep (1 mm/m)
Variation from end squareness or skew (±10 mm/m, ±25 mm maximum)
Camber variation from design camber1 (±1 mm/m, ±19 mm maximum)
Differential camber between adjacent members (1 mm/m, 19 mm maximum)
Position of Strands:
Individual (±6 mm)
Bundled (±13 mm)
Draped strand hold-down point (±300 mm)
Position of plates:
Bearing plates
(±13 mm)
Other plates
(±25 mm)
Tipping and flushness of plates:

Bearing plates (±0.5 percent, ±3 mm maximum)
Position of inserts including diaphragm holes (±13 mm)
Page 21-64
Dimension Tolerance

Position of stirrups:
Longitudinal spacing (±50 mm)
Projection above top (±19 mm)
Note 1: To be used when a design camber is specified.

Table 21-20: Maximum dimensional tolerances for prestressed concrete piling
Dimension Tolerance
Length (±25 mm)
Width or diameter (±10 mm)
Variation from longitudinal axis (bow) (1 mm/m)
Variation from end squareness or skew (±6 mm/300 mm, ±13 mm maximum)
Position of individual strands (±6 mm)
Position of handling devices (±150 mm)
Longitudinal spacing of spiral reinforcement (±19 mm)
Table 21-21: Maximum dimensional tolerances for prestressed concrete stay-in-place forms
Dimension Tolerance
Length (in direction of panel strands) (+18 mm, -6 mm)
Width (+6 mm, -12 mm)
Thickness (+6 mm, -3 mm)
Variation from end squareness or skew (±6 mm)
Camber, sweep, and warping1 (±2 mm per meter of length)
Position of individual strands:

Vertically (+0 mm, -6 mm)
Horizontally (±12 mm)
Page 21-65
Dimension Tolerance

Note 1: When measuring panel camber, account for dead-load deflection. Stay-in-place (SIP) form
deck panels are designed to have no camber, only dead-load deflection.
The Contractor shall remedy out-of-tolerance members in one of the following ways:
• Replacing the member at no additional cost to the Owner.
• Correcting the member tolerance problem, if possible, using an approved correction
procedure at no additional cost to the Owner.
• If correction is not possible but the member is considered usable, the Contractor shall submit
the member for review and acceptance at a reduced price acceptable to the Owner. A
description of the problem and any proposed corrective action shall be included. Structural
and physical evaluation by a Professional Engineer shall be provided, as required. If the
submittal is rejected, the member shall be replaced at no additional cost to the Owner.
21.14.5 Rejection of Prestressed Members

Any prestressed member displaying one of the following defects shall be rejected and a new member
shall be cast at the Contractor's own expense.
1. Strength requirement: Any member represented by cubes not meeting the specified strength.
2. Exposed prestressing steel: No prestressing strands shall be exposed.
3. Honeycombing: Honeycombing of the member to such an extent that chipping away of the
honeycombed concrete results in the condition described above, "Exposed prestressing
steel."
All honeycombed areas in a member shall be chipped until sound concrete is detected.
Sound concrete is defined as that point at which chipping causes fracture of the aggregates.
4. Stress cracks: Any member that has a stress crack in the area beginning 100 mm from the
unit end to the centre line of the unit that is greater than 13 mm in depth and five hundredths
(0.05) of a mm in width.
21.15 Post-tensioned Concrete Works

Post-tensioned concrete work shall be as indicated on the Contract plans, as specified herein,
Chapter 22, Prestressing Systems, and/or in the Contract documents. This work includes, but not by
way of limitation, supplying and fixing formwork, falsework and temporary works; supplying and
placing prestressing steel, ducts and anchors; supplying concrete of the class as indicated on the
Contract plans or specified herein and transporting and placing it in prepared forms; tamping,
vibrating, finishing and curing the concrete; pointing and jointing with cement mortar; post-tensioning
prestressing steel; pressure grouting ducts; and supplying and installing all joint materials, other than
fixed and neoprene expansion joints; all in accordance with the specifications and Contract
documents.
21.15.1 Standards and Codes

Standards and codes shall be as specified in Article 21.13.1.1, in the Contract documents, if any,
and the following in their latest edition:
• ASTM A421 / A421M – 10 Standard Specification for Uncoated Stress-Relieved
Steel Wire for Prestressed Concrete
• FS MMM-G-650A Federal Specifications - Epoxy Bonding Agent
Page 21-66
• FS SS-A-701 Federal Specifications - Bituminous Protective Coating

• CRD-C-566-64 Grout Fluidifier
21.15.2 Submittals
Shop drawings shall be submitted to the Engineer for approval in accordance with Section 21.13.2
and as specified herein.
Supplementing the requirements for shop drawings specified in Section 21.13.2, the Contractor shall
include a description of the equipment to be used and the proposed procedure for constructing post-
tensioned concrete work. The type and size of ducts and method of holding the ducts in position,
tendon sizes, jack clearances and procedures, stressing sequences, grout connections and vents,
anchorage details and bonding and grouting procedures shall also be indicated.
In addition the Contractor shall submit to the Engineer for approval calculations of the immediate
deflections and long term deflections for the different construction stages furnished with the required
cambers. A tabulation of these deflections and cambers shall be included on the shop drawings.
21.15.2.2 Certificates
Certificates from the Manufacturers shall be furnished to the Engineer certifying that the materials
and equipment to be provided comply with the requirements of these Standard Specifications.
21.15.2.3 Test Reports

The Contractor shall furnish to the Engineer six (6) copies of test reports and certificates as specified
herein, unless otherwise directed by the Engineer.
21.15.3 Scheduling of Post-tensioned Concrete Works

The scheduling of all post-tensioned concrete work shall be such that construction of each individual
superstructure unit can be completed within a 90-day period commencing with the first concrete pour
through completion of the post-tensioning and duct grouting operations unless otherwise indicated
on the Contract plans, specified in the Contract documents, or directed by the Engineer.
The Contractor shall have sufficient materials on hand prior to commencing work on any given
superstructure unit to ensure completion of the unit within the specified 90-day period.
After a minimum period of 30 days subsequent to the final stressing and grouting of the prestressing
steel, the superstructure ends at expansion bearings shall be raised with jacks, as specified in
Chapter 25, Bearings Devices, to relieve the shear strain in the bearings caused by shortening of
the concrete superstructure due to post-tensioning, shrinkage, creep and temperature change.
21.15.4 Material
21.15.4.1 Concrete
Concrete for post-tensioned works shall be Class C40/20 (unless otherwise indicated on the Contract
plans or in the Contract documents) as specified in Section 4.3 of Chapter 4, Concrete Works, of
these standard specifications, and in compliance with Section 21.3.4.
21.15.4.2 Post-tensioning Systems

Post-tensioning system including strands, ducts, anchorages, couplers, grouting, assemblies, etc.
shall be in compliance with the requirements of Chapter 22, Prestressing Systems.
Epoxy bonding agent shall comply with F.S. MMM-G-650A.
Bituminous protective coating shall comply with F.S. SS-A-701.
Page 21-67
21.15.4.3 Reinforcement Steel

Reinforcement steel shall comply with the requirements of Section 21.3.5, and Chapter 5,
Reinforcing Steel, of these standard specifications.
21.15.4.4 Built-in Materials

The Contractor shall furnish and install all built-in materials and items as indicated on the Contract
plans, as specified herein and as directed by the Engineer.
Built-in materials shall include, but not by way of limitations, all inserts, hardware or similar items as
indicated on the Contract plans or specified in the Contract documents.
21.15.5 Formwork
Formwork, shoring, and removal of forms shall be as specified in Section 1.20 of Chapter 01, General
Requirements, of these Standard Specifications, and as further specified herein and in the Contract
documents.
The deck slab forms and all related formwork for concrete box girder construction, including all
supporting falsework, shall be designed and constructed in order to facilitate removal of all formwork
materials from within the cells of the concrete box girders. The deck forms may be of 18 mm thick
marine plywood and shall be suspended from the girder stems which shall be stripped of all forms
prior to placing the deck forms. The deck slab forms shall in no way interfere with the required
concrete bond between the deck slab and the girder stems.
Stay-in-place deck forms will be permitted for the deck slab of concrete box girder construction,
provided they are galvanized steel or other noncombustible material acceptable to the Engineer
which will not deteriorate in any way. Further, such stay-in-place deck forms shall not increase the
volume of concrete, the depth of the deck slab or reduce the dimension of concrete coverage over
the reinforcement steel. The Contractor shall submit samples of the proposed form material and all
details and design for the use of stay-in-place deck forms. The decision of the Engineer shall be final
for acceptance or rejection of stay-in-place forms.
A 30 mm slip joint shall be placed transversely in the deck forming between each diaphragm to
eliminate resistance of the deck forms to deck shortening during prestressing.
The Contractor shall submit shop drawings and design calculations for the forms to the Engineer for
approval prior to commencing work.
Falsework and forms shall be set to provide the structural camber indicated in the Contract plans for
long term deflection, and shall comply with the required lines and grades.
Where indicated on the Contract plans, the Contractor shall include all formwork required to produce
the concrete surface ornamental pattern on the vertical surface of the box section of the post-
tensioned concrete works as indicated on the Contract plans, as specified herein and as approved
by the Engineer. The plywood forms supporting the bottom slab of the box girder shall be arranged
in a regular brick pattern as approved by the Engineer.
The Contractor shall include in his shop drawing submittal all details and a full description of all
formwork proposed by the Contractor to produce the concrete surface ornamental pattern. All details
and proposed methods and formwork material shall be subject to approval by the Engineer.
The construction of all formwork required to produce the concrete surface ornamental pattern shall
comply with the applicable requirements of Section 1.20 of Chapter 01, General Requirements, of
these Standard Specifications, and as specified herein. All formwork shall produce a smooth, even
surface with clean, straight, true and unbroken lines at the concrete surface ornamental pattern.
21.15.6 Placing Post-tensioning Systems

Anchorage devices, ducts, tendons and other appurtenant post-tensioning equipment and
accessories shall be placed by the Contractor in compliance with the requirements of Chapter 22,
Page 21-68
Prestressing Systems. They shall be accurately positioned in the forms and secured in place as
indicated on the Contract plans and approved shop drawings. Installation of the post-tensioning
system shall be coordinated with the placement of reinforcing steel and embedded items as specified
elsewhere in these Standard Specifications. Care shall be exercised to keep ducts and tendons free
of form coating compounds and other substances which might break or reduce the concrete bond.
Field measurements of vertical locations of centers of gravity of the tendons shall not vary from the
dimensions indicated on the Contract plans by more than the tolerance given in Table 22-6 of
Chapter 22, Prestressing Systems.
21.15.7 Mixing and Placing Concrete

Concrete work for box girder superstructure construction shall comply with the applicable provisions
of this chapter, Sections 4.3 and 4.4 of Chapter 04, Concrete Works, of these Standard
Specifications, and with the Contract documents.
Prior to placing concrete, tendon profiles shall be rechecked to ensure that proper location and
concrete cover will be maintained. Any ducts found to be damaged shall be repaired or replaced as
Prior to placing forms for box girder deck slabs, the Contractor shall demonstrate, to the satisfaction
of the Engineer, that either the prestressing steel is free and unbonded in the duct or, in the event
prestressing steel has not yet been placed, that all ducts are unobstructed.
The Contractor shall exercise care during concrete placement to prevent concrete from entering
anchorage hardware. Concrete shall be placed in such a manner that tendon alignment and
reinforcement positions are maintained, and concrete shall be vibrated with particular attention at
tendon anchorage locations to ensure optimum compaction and penetration at these points.
Placing sequence of concrete for box girders shall be in accordance with Article 21.7.1.2.
Curing of concrete shall be in accordance with the applicable provisions of Section 21.11, and
Section 4.4.2 of Chapter 4, Concrete Works, of these Standard Specification.
The Contractor shall keep a record showing the date and time of placement of cast-in-place, post-
tensioned concrete in each portion of the structure. This record shall be available for examination at
all times by the Engineer. Upon completion of construction of each structure, two copies of such
records shall be submitted to the Engineer.
21.15.8 Stressing Operations

Post-tensioning of cast-in-place concrete shall be performed as soon as the last placed concrete has
attained a cube compressive strength of 40 MPa, or as specified on the Contract plans, or more
based on the results of two cube tests.
Stressing operations shall comply with the requirements of Section 22.8.4 of Chapter 22,
Prestressing Systems. The Contractor shall employ, at no additional cost to the Owner, a technician
who is skilled in the post-tensioning method to give such aid and instruction in the use of the
prestressing equipment and installation of the prestressing steel as may be necessary to obtain the
specified results.
Prestressing tendons in continuous span post-tensioned structures shall be tensioned by jacking at
each end of the tendon or at one end of tendons as indicated on the Contract plans. Prestressing
tendons in single span post-tensioned structures may be tensioned by jacking from one end only as
All post-tensioning shall be by means of hydraulic jacks equipped with accurate reading calibrated
hydraulic pressure gauges to permit the stress in the prestressing steel to be computed at any time.
A certified calibration curve shall be furnished with each jack. In the event inconsistencies occur
between the measured elongation and the jack gauge reading, the jack gauge shall immediately be
recalibrated. In the event still further discrepancies occur, the cause shall be determined and
reported to the Engineer. An agreement within five percent shall be satisfactory.
Page 21-69
The Contract plans shall indicate jacking locations of the tendons. Proper allowance shall be made
for friction losses and one tendon shall be checked for friction loss at the very start of the post-
tensioning. In case the friction losses in tests exceed the computed losses, all wires shall be relieved
and lubricated with water soluble oil and re-tensioned. Each tendon shall be stressed until either the
required elongation or the maximum force is reached. Elongation is the preferred method of stress
determination wherever possible. The tendons shall be tensioned by jacking to the total forces
indicated on the shop drawings.
The post-tensioned prestressing steel shall be anchored at an “initial stress” that will result in the
ultimate retention of working forces or stresses of not less than those indicated on the Contract
drawings, but in no case shall the prestressing steel be tensioned above 80 percent of the ultimate
tensile strength of the wire or strands.
Prior to post-tensioning any member, the Contractor shall demonstrate to the satisfaction of the
Engineer that the prestressing steel is free and unbonded in the duct.
The Contractor shall keep records of the elongation and tension applied to each tendon, and this
record shall be submitted to the Engineer promptly upon the completion of stressing of each member.
At the time of stressing the first member, the stresses in the individual tendons shall be checked to
establish a procedure for ensuring uniform results. At any later time, a recheck may be ordered by
the Engineer if it appears that the design stresses are not being obtained. The Contractor shall have
written permission from the Engineer before capping any prestressing anchorage.
The effective prestress force “Pf” indicated on the Contract plans represents the force required after
all losses of prestress have occurred. The prestress losses due to creep and shrinkage of concrete,
and relaxation of prestressing steel and elastic shortening shall be estimated as per AASHTO LRFD
Bridge Design Specifications and Road Structures Design Manual (ADQCC TR-516). Unless
specified otherwise, friction shall be accounted for using wobble and curvature coefficients of k =
0.00066 per meter of tendon and μ = 0.23. The magnitude of the anchorage set, in case a grip type
anchorage is used, shall be the greater of that required to control the stress in the prestressing steel
at transfer or that recommended by the Manufacturer of the anchorage. The magnitude of the set
assumed for the design and used for set loss calculation shall be shown in the Contract documents
and verified during construction.
21.15.9 Grouting of Tendons

After the tensioning of all tendons has been completed and the total retained stress is equal to or
exceeds that indicated on the Contract plans, for each member, and the steel strands or wires have
been anchored, the annular space between the conduit and the tendons shall be grouted.
Grouting, grout mixture, grouting equipment, mixing of grout, and injection of grout shall comply with
the requirements of Sections 22.7.2 and 22.8.8 of Chapter 22, Prestressing Systems.
21.15.10 Protection of End Anchorages

As soon as possible after tensioning and grouting is completed, the Contractor shall clean exposed
end anchorages, wires and other metal accessories of rust, displaced mortar, grout and other such
materials, then shall apply to all such dry metal surfaces a heavy, unbroken coating of epoxy bonding
agent.
The Contractor shall install tight-fitting forms and hold in place securely against the previously placed
concrete.
After applying epoxy bonding agent, the Contractor shall apply a patching mortar prepared by mixing
one part type V, portland cement to three parts of clean sand (ASTM C33 / C33M - 11a) measured
by volume, and sufficient water to provide a stiff but workable consistency. The Contractor shall apply
the patching mortar, and manipulate, finish and cure as specified in this chapter. After mortar patches
have cured, the Contractor shall apply two heavy brush coats of bituminous protective coating
material, applied as recommended by the Manufacturer, including the recommended thickness.
Page 21-70
21.15.11 Access Doors

Access doors shall be installed in post-tensioned box girders as located and as detailed on the
Contract plans. All access doors shall be fabricated of steel shapes, plates and accessories
complying with Section 30.5 of Chapter 30, Miscellaneous Metal. All steel shall be galvanized in
accordance with Section 23.4.10 of Chapter 23, Steel Structures.
21.15.12 Vent Pipes

The Contractor shall include the unplasticized polyvinylchloride (uPVC) vent pipes in the cells of the
concrete box girders as indicated on the Contract plans.
The vent pipes shall be of the size as indicated on the Contract plans and shall be uPVC extruded
from one hundred percent virgin materials. The pipe material shall be new and homogeneous
throughout and free from visible cracks, holes, foreign materials, blisters, wrinkles and dents.
All vent pipes shall be anchored in an approved manner so as to prevent displacement or movement
during the placement of concrete.
21.15.13 Opening Bridges to Traffic

No equipment or vehicular traffic will be allowed on any bridge superstructure until the post-
tensioning and grouting operation is completed, falsework has been removed, and all concrete has
been cured for the time required in these Standard Specifications, or as further directed by the
Engineer. The Contractor shall carry out the required load tests on the bridge superstructure, as part
of the acceptance process of the bridge, as per Chapter 35, Bridge and Underpass Load Testing,
before opening the bridge to traffic.
21.16 Precast Concrete Fascia Panels

This section contains the requirements for the precast concrete fascia panels and the materials and
hardware for fastening the precast concrete fascia panels to the deck slab.
The Contractor shall be responsible for the construction of precast concrete fascia panels as
included in the Contract documents and as shown on the Contract plans.
The precast concrete fascia panels shall be constructed to the dimensions and details indicated on
the Contract plans. The construction of the precast concrete fascia panel for the curved portions of
the roadway shall be in curved sections. The curvature of the precast concrete panel shall match the
curvature of the roadway. The construction of the precast concrete fascia panel for the straight
portions of the roadway shall be in straight line segments.
21.16.1 Materials
Unless otherwise specified in the Contract documents, precast concrete fascia panels shall be
constructed of Class C40/20 concrete. Materials for concrete, preformed joint filler, and sealant shall
comply with the requirements of the applicable provisions of this chapter and Section 4.3 of Chapter
4, Concrete Works, of these Standard Specifications, and as described herein.
The embedded sleeves and the steel plates and hardware for fastening the precast concrete panels
to the cast-in-place bridge decks shall be manufactured of hot-dip galvanized ASTM A36 / A36M -
08 steel. The steel galvanization shall conform to the requirements of Section 21.3.5. The setting
grout and the grout cant shall meet the requirements of Section 21.18.3.
21.16.2 Moulds
The precast concrete fascia panels shall be cast in mortar-tight metal or metal-lined special moulds
that shall give a smooth, dense finish to the precast concrete parapets. The Contractor shall submit
to the Engineer for approval shop drawings of his proposed moulds. The mould release oil shall be
nonstaining.
Page 21-71
21.16.3 Shop Drawings and Method Statement

The Contractor shall submit complete shop drawings and method statement in accordance with the
Contract documents and provisions of Section 21.13.2, detailing his proposed method of fabricating,
transporting, and installing the precast concrete fascia panels. Further, the shop drawings shall
include details of the dimensions and lifting inserts. The shop drawings shall contain a schedule of
the quantities of each of the various types of precast concrete fascia panels.
21.16.4 Sample Panel

The Contractor shall fabricate one complete full-sized precast concrete fascia panel in accordance
with the Contract documents and provisions of Section 21.13.2, and as specified herein. This sample
unit shall be constructed in a location directed by the Engineer, and shall be protected and properly
stored in a secure place for reference. The sample unit, as approved by the Engineer, may be
installed in the works later if so directed or approved by the Engineer.
All precast concrete panels shall match the approved sample moulding panel in colour and quality.
Any precast concrete fascia panel not matching the approved sample parapet in colour and quality
or as rejected by the Engineer shall be replaced by the Contractor.
21.16.5 Fabrication
The Contractor shall provide a roughcast texture where indicated on the Contract plans in order to
provide a bond with the members to be constructed after the precast concrete fascia panels have
been installed. The dimensions of all precast concrete fascia panels shall be verified in the field
before they are cast.
The precast concrete fascia panels shall be constructed of a concrete mixture of cement, water, fine
aggregate and coarse aggregate having a maximum size of 10 mm. The concrete mixture shall meet
the requirements of Class C40/10 concrete as specified in Section 4.3 of Chapter 4, Concrete Works,
of these Standard Specifications. The Contractor shall submit to the Engineer for approval, a
proposed mix design proportioned by weight and based on trial mixes conducted with approved
materials. The mix design shall be accompanied by all relevant data.
The sand shall be specifically selected for colour and grading in order that the colour and texture of
the precast concrete fascia panels shall match the colour and texture of the adjacent precast facing
panels. Only sufficient water shall be used in mixing to permit the removal of the precast panel
segments from the moulds as soon as practical. The precast concrete fascia panels shall be kept
damp for a period of at least ten (10) days. During this period they shall be protected from the sun
and from wind. Any segments that show checking, soft corners, or soft surfaces shall be rejected.
The method of storage and handling shall be such as to preserve true and even edges and corners.
Any precast concrete fascia panels that become chipped, marred, or cracked before or during the
process of installation shall be rejected.
21.16.6 Surface Finish

Finishes shall be to shapes, lines and level as shown on the Contract plans and as approved by the
Engineer. Surface texture, smoothness or roughness and appearance shall be as approved by the
Engineer and shall be achieved by:
1. Maximum aggregate size selection.
2. Regulating the grading and workability of the mix.
3. Aggregate type and colour.
4. Addition of standard appropriate polypropylene fiber reinforcement at a rate of between
700g/m³ - 1000g/m³.
5. Use of special liners for patterned surface of type and motives approved by the Engineers
proposals and trials.
6. Use of specialized textile shutter liners for smooth finish.
7. Application of suitable surface retarders approved by the Engineer.
Page 21-72
8. Application of proper surface blasting, hacking grinding etc. techniques approved by the
Engineer.
The surfaces shall be free from cracks, blowholes, honeycomb, blemishes and similar effects. No
concrete surface repair system adversely affecting the quality and uniformity of the finish shall be
allowed. No additives or surface applications affecting the quality of finish or integrity of subsequent
coatings shall be used. A detailed concrete surface repair system including coatings (if any) shall be
submitted to the Engineer for approval. The finish quality, texture and general final appearance shall
be approved by the Engineer based on sample panels of other suitable pieces which shall be
inspected, approved and tagged by the Engineer. These tagged samples will serve as a reference
to document the approved finish and for use in subsequent quality control works.
21.16.7 Installation
The precast concrete fascia panels shall be installed after the bridge deck has been constructed.
The precast concrete fascia panels shall not be placed on the superstructure (bridge deck) until the
complete superstructure is in place and all post-tensioning works has been completed. The precast
concrete facing panels shall be installed on the superstructure in accordance with the details
indicated on the Contract plans. The recessed areas at the lifting inserts shall be sealed with
approved grout after the installation of the precast concrete panels has been approved by the
Engineer.
21.17 Cast-in-place Concrete Works for Bridge, Tunnel &

Underpass Structures
This section contains the cast-in-place concrete requirements for the following structural elements:
• Bridge superstructure: diaphragms and slabs.
• Bridge substructure: abutments, piers, wingwalls, retaining walls, and footings.
• Tunnel and underpass structures: roof solid slab, roof voided slab, retaining walls, base slab,
monolithic barriers and curbs.
• Associated structures: Lift stations, storm water reservoirs, and generator rooms.
21.17.1 Materials
Cast-in-place bridge superstructure and substructure, tunnel and underpass structures, and
associated structures shall be made of Class C40/20 concrete. All materials shall comply with all
applicable requirements of this chapter, and Section 4.3 of Chapter 4, Concrete Works, of these
21.17.2 Shop Drawings

The Contractor shall submit to the Engineer for approval shop drawings including all formwork, as
required by the Contract documents.
21.17.3 Construction
The construction of cast-in-place bridge superstructure and substructure, tunnel and underpass
structures, and associated structures shall comply with the applicable requirements of this chapter
and Section 4.4 of Chapter 4, Concrete Works, of these Standard Specifications, as specified herein,
and as per the lines, shapes, dimensions and details indicated in the Contract plans.
Junction boxes and electrical conduits shall be embedded as indicated in the Contract plans.
21.17.4 Formwork
The Contractor shall include all special formwork required to produce curved and decorative walls
and elements and the pattern on the surfaces of the cast-in-place bridge superstructure and
substructure, tunnel and underpass structures, associated structures, and other surfaces, as
Page 21-73
indicated on the Contract plans, as specified in Section 1.20 of Chapter 01, General Requirements,
of these Standard Specifications, and as approved by the Engineer.
Tie rods used in the formworks for areas below the ground water table should incorporate special
water-stops. Special water-stops shall be an accessory to the formwork. The Contractor shall show
water-stop details in the shop drawings.
21.17.5 Expanded Polystyrene Board

Tunnel and underpass voided slabs shall be constructed using commercially available expanded
polystyrene board. Expanded polystyrene shall have a minimum flexural strength of 240 kPa,
determined in conformance with the requirements of ASTM C203 - 05a(2012), and compressive
yield strength of ≥ 200 kPa, at 10% compression, as per ASTM D1621 - 10. Surfaces of expanded
polystyrene shall be faced with hardboard or similar material. The facing layer shall be 1.5mm
minimum thickness. Expanded polystyrene shall have maximum water absorption of 2% after 24
hour immersion, and maximum density of 25 kg/m³ as per ASTM D1622 - 08. Thermal conductivity
at 10o C mean temperature shall be 0.037 W/m² C maximum complying with ASTM E96/ E96M-10,
and the dimensional stability at 80o C shall be 0.5 maximum complying with BS 4370-2:1993. The
water vapour transmission at 38o C and 90% relative humidity, maximum per 50 mm sample
thickness, shall be 25 Mgm/m2/h, complying with BS 4370-2:1993.
Boards shall be held in place by a combination of nails, straps, waterproof adhesive or other means
approved by the Engineer. The expanded polystyrene shall be considered as an accessory to the
formwork.
Any special formwork and accessories for the formworks shall be at the Contractor’s expense.
21.18 Mortar and Grout

This work makes and places mortar and grout for use in concrete structures and precast works other
than in prestressing ducts. Such uses include mortar for filling under masonry plates and for filling
keyways between precast members, where shown in the Contract documents; mortar used to fill
voids and repair surface defects; grout used to fill sleeves for anchor bolts; grout for sealing bolt
pockets and the insides of the coil anchors; and mortar and grout for other such uses, where required
or approved.
21.18.1 Mortar and Grout Materials and Mixing

Materials for mortar and grout shall conform to the requirements of Section 21.3, Materials Used for
Concrete Structures. Grading of sand for use in grout or for use in mortar, when the width or depth
of the void to be filled is less than 20 mm, shall be modified so that all material passes the No. 8,
2.36-mm sieve.
Unless otherwise specified in the Contract documents, or later in this section, or ordered by the
Engineer, the proportion of portland cement to sand for mortar shall be one-to-two and for grout shall
be one-to-one. Proportioning shall be by loose volume.
When non-shrink mortar or grout is specified, either a non-shrink admixture, or expansive hydraulic
cement conforming to ASTM C845 - 04 of a type approved by the Engineer, shall be used.
Only sufficient water shall be used to permit placing and packing. For mortar, only enough water
shall be used so that the mortar will form a ball when squeezed gently in the hand.
Mixing shall be done by either hand methods or with rotating paddle-type mixing machines and shall
be continued until all ingredients are thoroughly mixed. Once mixed, mortar or grout shall not be re-
tempered by the addition of water and shall be placed within one hour.
Alternatively, proprietory, nonshrinkable, prepacked, flowable grout material having strength greater
than 1.5 times characteristic strength of surrounding concrete and with slant shear greater than or
equal 25 percent of its compressive strength may be used, provided the colour and texture are
Page 21-74
21.18.2 Placing and Curing of Mortar and Grout

Concrete areas to be in contact with the mortar or grout shall be cleaned of all loose or foreign
material that would in any way prevent bond, and the concrete surfaces shall be flushed with water
and allowed to dry to a surface-dry condition immediately prior to placing the mortar or grout.
Mortar or grout shall completely fill and shall be tightly packed into recesses and holes, on surfaces,
under structural members, and at other locations specified. After placing, all surfaces of mortar or
grout shall be cured by the water method as provided in Section 21.11, Curing Concrete, for a period
of not less than three days.
Keyways, spaces between structural members, holes, spaces under structural members, and other
locations where mortar could escape shall be mortar-tight before placing mortar.
No load shall be allowed on mortar that has been in place less than 72 hours, unless otherwise
permitted by the Engineer.
All improperly cured or otherwise defective mortar or grout shall be removed and replaced by the
Contractor at the Contractor's expense.
21.18.3 Grout in Precast Works

The grout for sealing bolt pockets and the insides of the coil anchors, the grout cant, and the setting
grout for the precast members shall be a nonmetallic, nonshrink grout containing a mixture of sulfate
resistant cement and sand approximately in the proportions of one part of cement to two and one-
half parts of sand. The sand shall be specifically selected for colour and grading in order that the
colour and texture of the grout shall match the colour and texture of the precast members. The sand
shall be sieved through a screen having 3.715 mm square meshes. All over-sized sand particles
shall be discarded. The grout shall show no expansion after final set takes place when tested in
accordance with ASTM C827 / C827M - 10. It shall have an initial setting time of not less than 45
minutes.
The grouting shall be performed in accordance with the recommendations of the American Concrete
Institute and with the grout Manufacturer's published literature for site preparation, product mixing,
and placing. An adequate number of metal shims shall be placed before the grout is placed.
The Contractor shall furnish, from an Owner’s approved independent laboratory, test results verifying
that the grout shows no shrinkage from the time of placement and no expansion after set, has a one-
day compressive strength of not less than 20 MPa, and has an initial set time of not less than 45
minutes.
21.19 Application of Loads

Loads shall not be applied to concrete structures until the concrete has attained sufficient strength
and, when applicable, sufficient prestressing has been completed, so that damage shall not occur.
21.19.1 Earth Loads

Whenever possible, the sequence of placing backfill around structures shall be such that overturning
or sliding forces are minimized. When the placement of backfill will cause flexural stresses in the
concrete, and unless otherwise permitted by the Engineer, the placement shall not begin until the
concrete has reached not less than 80 percent of its specified strength.
21.19.2 Construction Loads

Light materials and equipment may be carried on bridge decks only after the concrete has been in
place at least 24 hours, providing curing is not interfered with and the surface texture is not damaged.
Vehicles needed for construction activities and having a mass between 450 kg and 1,800 kg, and
comparable materials and equipment loads, shall be allowed on any span only after the last-placed
deck concrete has attained a compressive strength of at least 20 MPa. Loads in excess of the above
shall not be carried on bridge decks until the deck concrete has reached its specified strength.
Page 21-75
Additionally, for post-tensioned structures, vehicles weighing more than 2,000 kg, and comparable
materials and equipment loads, shall not be allowed on any span until the prestressing steel for that
span has been tensioned.
Precast concrete or steel girders shall not be placed on substructure elements until the substructure
concrete has attained 70 percent of its specified strength.
Otherwise, loads imposed on existing, new, or partially completed portions of structures due to
construction operations shall not exceed the load carrying capacity of the structure, or portion of
structure, as determined by the Strength II Load Combination in Table 3.4.1-1 of the AASHTO Load
and Resistance Factor Design (LRFD) Bridge Design Specifications. Compressive strengths of
concrete (fc') to be used in computing the load-carrying capacity shall be the smaller of the actual
compressive strength at the time of loading or the specified compressive strength of the concrete.
21.19.3 Traffic Loads

Unless otherwise provided in the Contract documents, traffic shall not be permitted on concrete
decks until at least 14 days after the last placement of deck concrete and until such concrete has
attained its specified strength.
21.20 Special Requirements for Segmental Bridges

21.20.1 Geometry Control
21.20.1.1 Deflection and Camber Data
Deflection or camber data shall be submitted by the Contractor for each stage of construction, as
required to construct the structure to its final grade. Procedures used shall account for the effect of
the time-dependent prestress losses and creep that will occur during the construction phase. Data
for the entire bridge, based on the Contractor's proposed erection sequence, method, and schedule,
shall be submitted to the Engineer for review prior to commencing pier shaft construction.
Structure cambers will be monitored by the Contractor at each stage and corrective actions, as
approved by the Engineer, shall be performed by the Contractor to assure proper erection of the
structure to its final grade.
21.20.1.2 Geometry Control

A geometric control plan that indicates, in detail, how the survey is to be performed shall be submitted
by the Contractor for the Engineer’s approval. These proposed actions shall assure proper erection
of the structure to the final grade shown in the working drawings. This plan shall provide for regular
monitoring of the superstructure deflections beginning with the addition of the first cantilever
segments and concluding with the last cantilever segment. It shall also include the adjusting
procedure to be utilized, shall the cantilever, as erected, deviate from the predicted alignment by
more than 25 mm.
Elevations and alignments of the structure shall be checked by the Contractor at every stage of
construction and the Contractor must maintain a record of all these checks and of all adjustments
and corrections made. All surveying shall be performed at a time that will minimize the influence of
temperature. Corrections by shimming shall be done only when approved by the Engineer.
For precast segmental construction using short-line forming techniques, the Contractor shall provide
precision surveying systems so that levels and horizontal alignment during precasting are measured
to an accuracy of ±0.3 mm. For all other types of segmental construction and for erection of
segmental bridges, surveying shall be provided to an accuracy of ±3 mm.
For precast segmental construction using match-cast segments, careful checks of both
measurements and computations of geometry shall be made by the Contractor before moving
segments from their casting position. Computed coordinates of all sections cast shall be completed
before casting a new segment. In addition to the computed as-built casting curves for vertical and
Page 21-76
horizontal deflections, a cumulative twist curve shall be computed using the measured cross slopes
of the individual units as a check on the extrapolated deflections. In computing set-up elevations in
the match-cast process, priority shall be given to correcting twist errors by proper counter rotation.
Segments in the match-cast position shall not be subjected to a stress-inducing twist.
21.20.2 Segmental Bridge Tolerances

Unless otherwise specified, reinforcement shall be fabricated and placed within the tolerances
specified herein as recommended by the Concrete Reinforcing Steel Institute [CRSI] 1990.
• For specified effective depth (d) and the minimum clear concrete protection in flexural
members, walls, and compression members, Table 21-22 illustrates the admissible
tolerances.
Table 21-22: Tolerances on effective depth and minimum cover
Tolerance on
Effective depth d Tolerance on d
minimum mover
200 mm or less ±10 mm -10 mm
More than 200 mm ±12 mm -12 mm
• However, tolerances on the clear distance to formed soffits shall be -6 mm, and in no case
shall the tolerance on cover exceed minimum one-third of the minimum cover stipulated on
the structural drawings or in the specifications.
• For longitudinal location of bends and ends of bars: ±50 mm, except at discontinuous ends
of members where tolerance shall be ± 12 mm.
• As long as the total number of bars specified is maintained, a reasonable tolerance in spacing
individual bars is ±25 mm, except where openings, inserts, and embedded items might
require some additional shifting of bars.
Embedded ducts for all types of segmental bridge construction shall be positioned to tolerances as
specified in Chapter 22, Prestressing Systems, Article 22.8.4.2, Placement of Ducts.
Tolerances for completed segments shall be taken, as shown in Table 21-23. For bridges without an
overlay, the flatness of the top slab shall be 3 mm in 3 m in the direction of traffic.
Dimensions from segment-to-segment shall be adjusted to compensate for any deviations within a
single segment so that the overall alignment of the completed structure will conform to the
dimensions shown in the Contract documents.
When cantilever construction is used, the tolerances for the alignment of the opposing cantilevers in
a span shall be stated in the Contract documents. Forces up and down that can be placed on the
end of the cantilever shall also be stated on the design drawings and shall consider the allowable
tensile stresses for construction load combinations, as stated in Table 5.14.2.3.3-1 of the AASHTO
LRFD Bridge Design Specifications.
After erection, final post-tensioning, final corrections, and adjustments are complete and the
structure has been placed on its permanent bearings, the superstructure shall conform to the grade
and alignment shown in the Contract drawings, with due consideration of creep and superimposed
dead-load deflections within tolerances as specified in the Contract documents.
Finished segment tolerances shall not exceed those listed in Table 21-23.
Table 21-23: Completed segment tolerance for segmental box girder bridge construction
Dimension Tolerance
Length of Match-Cast Segment (Not Cumulative) (10
±10 mm /m
mm/m +25 mm max)
±12.5 mm but not greater than +50
Length of Cast-in-Place Segment
mm per span
Web Thickness ±9.5 mm
Depth of Bottom Slab ±9.5 mm
Page 21-77
Dimension Tolerance
Depth of Top Slab ±9.5 mm
Overall Top Slab Width ±5 mm/m, ± 25 mm. max.
Diaphragm Thickness ±12.5mm
Grade of Form Edge and Soffit ±3 mm in 3 m
Tendon Hole Location ±3 mm
Position of Shear Keys ±6 mm
21.20.3 Shop Drawings and Design Calculation for Construction

Procedures
Sufficiently in advance of the start of superstructure field construction operations, so as to allow the
Engineer not less than a 30 day-review period, the Contractor shall submit complete details and
information concerning the method, materials, equipment, and procedures it proposes to use in
constructing that portion of the superstructure for which the information is furnished. This submittal
shall include step-by-step erection procedures.
More than one method or technique of erection may be permitted in the overall scope of work. Any
subsequent deviation from the approved materials or details shall not be permitted unless details are
submitted by the Contractor and approved by the Engineer in advance of use.
Submittals for approval shall include calculations, drawings, and information outlined in Article
21.20.3.1, Design Calculations for Construction Procedures, and Article 21.20.3.2, Shop Drawings.
Two sets of all required drawings and calculations shall be submitted and resubmitted until approved
by the Engineer. A specified number of distribution copies shall be furnished after approval.
21.20.3.1 Design Calculation for Construction Procedures

Design calculations shall be submitted for falsework, erection devices, formwork, or other temporary
construction that may be required and that will be subject to calculated stresses.
Design of the falsework or erection devices for all superstructure concrete shall be done under the
direction of and sealed by a specialty engineer. Calculations shall also be submitted to substantiate
the system and method of stressing proposed by the Contractor. Such calculations shall include the
required jacking force and elongation of tendons at the time of tensioning, tendon stress level at
stressing ends after seating, stresses in anchorage zones and distribution plates, stress-strain
curves typical of the prestressing steel to be furnished, seating losses, temporary overstresses, and
reinforcement required to resist anchor block stresses.
In addition to the above, computations shall be submitted for approval for the following:
• Computations of deflections and required camber due to dead loads, post-tensioning forces,
creep, and shrinkage. A tabulation of deflections and camber dimensions shall be included
on the shop drawings.
• Computations of jacking forces required at joints during temporary post-tensioning.

Detailed shop drawings shall be submitted by the Contractor for approval in accordance with the
Contract documents. These drawings shall include, but not necessarily be limited to, the following
information:
• Fully and accurately dimensioned views showing the geometry of the segments, including all
projections, recesses, notches, openings, block outs, and other pertinent details.
• Details of non-prestressed steel reinforcing shall be clearly shown as to size, spacing, and
location — including any special reinforcing required but not shown in the Contract plans.
• Size and type of ducts for all post-tensioning tendons and their horizontal and vertical profiles
shall be clearly detailed. Duct supports, grout tubes, vents, and drains shall be shown —
including size, type, and locations.
Page 21-78
• Details and locations of all other items to be embedded in the segments, such as inserts,
lifting devices, and post-tensioning hardware, shall be shown.
• Prestressing details shall include sizes and properties of tendons, anchorages, plates,
assemblies, and stressing equipment — as well as details of the stressing procedure and
stressing sequence, details and locations of all couplers, and additional reinforcement
necessary to resist anchor block stresses.
• A table giving jacking sequence, jacking forces, and initial elongation of each tendon at each
stage of erection for all post-tensioning.
• A table showing elevations and geometry to be used in positioning the forms for the next
segment to be cast.
• Graphs, charts, or tables showing the theoretical location of each segment, as erected or
placed, shall be furnished to the Engineer for use in checking the erection of the
superstructure. Detailed procedures for making geometry corrections shall be described.
• Details of tie-down tendons and temporary and permanent bearing assemblies as required.
• Details of grouting equipment, grout mix design, method of mixing, and placing grout shall be
provided.
21.20.4 Forms
Shop drawings shall be submitted for forms and form travellers, as required by the Contract
documents.
In addition to the requirements of the Contract documents, the forms used to cast the concrete
segments shall be capable of the following:
• Match-casting for precast segmental construction.
• Producing the segments within the tolerances permitted.
• Accommodating block outs, openings, and protrusions.
• Adjusting to changes in segment geometry as shown in the Contract documents, or for
correcting previous minor casting errors to prevent accumulations.
• Stripping without damage to the concrete.
• Providing a tight, leak-proof joining to the previous segment.
Bulkheads must be capable of connecting the ducts in a manner to hold their position and prevent
intrusion of grout.
Where sections of forms are to be joined on the exterior face of the segment, an offset in excess of
1.5 mm for flat surfaces and 3 mm for corners and bends shall not be permitted. Offsets between
adjacent matching faces of cast-in-place segments shall not exceed 6 mm.
Forms shall not be removed until the concrete has attained the release strength specified in the
Contract documents, as evidenced by test cubes made and cured in the same manner as the
segment. Alternatively, maturity metres or instrument control cubes may be used to evaluate the
strength of the concrete in the segment. Care shall be exercised in removing the forms to prevent
spalling and chipping of the concrete.
21.20.4.1 Forms for Precast Segmental Construction

All side, bottom, inside, and header forms for precast segmental construction shall be constructed
of steel unless use of other materials is approved by the Engineer.
Forms shall be of sufficient thickness, with adequate external bracing and stiffeners, and shall be
sufficiently anchored to withstand the forces due to placement and vibration of concrete. Internal
bracing and holding devices in forms shall be limited to stay bolts in webs that can be removed from
the concrete surface to permit patching following form removal. Joints shall be designed and
maintained for mortar tightness.
Form grades and alignments shall be checked each time they are set and shall be maintained during
the casting of concrete. Slab finish grades will be checked after the concrete is in place.
Page 21-79
Metal forms shall be reasonably free from rust, grease, or other foreign materials. All forms shall be
cleaned thoroughly prior to each casting operation. End headers shall be maintained to provide a
smooth casting surface.
Wood forms may be used on the cast-in-place longitudinal and transverse closure strips.
All form surfaces for casting members shall be constructed and maintained to provide segment
tolerances in accordance with Section 21.20.2, Segmental Bridge Tolerances.
The faces of all forms, other than end headers, shall be properly cleaned and treated with form oil
or other bond-breaking coating prior to placing concrete. Bond-breaking material between segments
and headers shall be provided in accordance with Article 21.20.7.2, Separation of Match-cast
Segments. Oil or other materials used for this purpose shall be of a consistency and composition to
facilitate form removal. Materials that appreciably stain or react with the concrete shall not be
constructed to facilitate segment removal without damage to the concrete.
21.20.5 Permanent Bearings

This work shall furnish all materials, fabrication, and installation of the permanent bearings, as shown
in the Contract plans, as herein specified conforming to Chapter 25, Bearing Devices, and as
Bearings shall be fabricated in conformance with the Contract plans, except as otherwise and
specifically approved by the Engineer.
Prior to approval of the bearings to be used, the Contractor shall submit a certification by the
Manufacturer stating that it and the accessory items meet the requirements set forth. This shall not
constitute a waiver on the part of the Owner of any requirements with respect to samples and
sampling, and the right is retained to perform any of the tests specified or such test deemed by the
Engineer as necessary to qualify the material.
Installation instructions shall be obtained by the Contractor from the Supplier of the bearing
assemblies and shall comply with the procedures specified in the installation of the bearing and
Chapter 25, Bearing Devices. Shop drawings shall be submitted to the Engineer for approval in
accordance with the provisions of the section of these Standard Specifications applicable to the
bearing being provided. Adequacy of the design and installation details shall meet with the approval
of the Engineer, whose decision shall be final.
21.20.6 Special Provisions for cast-in-place Segmental Construction

The Contract plans shall be prepared on the assumption that the superstructure will be constructed
by a selected method of cast-in-place reinforced-concrete segmental construction. Alternate
construction methods may be permitted in accordance with the Contract documents.
21.20.6.1 Forming System

In addition to the submittals required in Section 21.20.3, Shop Drawings and design calculations for
construction procedures, the following computations and working drawings shall be submitted for
the Engineer’s review and for compliance with the Contract documents:
• Complete details and computations for the forms and form support system, including
maximum loadings and stresses created in the completed segments due to equipment forms
and concrete placement. Design of form support system shall include adequate allowances
for impact loadings which may occur during concrete placement and advancement of forming
system.
• Computations of deflection of the forming system during concrete placement.
• Details for temporary supports and tie-downs as needed to stabilize the cantilevers during
construction.
• Detailed step-by-step procedures for concrete placement, stressing and advancing the form
support system, and adjusting the system for calculated deflection.
Page 21-80
• Detailed procedures for fixing the cantilever ends against changes in position or rotation of
one cantilever relative to the other during and following placement of concrete for the closure
between the cantilevers.
In every stage of construction, the stability of the partially completed structure is a major concern.
Therefore, the Contractor shall evaluate the stability of partial structures to avoid any collapse due
to various combination of loads, including construction, wind loading, and vibration from equipment.
21.20.6.2 Superstructure Construction

This work shall consist of setting temporary bearings, if applicable; casting segments in place; and
setting the superstructure on permanent bearings.
Complete details and description of the methods, arrangements, and equipment shall be submitted
by the Contractor for the Engineer’s approval before superstructure construction is started.
Chosen construction methods shall include casting of the segments, methods of the tie-down of
superstructures during cantilever erection, and methods of application of all temporary forces to be
used for adjusting horizontal and vertical alignments and to place the structure on permanent
bearings. This shall also include control methods to ensure the accuracy of alignment of the
completed superstructure.
Work equipment includes all machinery, devices, labour, and materials that are to be used for
erection but shall not become a permanent part of the completed superstructure. Equipment must
not be operated from or placed upon any part of erected superstructure at any stage of construction
other than that which specifically meets the requirement of total working load per segment, as
allowed by the Contract documents, or as approved by the Engineer. This includes the post-
tensioning hardware; jointing, jacking, and grouting equipment; and personnel and materials of any
kind.
In addition to segment unbalanced loads that are permitted for the construction method, a (4.8 × 10-
4 MPa) load is permissible and shall include personnel, miscellaneous equipment, and stored
material. It shall be the Contractor's responsibility to ensure that this allowable load is not exceeded.
Stressing may be performed in accordance with the following schedule:
• Fifty percent of the post-tensioning force may be applied when field cured compression cubes
indicate the compressive strength of the segment concrete is 17.2 MPa, and 18 hours have
elapsed after completion of concrete placement.
• Form support system may be released and advanced when 50 percent of the post-tensioning
stress has been applied.
• Transverse stressing shall be staged to avoid exceeding the allowable stresses in the top
slab.
• Tendons shall be fully tensioned prior to placement of concrete for the next segment, except
the transverse tendon nearest the segment to be constructed. That tendon shall be stressed
to 50 percent, and then stressed the remainder when tendons in the new segment are
stressed. Form support systems shall be designed to avoid overstressing the top slab in the
area of the partially stressed tendon.
Construction joints shall be limited to locations shown in the Contract documents or as approved, in
advance, by the Engineer. All construction joints shall be thoroughly cleaned of laitance and foreign
material prior to placing concrete for the abutting section.
Surface of the segment joints shall be prepared in accordance with the Contract documents
immediately prior to placement of concrete for the next segment.
For placement of closure concrete between cantilevers, the cantilevers shall be fixed to prevent
rotation or movement of one cantilever relative to the other. Systems for locking the cantilevers and
forming for the closure and the procedure for placing the concrete for the closure shall be such that
the concrete after the initial set shall not be subjected to tension that could cause cracking.
Page 21-81
A construction schedule or check list that shows the chronological order of every phase and stage
of erection and construction of the superstructure shall be submitted by the Contractor. Additionally,
the Contractor shall prepare a table of elevations and alignments required at each stage of erection,
as required by the Contract documents, at the check points listed below, or an alternative at the
Contractor's option, and submit the same to the Engineer.
• One of the lowest corners at the top surface of any temporary bearing pads to be used as
datum during erection and to establish a reference point with the actual elevations and
alignment required of the permanently positioned superstructure.
• All four corners and centreline (at segment faces) of top slab of pier segments to establish
grade and crown.
• Two points on the longitudinal centreline of each pier segment, one on each edge, to
establish alignment.
• One point on the longitudinal centreline and at least one corner of each segment along every
joint between cast-in-place segments to establish elevations and alignment at every stage of
erection.
Temporary bearing pads, if applicable, at the piers shall be carefully placed. Surfaces tops of these
pads shall have the correct elevations, alignments, and slopes — as required by the Contract plans
and so established by the provisions above for temporary bearing pads. Shims may be used
underneath the pads to accomplish accuracy. Measures to hold temporary bearing pads in position
while the pier segment is being cast shall be devised and provided by the Contractor.
Elevations and alignment of the structure shall be checked by the Contractor at every stage of
construction, in accordance with the geometry control plan submitted in accordance with the
provisions of Section 21.20.1, Geometry Control, and shall maintain a record of all these checks and
of all adjustments and corrections made.
21.20.7 Special Provisions for Precast Concrete Segmental

Construction
Superstructure erections shall be executed by the method designed and detailed in the Contract
documents or by an alternate method submitted by the Contractor. Alternate erection methods may
be permitted, when specified in the Contract documents.
When required by the Contract documents, the stressing system and all reinforcement and lifting
details shall be successfully demonstrated on a segment designated in the Contract documents prior
to casting any permanent segments. The segment shall conform to the size and configuration
required by the Contract documents, including post-tensioning anchorage pockets, reinforcing steel,
concrete, and conduits, including curvature and spacing. Tendons designated in the Contract
documents for this test shall be stressed to the forces shown. No additional payment shall be made
for this test.
Casting beds and forms shall be structurally adequate to support the segments without settlement
or distortion. Casting beds shall be designed for a method and the hardware needed to adjust and
maintain grade and alignment. Details for hardware and adjustment procedures shall be included in
the Contract plans and specifications for the casting bed.
Grading of the soffit form and the top portion of each segment shall take into consideration the
relative position of the member in the structure.
After the first segment of each unit is cast, all succeeding segments shall be cast against previously
cast segments to ensure complete bearing and proper alignment on all mating surfaces.
Anchorage systems shall permit tendons to be inserted in the member after erection of segments.
Tendon couplers shall be used only at locations specifically shown in the Contract documents or
when approved by the Engineer. Not more than 50 percent of the tendons shall be coupled at anyone
section. When temporary external tendons are required by the Contract documents, the tendons and
anchors shall be in a protective enclosure capable of protecting the tendons from damage by erection
equipment and capable of confining a strand or bar tendon that breaks or otherwise releases tension
Page 21-82
rapidly during or after tensioning and anchorage. Protective enclosure proposals shall be submitted
to the Engineer for approval.
Care shall be taken to ensure that deformations of match-cast segments due to thermal gradients
caused by the heat of hydration of the new cast concrete do not exceed, at the time of initial set of
the new concrete, 0.8 mm for a single segment or 19 mm cumulative for an entire span. These
deformations shall be prevented by properly protecting both the match-cast and new cast segments
in an isothermal enclosure or with curing blankets and plastic sheeting. The design gradient in the
AASHTO LRFD Bridge Design Specifications can assist the Contractor in determining to what extent
this type of deformation will occur and if additional protection of the match-cast segment is
necessary.
21.20.7.1 Fabrication
Reinforcing steel shall be fabricated and placed according to the Contract documents. Any conflict
or interference with the proper location of ducts, reinforcing, or block outs shall be promptly resolved
and corrections made — as directed by the Engineer. No reinforcing steel shall be cut and removed
to permit proper alignment of stressing conduits. Any bar that cannot be fabricated to clear the post-
tensioning duct shall be replaced by additional bars with adequate lap lengths and shall be submitted
to the Engineer for approval.
All segments shall be marked on the inside with a unique identification at the time of form removal.
This identification shall be used to identify each segment on shop drawings, post-tensioning details
and calculations, and any other document pertaining to the fabrication and erection of precast
concrete segments.
Positive means of holding the conduit in its correct position shall be provided in all cases and shall
be indicated on the working drawings submitted for approval. The conduit shall be supported at
intervals as specified in Chapter 22, Prestressing Systems, Section 22.8.4.2, Placement of Ducts,
or as shown in the Contract documents, and shall be securely fastened to prevent movement during
placement of concrete.
21.20.7.2 Separation of Match-cast Segments

Equipment to be used for uniform separation of match-cast segments shall be provided by the
Contractor without damage. Methods, as well as details of the equipment to be used for separating
match-cast segments, shall be included in the shop drawings. A bond-breaking material shall be
used on the web and flanges of the previously cast segment to facilitate separation of segments.
Bond-breaking materials shall be used to break the bond of concrete between the face of previously
cast segments and a newly cast segment, as well as the end headers, when required. Bond breakers
shall consist of flax soap and talc, or another material approved by the Engineer. A demonstration
shall be performed on a 600-mm by 1,200-mm specimen, prior to the casting of segments, to prove
the adequacy of the material. Materials shall not be injurious to the concrete and shall permit removal
of a segment without pullouts caused by adhesion of the concrete.
21.20.7.3 Handling and Erection of Segments

Proper handling, lifting, storing, transporting, and erection of all segments shall be the responsibility
of the Contractor so that they may be placed in the structure without damage.
Segments shall be maintained in an upright position at all times and shall be stored, lifted, or moved
in a manner to prevent torsion and other undue stress. Members shall be lifted, hoisted, or stored
with lifting devices approved on the shop drawings or by another method approved by the Engineer,
in writing.
Segments shall not be moved from the casting yard until all curing and strength requirements have
been attained and shall be supported in a manner that will minimize warping.
A full-scale test of the lifting and temporary holding hardware shall be performed to demonstrate the
adequacy of this equipment prior to beginning any erection of the segments.
Page 21-83
21.20.8 Special Provisions for Incremental Launching

Structures built by the incremental launching method shall comply with the provisions of Section
21.20.3, Shop Drawings and design calculations for construction procedures, and the additional
provisions of the following section.
21.20.8.1 Casting of Segments

Construction of incrementally launched bridges shall be based on a weekly cycle for the construction
of each segment. When the bottom flange and webs, or portions of webs, of segments are cast first
and the top flange afterward, the time between concrete placements shall not exceed three days.
21.20.8.2 Geometric Tolerances

The following tolerances shall not be exceeded in the region of the sliding surfaces:
• In the Forms:
• Vertical deviations in longitudinal and transverse direction: ±0.8 mm
• Horizontal deviation at the outside of webs: ±1.5 mm
• On the Launching Bearings:
• Vertical: Longitudinally between piers: ±1.5 mm
• Transversely between bearings: ±0.8 mm
• Horizontal: Deviation of lateral guides: ±1.5 mm
21.20.8.3 Launching Force

Launching forces shall be monitored continuously and checked against the theoretical value. A
friction value between 0 percent and 4 percent shall be maintained. Grease may be used on the
sliding plates, as required to maintain friction values. Friction values of zero shall be considered in
calculation of the force required to hold back a structure launched on a negative gradient.
21.20.8.4 Pier Monitoring

Pier top deflection shall be continuously monitored. Monitoring devices that automatically switch off
the launching equipment in case the permissible pier deflections are exceeded are recommended.
Communication between each sliding bearing and the launching equipment shall be provided.
At regular intervals, the Contractor shall check the correct level of all sliding bearings. Shim plates
shall be kept in stock for all sliding bearings to compensate for pier settlements, if any.
21.20.9 Defects and Breakage

Failure of individual wires in a seven-wire strand is acceptable with the approval of the Engineer,
provided the total area of wire failure is not more than 2 percent of the total cross-sectional area of
the tendon.
Minor or non-structural cracks or checks on the surface of the member which, as determined by the
Engineer, do not extend to the plane of the nearest reinforcement, will be acceptable unless they
are numerous and extensive. Diagonal cracks that indicate damage from torsion, longitudinal cracks
that follow stressing tendons, or any cracks that extend into the plane of the reinforcing steel or
prestressed tendons shall be subject to a structural review prior to acceptance. If found acceptable,
the cracks shall be repaired by veeing out 6 mm deep and wide and sealing with epoxy or shall be
repaired by epoxy injection.
Prior to the start of segment fabrication, the Contractor shall repair minor breakage, spalling, or
honeycombing not more than 25 mm deep in accordance with an established repair procedure, as
approved by the Engineer. Major breakage or honeycombing in excess of that specified herein shall
be subject to structural review. If the established repair procedure is found to be satisfactory, the
Contractor shall repair these areas as directed by the Engineer. Breakage, spalling, or
Page 21-84
honeycombing on any mating surface found to be acceptable shall be repaired and the concrete
cured prior to casting the mating segment — if such segment has not yet been cast.
21.21 Architectural Surface Treatment for Tunnel and

Underpass Walls
The Contractor shall furnish and install the architectural surface treatment on the tunnel and
underpass walls and any associated structures as shown on the Contract plans, as specified herein,
or as directed by the Engineer.
The Engineer shall provide the Contractor with conceptual design details and the Contractor shall
develop complete design details and shop drawings for the Owner’s review and approval.
21.21.1 Types of Surface Treatment

The Contractor shall furnish and install surface treatments of the types specified herein, as shown
on the Contract plans, or as directed by the Engineer.
The specific type of finishing technique and materials to be applied at the various structures may be
subject to change and the Contractor shall take account of this likelihood as no additional
reimbursement shall be made for such revisions. All finishes shall be of the highest quality, and the
Contractor shall provide samples and mock-up for all the types of finishes on the Project for the
Engineer’s approval. The surface treatment for each structure shall be one or more of the following:
1. Ceramic wall tiles
2. Textured concrete finish
3. Painting of exposed concrete
4. Fire protection boards
All concrete surfaces not in contact with soil and not shown on the Contract plans to be painted, shall
be sealed as per the requirements of Section 29.6 of Chapter 29, Miscellaneous Items for Structures,
of these standard specifications.
21.21.1.1 Ceramic Wall Tiles

Ceramic wall tiles shall be clay body, heavy duty type with nominal sizes as noted on the Drawings,
and thickness not less than 6mm. The tiles shall have reasonably flat matte surface and bondable
back and shall be UV, and acid/alkali resistant.
Ceramic wall tiles shall contain a wide range of shades and colours matching with the colours shown
on the approved design or pattern. The final shades and colours shall be selected by the Engineer
and approved by the Owner. The surface finish of all the selected shades and colours shall be
uniform and consistent unless otherwise required by the Engineer.
Where required, the Contractor shall cut tiles to achieve the required design or pattern approved by
the Owner. Cutting shall be by water jet cutting or another approved technique.
Final colours shall be selected by the Engineer, installed at locations indicated on the Contract plans
and as directed by the Engineer. Five full size sample units of each of the selected colours and
representative of the anticipated shade range of each colour shall be submitted to the Engineer for
approval. Upon delivery, all tiles furnished shall be inspected by the Engineer and shall match the
previously approved samples within the approved shade range. Tiles outside the approved shade
range will be rejected, removed from the job site, and replaced with approved material at no
additional cost to the Owner.
a. Sampling, Inspection and Test Procedures for Tiling

In addition to the visual colour inspection specified above, the sampling, inspection, and test
procedures and the basis for acceptance and rejection shall be as specified hereinafter.
Page 21-85
1. Samples
Samples of tile for test purposes shall be selected by the testing laboratory's inspector at the place
of manufacture. Each sample shall consist of 5 tiles taken at random from each manufactured lot of
8,000 units, furnished at the Contractor's expense. No tile from any lot shall be shipped from the
point of manufacture until the samples from that lot have successfully passed all tests. If a sample
fails to meet the requirements and a maximum of two additional samples also fail, the lot shall be
rejected. Tile which has been rejected at the place of manufacture shall not be shipped to the work
site, and any tile which may be rejected at the work site shall be promptly removed from the site.
Such rejected tiles shall not be resubmitted for inspection or tests.
2. Certification of Tests
Tests shall be performed by an engineer approved independent testing laboratory at the Contractor's
expense. The Contractor shall submit duplicate certified reports to the Engineer. Such test reports
shall clearly identify the tile tested and the boxed tiles represented by the tile tested, which shall be
clearly identified.
3. Inspection
Tile samples shall be carefully inspected for compliance with dimension requirements specified
herein. The backs shall be free from glaze, glaze sheen or film. The edges shall be reasonably free
from a glaze coating and shall not have drops or globules exceeding 0.4mm thickness. The body
shall be free from concave warpage exceeding 0.2 of one percent of the diagonal of the rectangle
and shall be free from convex warpage 0.3 of one percent of the diagonal. They shall be free from
wedging or crooked edges exceeding 0.5 of one percent. Tiles shall also be free from other
imperfections such as pressing cracks, dents, swelling, and chipping. The glazed surface shall be
smooth, easily cleaned, and free from all imperfections or defects such as waviness, pinholes,
specks, spots, blisters, feathering, crawling, crazing, scumming, discolouration, or sanding to an
extent which would affect the appearance of the tile.
4. Absorption Test
A sample lot of tiles shall be dried in an oven for 2 hours at 100°C, cooled to room temperature, and
weighed separately on a scale sensitive to 0.5 gram. The dry samples shall then be placed in water
at a temperature of 15 to 30°C. The tile samples shall be boiled in water for two hours and permitted
to cool gradually to within 15 to 27°C. The samples shall be removed from the water 24 hours after
the initial immersion, their surfaces wiped dry with a clean damp cloth, and the tiles quickly weighed
separately. The percent absorption of each sample shall be calculated on the basis of its dry weight.
The average water absorption of the 5 samples tested shall not exceed 2 percent. The water
absorption of any individual sample shall not exceed 2.75 percent.
5. Crazing Test
An autoclave with sufficient capacity to contain a sample lot of tiles shall be used. The apparatus
shall be equipped with a safety valve, blow-off valve, pressure gauge whose accuracy is within 2
percent of the scale range, and a burner of sufficient capacity to ensure a constant steam pressure.
A sufficient amount of water shall be placed in the autoclave so that after a one-hour test at 1.38
MPa steam pressure, a slight excess of water will remain. A sample lot of tiles shall be loosely placed
on edge in a suitable wire container above the water line within the autoclave at room temperature.
The autoclave head shall be securely fastened in place. The water in the bottom of the autoclave
shall be heated from an external source. The blow-off valve shall be kept open until steam begins to
escape, thereby expelling most of the air. After closing the blow-off valve, the water shall be kept
boiling and the steam pressure increased at a uniform rate until 1.38 MPa of pressure is reached
within a period not exceeding one hour. Sufficient heat shall be applied to maintain constant steam
pressure of 1.38 MPa for an additional hour. The burner shall be shut off and the steam pressure
immediately released by opening the blow-off valve. The autoclave head shall be loosened but not
removed until the samples have cooled slowly to room temperature in a period not less than one
hour. The samples shall then be removed and a liquid dye rubbed on their surfaces to aid in the
Page 21-86
detection and examination for failure. After being subjected to 5 consecutive cycles of the foregoing
crazing test, the sample lot tested shall show no crazing, chipping, spalling, or cracking of either the
body or glaze. The glazed surface of the tile shall show no permanent clouding, dulling, or pitting.
Slight dull streaks will be permitted, provided they do not comprise more than 20 percent of the
glazed surface area.
6. Thermal Shock Test

A sample of tiles shall be placed in an oven at room temperature. The temperature within the oven
shall be uniformly raised to 110o C, in a period of one hour after which the tiles shall be removed
from the oven and immediately plunged into a mixture of ice and water having a temperature of not
more than two degrees C. At the end of 10 minutes the tiles shall be removed from the water mixture
and a liquid dye applied upon the glazed surfaces and bodies to aid in the detection and examination
of failures. After being subjected to 5 consecutive cycles of the foregoing thermal shock test, the
sample lot shall show no crazing, chipping, spalling, or cracking of either the body or glaze.
7. Weather Test
A sample lot of tiles shall be placed in water at room temperature. The water shall then be boiled for
a period of 2 hours and permitted to cool gradually to room temperature. The tiles shall then be
removed from the water and their surfaces wiped dry with a clean damp cloth. Immediately thereafter
they shall be placed in a freezing chamber (not immersed in water) for a period of 4 hours. The
freezing chamber shall be maintained at a temperature of -12o C. The tiles shall then be immediately
immersed in water at room temperature. After the tiles have completely thawed in the water they
shall be removed, their surfaces wiped dry with a clean, damp cloth and a liquid dye rubbed upon
their surfaces. After being examined, the tiles shall again be immersed in water until such time as is
convenient to again place them in the freezing chamber for the additional cycles of the weather test.
After being subjected to 5 consecutive cycles of the foregoing weather test, the 5 samples tested
shall show no crazing, chipping, spalling, or cracking of either the body or glaze.
8. Glaze Hardness Test

A sample lot of tiles shall be used in the glaze hardness test utilizing Mohs Scale of Minerals. A piece
of mineral having a hardness of 4 as measured by Mohs Scale shall be slowly drawn across the
glazed surface of the tiles with a steady, uniform pressure approximately 11.3 kg. When subjected
to the above test, the glaze shall not show a scratch.
9. Flexural Strength
When tested according to EN 100 the flexural strength shall be ≥ 27 PMa.
b. Standards and Codes for Tiling

Unless otherwise specified herein, installation procedures for ceramic tiles shall comply with the
current edition of the Tile Council of America (TCA) Installation Guide Handbook, ASTM Standards
listed herein, the American National Standards Institute (ANSI), as endorsed by the tile
Manufacturer, and as listed below:
• ANSI A108.1B-1999
• ANSI A108.5-1999
• ANSI A108.10-1999
• ANSI A108/A118/A136.1-2012
• ANSI A137.1:2008
• ASTM C150 / C150M - 12
• ASTM C207 - 06(2011)
• ASTM C778 - 12
• ASTM C126 - 12
• ASTM C499 - 09
• ASTM C627 – 10
Page 21-87
c. Submittals for Tiling

The Contractor shall submit shop drawings to the Engineer showing, in detail the dimensions,
sections, jointing, anchoring devices, and tile setting numbers. No final sizing or finishing shall be
done until the shop drawings for that part of the work have been approved. Typical sections of the
wall shall be included on the shop drawings showing all configurations to be utilized on the walls.
Also full size details of perimeter terminations and details of joint conditions at concrete structural
wall expansion joints as well as at intermediate control joints in tile field between wall expansion
joints shall be shown.
The Contractor shall submit, for selection by the Engineer, samples of available stock tile colours in
the size and face finish specified, and available stock shades of tile grout compound and expansion
joint and control joint sealant proposed for use. After selection by the Engineer, the Contractor shall
prepare a site mock-up for review.
The Contractor shall submit for approval, as applicable, three samples for each of the following:
1. Waterproofing and anti-fracture membrane
2. Latex liquid, one-half litre with manufacturer's data
3. Dry set mortar compound, one kilogram
4. Dry set tile grout, one kilogram
Also, the Contractor shall submit the following:
1. A detailed method statement for tile fixing with specific Manufacturer’s recommendations.
2. Certified copies of results of tests performed on the facing tile as specified hereinafter.
d. Delivery, Storage, and Handling for Tiling

Where applicable, the Contractor shall deliver the materials in original unopened containers with
labels legible and intact, identifying brand name and contents. Manufactured mortars, additives, and
grouts shall bear hall-marks certifying compliance with specified standards. Materials shall be stored
under cover in a manner to prevent damage and to keep all material dry.
e. Site Conditions for Tiling

The Contractor shall adapt techniques approved by the Engineer to ensure that storage, handling,
and execution methods suit the environmental conditions that are encountered at the site and cause
no damage to the products or to the performance of the products in use. The Contractor shall follow
the recommendations of the product Manufacturers for storage of their products on site.
Environmental conditions shall include, but shall not be limited to, ambient temperature, humidity,
excessive sand/dust laden winds moisture in the air and on the products and surfaces with which
they are in contact, moisture content of the products and materials with which they are in contact,
and temperature of the product and the materials with which they are in contact.
f. Sealing for Tiling

The joints to be sealed shall be raked out free of mortar and grout compounds, dust and other foreign
material. The joints in contact with the sealant shall be primed or surface conditioned if
recommended by the sealant Manufacturer. A joint backer rod of proper diameter for the joint width
and to the depth recommended by the sealant Manufacturer shall be installed to provide the proper
sealant depth for the product used. Proper sealant as specified for the different joint widths shall be
applied, in a continuous operation, using positive pressure adequate to properly fill and seal the joint
against the backer rod and joint surfaces. The joints shall be lightly tooled to a smooth, slightly
concave surface. Surfaces adjacent to the sealant shall be protected by an approved means and
misplaced sealant removed from surfaces outside the recess provided for the sealant.
g. Cleaning for Tiling

Tiles shall be cleaned as the work progresses, and tile setting and grouting material shall be
prevented from accumulating on the tile faces. The area of the work shall be kept clean and all
cuttings, droppings and general debris shall be removed. Upon completion and curing of sealant
Page 21-88
material, the tiles shall be washed down with a solution of detergent and water only, using soft fibre
brushes and clean cloths. No acids or metal tools of any kind shall be used. The tile surface shall be
rinsed with clean water and wiped dry with clean, soft cloths.
21.21.1.2 Textured Concrete Finish

Textured architectural concrete surfaces shall be as indicated on the Contract drawing, or as directed
by the Engineer, and shall be formed using proprietary architectural form liners.
21.21.1.3 Painting of Exposed Concrete

The surface preparation and painting of the exposed surfaces of the structures shall be as indicated
on the Contract drawings, as specified herein, and as directed by the Engineer.
Painting of exposed concrete shall comply with the requirements of Section 24.7 of Chapter 24,
Painting, of these Standard Specifications.
21.21.1.4 Fire Protection Boards

This section includes, but is not limited, to the supply and installation of fire boards to provide fire
protection to the tunnel/underpass ceiling and critical areas of the side walls, as shown on the
Contract plans, including fixing screws and anchors, and all accessories, to prevent the concrete
spalling in the event of a fire.
a. Tolerances
Fire protection boards shall be installed within 3 mm of the dimensioned height above the finish floor
level at any location, and shall be level within a maximum tolerance of 3 mm in 3 meters. Each
individual component shall have length and width tolerance of ± 1 mm in 2 meters and thickness
tolerance of ± 0.5 mm in 20 millimeters.
b. Quality Assurance
The installation of the fire boards shall be performed by a firm who has adequate equipment and
skilled mechanics to perform it expeditiously, and is known to have been responsible for satisfactory
installations similar to that specified during a period of at least five years.
c. Submittals
The Contractor shall submit shop drawings and material submittals showing, but not limited to,
details of all materials, boards layout, and the fixing screws and anchors layout with their type and
weight supported. A 600 mm x 600 mm sample of the fire board, and samples of screws and anchors,
shall be submitted to the Engineer for approval.
d. Materials
The following requirements are for the fire boards and their fixing system to the concrete. The fire
boards shall have a minimum two (2) hour fire rating as measured against the Rijkswaterstaat (RWS)
time-dependent curve. The temperature at the contact between the concrete and the fire board shall
not exceed 380o C and the temperature of the reinforcement within the structure shall not exceed
250o C. The thermal performance of the fire protection system shall be such that spalling of the
concrete is prevented. A fire test report of a certified test laboratory shall be submitted by the board
manufacturer. The test report shall describe fire test in which boards are tested on a similar concrete
surface. Extrapolations on the basis of other test reports are not permitted. The fire boards shall be
noncombustible in accordance with ASTM E136 - 12, and/or as defined in EN 13501, and shall meet
the requirements of NFPA 502 with a melting point of not less than 1350o C. It shall not produce toxic
smoke or fumes under fire exposure in accordance with ASTM E84 - 12b or equivalent international
standards. The complete fire protection system shall be designed to withstand a maximum wind
speed through the tunnel/underpass of 12m/s.
Page 21-89
e. Site Conditions
The Contractor shall adapt techniques specified by the manufacturer and approved by the Engineer
to ensure that storage, handling, and execution methods suit environmental conditions that are
encountered at the site, and cause no damage to the products or to the performance of the products
in use. The Contractor shall follow the Manufacturer’s recommendations for storage of their products
on site. Environmental conditions shall include, but shall not be limited to, ambient temperature,
humidity, moisture in the air and on the products and surfaces with which they are in contact, and
temperature of the products and the materials with which they are in contact.
f. Products
Where indicated on the Contract plans, the system shall consist of light weight boards complete with
all accessories, fixing screws and anchors, and other standard metal accessories of strength and
design compatible with Lost Formwork method and system specified by the Manufacturer. The board
thickness shall not exceed 270mm and shall be as recommended by the manufacturer to meet the
requirements of the relevant supporting fire test. All fixings used to secure the boards to the structure
shall be Stainless steel as follows. For boards fixed as “Lost Formwork” screws shall be stainless
steel Grade 304 or A2 (1.4567). For boards “Post Fixed” anchors shall be stainless steel Grade 316
or A4 (1.4401). The complete fixing and anchoring system shall be such that, when used in practice,
will not fail or collapse during tunnel/underpass operation and during a fire. The fixing details shall
have an adequate level of redundancy to prevent any failure during its service life, as recommended
by the manufacturer and as approved by the Engineer.
g. Execution
Prior to installation of the fire protection system, the Contractor shall prepare a complete mock-up
(approximately 2.5m x 2.5m) for the Engineer’s approval. The Contractor shall coordinate the
installation of the fire boards specified in this article with that of other sections and articles. Adequate
preparation shall be made for attachment of fixing screw and anchors. Provision shall be made for
support and incorporation of flush-mounted and recessed service components. The fire protection
system shall be installed in accordance with the Manufacturer’s recommendations and as approved
by the Engineer. Where boards are to be installed at the concreting stage they shall be anchored to
the concrete by means of 50mm screws set into the boards prior to concreting. Type of screws and
spacing of same, must be as recommended by the board Manufacturer and in compliance with the
relevant supporting fire test as approved by the Engineer. Where boards are to be fixed to the
finished concrete surface stainless steel anchors are to be used. Size, type and spacing of same to
be as per the board Manufacturer’s recommendation and in accordance with the relevant supporting
fire test, as approved by the Engineer.
h. Extra Stock
The Contractor shall provide 2 percent of the quantity of each specified fire protection board, in each
finish, for extra stock. Extra stock shall be delivered in sealed labeled packages to a location as
directed by the Owner at completion of the maintenance period.
21.21.2 Miscellaneous Materials

Other miscellaneous materials used in conjunction with the surface finishing shall include, but not
be limited to the following.
1. Waterproofing and anti-fracture membrane shall be used in wet tiled areas and shall be thin,
cold applied, load bearing and non-toxic. The waterproof membrane shall be resistant to
urine, dilute acid, alkali, sugar, brine, and food waste products. Reinforcing fabric shall be
nonwoven rot-proof fabric specifically for use with waterproof membrane. All materials shall
be non-toxic, non-flammable, and non-hazardous during storage, mixing, application and
when cured. Waterproofing, crack suppression and anti-fracture membranes shall meet the
following requirements:
Page 21-90
Water Permeability (at 91.2 kPa) Nil
Elongation at break (ASTM D751 - 06(2011)) 40%
Service Temperatures -28° to +137°C
Tensile breaking strength 20.4 MPa
Thickness 0.5mm
Bond strength to concrete 2.4MPa
Resistance to chemicals (90 day immersion):
Brine solution not affected
Sugar solution not affected
Milk not affected
10% Acid not affected
10% Alkali not affected
Rubber solvents or ketones not recommended
Calcium chloride excellent
Aromatic solvents not recommended
Floor tile installation evaluation (ASTM C627 - 10) 900 cycles
Service Rating (TCA) extra heavy duty
2. Cement shall be Portland Cement complying with ASTM C150 / C150M - 12, SRC Type V.
3. Aggregate shall be washed, sharp, natural sand complying with ASTM C144 - 11. Rounded
shape sand will not be acceptable.
4. The mortar bed shall be 15 mm thick (-2 and +5 mm) with styrene butadiene rubber (SBR)
emulsion additive, and meet the following requirements:
Sand 5.0 mm (max.) Natural As per BS EN 12620:2002+A1:2008
Cement SRC Type V ASTM C150 / C150M - 12
Compressive Strength (MPa) 28 days 27.0 (ASTM C109 / C109M - 11b)
Tensile Strength (MPa) 28 days 2.5 (ASTM C496 / C496M – 11)
With at least 70.0% strength recovery in 7 days
5. Tile adhesive shall be cementitious with a thickness of 3.0 mm  1.0 mm, and meet the
Compressive Strength (MPa) 1 day 5.0
Page 21-91
Tensile Strength (MPa) 3 days 1.5
6. Tile grout shall be cementitious and have the following properties.
Compressive Strength (MPa) 1 day 4.0
Tensile Strength (MPa) 28 days 2.7
7. Joint sealant for application at 15 and 30 mm wide expansion joints shall be a

multicomponent, non-sag expoxidised polyurethane complying with ASTM C920 - 11, Type
II, Class A, 19-GP-24. Sealant for application at 10 mm wide control joints shall be single
component acrylic terpolymer complying with U.S. Federal Specification TT-S-230, non-sag,
19-GP-5b, AAMA 808.3; or single component polyurethane complying with U.S. Federal
Specification TT-S-230, Type II, Class A; or single component silicone complying with U.S.
Federal Specification TT-S-1543, Class A or TT-S-230, Type II, Class A, 19-GP-9M. Colour
shall be dark brown or dark bronze as approved by the Engineer. The Contractor shall provide
joint primer or conditioner if required by the sealant Manufacturer. The Contractor shall
provide expanded, flexible and compressible closed cell polyethylene or butyl rubber backer
rod for all joints to be sealed. Backer rod shall be 12.7 mm in diameter for 10 mm wide joints,
19 mm in diameter for 15 mm wide joints and 38 mm in diameter for 30 mm wide joints.
8. Debonders shall be bituminous or tar based paint (two coats) as per the Manufacturer’s
recommendations and as approved by the Engineer.
9. Wire mesh reinforcement shall be galvanized welded steel wire fabric, 50mm by 50mm, 16
ga. (U.S. Std.).
10. Powder actuated fasteners shall be standard velocity, 31.75mm long by 3.57mm diameter
shank, tempered steel drive pins meeting the requirements of U.S. Federal Specifications
FF-P-395 and QQ-Z-325. The Contractor shall provide 38mm diameter galvanized sheet
steel washers for use with each drive pin in fastening wire reinforcement.
21.22 Scarifying Concrete Bridge Slabs

This work consists of scarifying concrete bridge slabs; removing and disposing of the cuttings
produced in accordance with these specifications; and conforming to the depths, profile grades, and
cross slopes at locations shown in the Contract documents.
21.22.1 Scarifying Equipment

Scarifying equipment provided by the Contractor shall be capable of the following:
• Maintaining accurate depth of cut and slope;
• Accurately establishing profile grades along each edge of the machine;
• Automatically controlling cross slope at a given rate;
• Uniformly varying the depth of cut while the machine is in motion; and,
• Controlling dust created by the cutting action.
Unless otherwise permitted by the Engineer, the Contractor shall provide a machine equipped with
integral loading and reclaiming devices to immediately remove the cuttings from the surface of the
roadway and discharge them into a truck, all in a single operation.
Chipping tools shall be provided by the Contractor to remove concrete in small areas not accessible
to the mechanical scarifier.
21.22.2 Concrete Bridge Slab Construction

Existing concrete slabs shall be scarified to a uniform, rough surface having a chipped appearance
suitable for bonding a concrete overlay. Locations shown in the Contract plans, or as directed by the
Engineer, shall be scarified by the Contractor to the depths shown in the Contract plans. Depths
Page 21-92
shall be measured by the Contractor from the level of the existing surface to the high points on the
scarified surface.
Appropriate care shall be taken by the Contractor to prevent damage to the bridge slab reinforcing
steel, armoured joints, slab joints, drainage hardware, and other appurtenances.
When appropriate, or required, the Contractor shall establish and maintain independent grade
control for concrete scarifying operations.
Chipping tools shall be used to remove concrete in small areas not accessible to the mechanical
scarifier.
Deck surfaces shall be immediately cleaned by the Contractor to remove all cuttings and debris,
which shall be disposed by the Contractor in locations outside the right-of-way (ROW).
21.23 Extending Concrete Structures

This work shall prepare and construct extensions and widenings of existing structures in accordance
with these specifications and conforming to requirements and details shown in the Contract
documents. Materials shall be furnished by the Contractor in accordance with the pertinent
requirements of the following:
• Chapter 5, Reinforcing Steel, of these Standard Specifications; and,
• Chapter 21, Concrete Structures, of these Standard Specifications.
21.23.1 Concrete Structure Construction

Work shall be performed by the Contractor in accordance with Section 4.4 of Chapter 4, Concrete
Works, of these Standard Specifications; and the requirements of this chapter and this section.
Pertinent dimensions and elevations of existing structures shall be verified by the Contractor before
ordering any required materials.
21.23.1.1 Removal of the Existing Structure

Portions of the existing structure shall be removed by the Contractor to the lines and dimensions
shown in the Contract plans, or as directed by the Engineer. These materials shall be disposed of
by the Contractor as shown in the Contract plans, or as directed. Any metal railing shall be removed
without damaging it, and shall be stacked neatly along the ROW, at locations that do not interfere
with traffic or construction or at locations shown in the Contract plans. All removed metal railing
remains the property of the Owner, unless otherwise shown in the Contract plans. Any portion of the
remaining structure damaged as a result of construction shall be repaired by the Contractor.
Explosives shall not be used to remove portions of the existing structure, unless approved in writing
by the Owner. A demolition ball, other swinging weight, or impact equipment shall not be used by
the Contractor, unless show in the Concrete plans. Pneumatic or hydraulic tools shall be used for
final removal of concrete at the break line. Removal equipment shall be used as approved in a
manner not to cause any damage to the remaining concrete.
21.23.1.2 Reuse of Removed Portions of the Structure

All portions of the old structure that shall be incorporated into the extended structure shall be
detached and removed to the lines and details as specified in the Contract plans, or as directed by
the Engineer. Units to be reused shall be moved by the Contractor to new the new location specified
using approved methods. Reinforcement and extension concrete shall be placed according to the
Contract plan details.
21.23.1.3 Breaking Back Bridge Slabs

For bridge slabs and direct traffic slabs of box culverts, the Contractor shall saw the top surface of
the slab along the break line to a depth of 12.5 mm before breaking back. Reinforcements shall not
Page 21-93
be cut at the break line and shall sever the concrete at the break line. During removal of the
designated portion of the existing structure, the Contractor shall not damage the remaining
reinforcement within 1 lap length of the break line.
21.23.1.4 Splicing Reinforcing Steel

New reinforcing bars shall be spliced by the Contractor to exposed bars in the existing structure
using lap splices in accordance with Section 5.5.4 of Chapter 5, Reinforcing Steel, of these Standard
Specifications, unless otherwise shown in the Contract plans. New reinforcing steel does not need
to be tied to the existing steel, where spacing or elevation does not match that of the existing steel,
provided that the lap length is attained. Welding shall be in accordance with Article 5.5.4.2 of Chapter
5, Reinforcing Steel, when welded splices are permitted. Any required dowels shall be installed by
the Contractor in accordance with Section 21.8 and Section 4.4.4 of Chapter 4, Concrete Works, of
21.23.1.5 Concrete Preparation

Concrete surfaces that are in contact with new construction shall be roughened and cleaned by the
Contractor before placing of the forms. These construction joint surfaces shall be prepared in
accordance with this chapter. Roadway slabs shall be finished and cured in accordance with this
chapter.
21.24 Raising Existing Structures

This work consists of raising existing structures in accordance with these specifications and
conforming to requirements and details shown in the Contract plans. Materials shall be furnished in
accordance with the pertinent requirements of the following:
• Chapter 25, Bearing Devices, of these Standard Specifications.
21.24.1 Construction While Raising Existing Structures

Detailed plans to raise the structure shall be submitted by the Contractor. Approval of plans is
required before work may begin. A licensed professional engineer must sign and seal the plans and
the methods, materials, cribbing, falsework or other supports, and equipment proposed shall be
clearly indicated by the Contractor. Any portions of the structure damaged by the raising operation
shall be repaired or replaced by the Contractor. Approval of these plans by the Engineer does not
relieve the Contractor from responsibility for the completion of the work nor from liability for repair or
replacement of damaged portions of the structure due to the methods approved and employed.
21.24.1.1 Preparation of Plans

Loads shall be applied so that the load capacities in bearing, shear, and flexure are not exceeded
for any material or member carrying the load. Jack positions and capacities and temporary hardware
attachments shall be indicated on the plan. Jackings shall be avoided by the Contractor against the
bottom of the slab. A jack with a minimum capacity of two times the dead load shall be used. Traffic
on the structure shall be prohibited until the structure is supported by cribbing, falsework, or the final
supports.
Suitable cribbing, falsework, or other supports shall be provided by the Contractor until the span or
unit is resting on its final supports to prevent the various spans or units from dropping due to jack
failure or other causes during the lifting operation. Supports shall be designed to carry the greater of
the following loads:
• Two times the dead load if traffic is not allowed on the structure; or,
• One and one-quarter times the dead load plus 1.75 times the live load, including impact if the
plans allow traffic on the structure before it is placed on the final supports.
Page 21-94
21.24.1.2 Raising of Spans

Before jacking, the Contractor shall verify that anchor bolts, closed joints, or other appurtenances do
not restrict vertical movement. Spans shall be jacked from the existing bent cap or temporary
falsework, unless otherwise shown on the Contract plans. All anchor bolts shall be loosened and
removed by the Contractor; or shall cut the anchor bolts to allow free vertical movement before
raising. All damaged or cut anchor bolts shall be replaced either by butt welding to existing bolts or
by drilling into the existing concrete cap a minimum of 300 mm and grouting in new bolts. Bent cap
reinforcing steel shall not be damaged when installing new anchor bolts. All damaged or lost anchor
bolt nuts shall be replaced. Welding shall be in conformance with 23.4.11 of Chapter 23, Steel
Structures.
Adequate guides or force shall be provided by the Contractor to ensure vertical lifting and prevent
drifting of the structure during the jacking operation. Pedestals shall be provided as shown in the
Contract plans.
a. Simple Spans with an Expansion Joint in the Deck at Every Bent

Spans shall be raised by jacking, as shown in the Contract plans. All of the beams shall be raised
on one side of the bent simultaneously. Raising one end of a simple span more than 100 mm before
raising the opposite end shall not be allowed.
b. Simple Beam Spans with a Continuous Deck over the Bent

All beams shall be raised on both sides of the bent simultaneously by jacking, according to the
Contract plans. Raising one end of a span more than 50 mm before raising the opposite end of the
span shall not be allowed.
c. Continuous Beams
Units shall be raised by jacking, according to the approved Contract plans. All beams shall be raised
at a single bent simultaneously. Units may be raised incrementally from bent to bent. Raising the
unit more than 50 mm at any bent before raising it at the adjacent bents shall not be allowed.
21.25 Spread Footings

This work shall construct reinforced-concrete spread footing foundations and shall include
dewatering, when necessary; excavating to the required limits; compacting the underlying soil as
required; and constructing seals, when required —in accordance with these specifications and
conforming to requirements and details shown in the Contract documents. Materials shall be
furnished by the Contractor in accordance with the pertinent requirements of the following:
21.25.1 General Requirements for Spread Footings

The Contractor shall meet the following requirements for all spread footings:
• Perform excavations, including the removal of all material, of whatever nature, necessary for
the construction of spread footings. As used herein, the term soil shall constitute any material,
whether soil, rock, or other materials.
• Slope excavations, as required, or support them with sheeting, and shore them to provide a
safe excavation that is adequate for construction purposes and that will adequately protect
any existing adjacent structures.
• Ensure that the foundation soils are firm, stable, and, in the opinion of the Engineer, meet or
exceed the design bearing and compressibility requirements before constructing the footings
or any required seals. Owner may elect to use any type of tests to evaluate the foundation
soils that is appropriate in the opinion of the Engineer. When evaluating the foundation soils,
Page 21-95
the Contractor shall cooperate and assist the Engineer, as necessary, to provide access to
the site.
• Elevations of the bottom of footings or seals or the depth of over-excavation shown in the
Contract plans is approximate and the Engineer may order, in writing, such changes as may
be necessary to secure a satisfactory foundation.
• Place all spread footing concrete in the dry.

Existing structures shall be protected in accordance with Section 1.16.6 of Chapter 1, General
Requirements. Also, if not otherwise provided in the Contract plans, the Contractor shall evaluate
the need for, design, and provide all reasonable precautionary features to prevent damage,
including, but not limited to, the installation of sheet piling, shoring as necessary, maintenance of the
water table beneath such structures as nearly as practical to existing conditions, and monitoring and
controlling vibrations from construction activities including driving of sheeting or from blasting.
21.25.3 Dewatering
Design, installation, and operation of an adequate dewatering system to dewater excavations for
spread footings is the responsibility of the Contractor, which shall use a well point or well system,
and submit a dewatering plan to the Engineer for its records before beginning construction.
Well points or wells shall be used by the Contractor where the piezometric water level is above an
elevation of 0.9 m below the bottom of the excavation. Water tables shall be maintained at 0.9 m or
more below the maximum depth of excavation. Continuous dewatering shall be provided until
completing construction of the footing and backfill the excavation at least 0.9 m above the
piezometric water table elevation. During dewatering operation, the shoring system shall be carefully
monitored until construction is completed and shoring system is no more needed, to avoid any
migration of soil from behind the shoring system to avoid any caving under adjacent locations to
deter the collapse of soil / structures. Dewatering shall continue until the Engineer considers
conditions safe to discontinue dewatering. If a dewatering failure occurs, the Contractor shall assist
the Engineer, as required in determining the effects of such a failure on the foundation soils, and
take whatever corrective measures are required at no additional expense to the Owner. When the
Engineer approves the discontinuing of dewatering, the Contractor shall decrease the rate of
pumping, allowing the water level to rise slowly. Rates measured in metres per hour shall be used
by the Contractor to ensure that the water table is allowed to rise equal to the total number of metres
the water table was lowered, divided by ten hours or a rate of 1 m/hr, whichever is less.
One piezometer well shall be installed by the Contractor approximately every 4.5 m of footing
perimeter. A minimum of two and a maximum of six piezometers shall be provided at locations within
0.6 m from the outside of the footing perimeter. Piezometer wells shall be installed by the Contractor
to a depth at least 3 m below the bottom of footing elevation, or as directed by the Engineer. Water
elevation shall be measured in the piezometer wells prior to excavation and at 12-hour intervals
between excavation and discontinuation of dewatering. Piezometers shall be maintained in working
condition throughout the dewatering process, and the Contractor shall repair or replace them when
damaged at no expense to the Owner.
21.25.4 Excavations
21.25.4.1 Dry Excavations
Dry excavations are excavations that can be completed without the need to lower the piezometric
water level. Dry excavations shall be performed by the Contractor when the piezometric water level
at the time of construction is and, in the opinion of the Engineer, will remain at least 0.9 m below the
bottom of the authorized excavation or over-excavation. It shall be demonstrated by the Contractor
to the Engineer that a stable excavation can be made without dewatering. Adequate provisions shall
be made to divert surface runoff and to collect and remove any water entering the excavation.
Page 21-96
Excavation shall occur to the bottom of the footing, to the over-excavation limits shown in the
Contract plans, or as directed by the Engineer. Any suitable materials shall be saved for backfill.
Areas for the disposal of all unsuitable materials shall be provided by the Contractor, which shall
dispose of them in a satisfactory method. Foundation soils shall be compacted below the footing, as
shown in the Contract plans or described herein before constructing the footing.
21.25.4.2 Dewatered Excavations

Dewatered excavations are excavations made after first lowering the piezometric water level with
well points or wells. Dewatering shall be performed as described in Section 21.25.3, Dewatering.
Excavation shall occur in the dry after lowering of the water table.
When dewatering is required, the Contractor may excavate within 0.9 m of the ground water table
before dewatering begins — if the dewatering system is operating and the Contractor has
demonstrated that the water level has been lowered to and maintained at acceptable limits. Where
large excavations require stage lowering of the water table, and where additional well point systems
are installed at lower elevations, the Contractor may continue excavating as long as the water
elevation is maintained at least 0.9 m below the excavation.
Surface runoff shall be diverted from the excavation. Foundation soils shall be compacted as shown
in the Contract plans or as described herein before constructing the footing.
21.25.4.3 Wet Excavations

Wet excavations are excavations made below the existing water table, without prior dewatering.
When the Contract plans show a cofferdam and seal, the Contractor shall perform the excavation in
the wet. Water levels shall be maintained during excavation at or above the water level outside the
cofferdam.
Seals shall be placed by the Contractor directly upon the foundation soils or rock when using wet
excavations. Foundation soils shall not be compacted for wet excavations. Foundation soils or rocks
shall be disturbed by the Contractor as little as practical. All materials that are determined by the
Engineer to be loose or disturbed before placing the seal concrete shall be removed.
21.25.5 Fill or Backfill

The Contractor shall only use fill or backfill, including over-excavations below the footing that is clean
cohesionless material, free of rubble, debris, or rocks that would prevent uniform placement and
compaction. For backfill materials, the Contractor shall use A-1, A-2, or A-3 materials conforming to
AASHTO M 145-91 (2008), materials as shown in the Contract plans, or materials approved by the
Engineer.
21.25.6 Compaction and Density Requirements

Excavation bottoms shall be compacted by the Contractor with suitable equipment. Soils beneath
footing excavation shall be compacted — whether dug to the bottom of footing or over-excavated —
to a density not less than 95 percent of the maximum density, as determined by AASHTO T180, for
a minimum depth of 60 mm below the bottom of the excavation or to the depth shown in the Contract
plans before backfilling begins. At least one density determination shall be performed by the
Contractor at each footing excavation at a depth of 0.3 m to 0.6 m below the bottom of the excavation.
Backfill shall be compacted by the Contractor in footing excavations that have been over-excavated
in 0.3-m maximum loose lifts to a density not less than 95 percent of the maximum density — as
determined by AASHTO T180 to the bottom of footing elevation. At least one density determination
shall be performed in each lift of backfill at each footing excavation.
For compaction, the Contractor shall use an approved heavy vibratory roller with a static drum weight
of at least 4 tons. Each lift shall be compacted to the required density. Also, the Contractor shall
compact the final lift below the footing with a suitable sled vibratory compactor to remove any upper
disturbance caused by the drum roller. When conditions require use of smaller compaction
Page 21-97
equipment, the Contractor shall obtain the Engineer’s approval for the equipment, and reduce the lift
thickness to achieve the required density.
Backfilling shall be performed by the Contractor to the original ground surface, finished grade, or
subgrade — as required by the Contract plans in the immediate vicinity by approved mechanical
compactors weighing less than 450 kg. Backfill located more than 4.5 m away from the exterior
periphery of the footings may be compacted by the Contractor with heavier compactors. Backfill shall
not be placed on the footings until the Engineer has given permission and until the concrete is at
least seven days old.
21.25.7 Forming
Spread footings shall be formed by the Contractor if it cannot be demonstrated that the natural soil
or rock is strong enough to prevent caving during construction. For forms, the applicable
requirements of Section 1.20 of Chapter 1, General Requirements, shall be met. When forms are
not required, where footing concrete can be placed in dry excavation, the Contractor may omit cribs,
cofferdams, and forms, subject to compliance with the following limitations and conditions:
• Use this procedure only in locations not exposed to view from travelled roadways.
• Obtain required elevations shown in the Contract plans.
• Obtain neat line dimensions shown in the plans.
• Fill the entire excavation with concrete to the required elevation of the top of the footing.
• The Engineer will determine the volume of footing concrete to be paid for from the neat line
dimensions shown in the Contract plans.
21.25.8 Reinforcing Steel Placement

Reinforcing steel for footings shall be placed and fastened by the Contractor according to the
applicable provisions of Section 5.5.2 of Chapter 5, Reinforcing Steel, of these Standard
Specifications.
21.25.9 Concrete Placement

21.25.9.1 Placement
All footing concrete shall be placed by the Contractor in the dry and according to the applicable
provisions of this chapter. Joints shall not be constructed in the footings.
21.25.9.2 Finish
After placing and consolidating the concrete, the Contractor shall strike-off the top surface to the
grades shown in the Contract documents, leaving the surface smooth and free of undesirable
cavities and other defects. A special finish shall not be provided by the Contractor unless the footing
will be visible after construction, in which case, the applicable provisions of this chapter shall be met.
21.25.9.3 Curing
Continuous-moisture-curing for footings shall be provided by the Contractor. For cover materials, the
Contractor shall use clean sand, sawdust, or other materials meeting the approval of the Engineer.
Continuously the cover materials shall be wetted for a period of 72 hours.
21.26 Steps
Steps, ramps, or other grade adjustment-type concrete works shall be constructed where final
sidewalk grades are too low or too high to match existing plot entries, building floor levels or other
existing paving or sidewalk areas. When required, each site shall be designed site-specific by the
Contractor, and shown in the plans and sections in the shop drawings for approval by the Engineer.
This section covers any concrete work required to match paved pedestrian areas to existing
Page 21-98
pedestrian areas or other features that require some type of concrete grade adjustment structure
such as steps, ramps, barriers or low retaining walls.
Although each site is to be designed site-specific, steps shall be maintained as close as possible to
the ideal dimensions of 30-cm tread width to 15-cm rise, with the tread sloping down 12.5 percent
from inner to outer edges, and the riser sloping inwards 14.3 percent from top to bottom. Step edges
shall also be rounded 1.5 cm and provided with a nonslip surface by lightly brooming the finished
tread surface lengthwise, all as approved by the Engineer. Steps, ramps, and other concrete grade
adjustment works shall be reinforced with minimum shrinkage and cracking reinforcement, or to the
reinforcement percentage required for structural load bearing capacity as per American Concrete
Institute (ACI) codes, as required and approved by the Engineer.
21.26.1 Materials for Steps

All reinforcing steel and concrete shall comply with the requirements under Chapter 5, Reinforcing
Steel, of these Standard Specifications; and this chapter. The class of concrete shall be C35/20.
Reinforcement shall be Grade 60 rebar or welded wire mesh complying with Section 5.3 of Chapter
5, Reinforcing Steel, of these standard specifications. Concrete surface sealants shall meet the
requirements of Section 29.6 of Chapter 29, Miscellaneous Items for Structures, of these standard
specifications.
21.26.2 Steps Construction

All steps, ramps, and other concrete works under this section shall be cast-in-situ. Forms shall be
smooth and tight-fitting, which can be held rigidly to line and grade during placing of concrete, and
which can be readily removed without injuring the green concrete. All form detail work shall comply
with the requirement as specified in Section 1.20 of Chapter 1, General Requirements.
Expansion and contraction joints shall be placed in all concrete sections larger than 3 m in any one
direction, and between existing concrete works and the new concrete. Where steps and ramps abut
existing concrete grade structures, the new concrete shall be tied to the existing concrete by shear
dowels drilled and epoxied into the existing concrete face, which shall be used where the possibility
of excessive load transfers may exist or where the foundation for the steps or ramps is of marginal
support capability.
Tread surfaces of steps and ramps shall be finished with at least two passes of a trowel to a smooth,
even finish, then roughed up for a nonslip surface by lightly brooming 90 degrees to the travel axis
of the ramp or steps with a wet straw broom. Step riser faces, sidewalls, and fronts of barriers and
retaining walls shall receive a Class 2, Rubbed Finish. In some instances, the steps or ramp treads
may be faced with Quarry Tiles, in which case the tread shall be finished to a level surface with the
Quarry Tiles grouted into place — as per the requirements of Article 7.6.2.1 of Chapter 7, Incidental
construction, of these Standard Specifications. Exposed surfaces of all steps, ramps, and other
concrete grade adjustment structures shall be protected by a clear penetrate sealer — as per the
requirements of Section 29.6 of Chapter 29, Miscellaneous Items for Structures, of these standard
specifications.
21.27 Concrete for Minor Structures

This work shall construct minor concrete structures, such as pipe culvert headwalls, wing-walls and
aprons, spillways, slope paving, sidewalks, curbs, and other minor concrete structures in accordance
with these specifications and in reasonable close conformity with the lines, grades, details and
locations shown on the Contract plans or established by the Engineer.
21.27.1 Materials for Minor Structures

All minor concrete structure materials shall conform to the requirements contained in Chapter 4,
Concrete Works, of these Standard Specifications; and this chapter.
Page 21-99
21.27.2 Composition of Concrete for Minor Structures

Concrete for minor structures shall conform to the requirements of Chapter 4, Concrete Works, of
these Standard Specifications; and this chapter. Before batching concrete, the Contractor shall
submit the proposed concrete proportions for approval. As a minimum, the following shall be
submitted:
• Type and sources of all material proposed for use.
• Material certification for all material proposed for use including cement.
• Saturated surface dry weight of the fine and coarse aggregate per cubic metre of concrete.
• Gradation of fine and coarse aggregate.
• Weight of mixing water per cubic metre of concrete.
• Weight of cement per cubic metre of concrete.
For structural applications, Class C35/20 concrete complying with Chapter 4, Concrete Works, of
these Standard Specifications, will be acceptable as an approved mixture with appropriate
certification.
Preparatory work shall be performed by the Contractor in accordance with the applicable
requirements of Chapter 1, General Requirements, and Chapter 2, Earthworks, of these Standard
Specifications, for the structure excavation and backfill. Forms shall be designed and constructed by
the Contractor in accordance with Section 1.20.8 of Chapter 1, General Requirements. Forms shall
be free of bulge and warp and allow for removal without injuring the concrete. Reinforcing steel shall
be placed in accordance of Chapter 5, Reinforcing Steel, of these Standard Specifications. When
concrete contains a retarding admixture, fly ash, or other pozzolan replacement for cement, forms
shall be designed for a lateral pressure equal to that exerted by a fluid having a mass of 2,400 kg/m3.
Wood, metal, or other suitable material shall be used. Forms shall be kept clean and coated with
form release agent or form oil before placing concrete.
21.27.3 Placing of Concrete

Forms and foundations shall be moistened immediately before placing concrete. Concrete shall be
discharged within the proper time limit specified in Chapter 4, Concrete Works, of these Standard
Specifications.
Concrete shall be handled and placed to avoid segregation in accordance with Section 21.7,
Handling and Placing Concrete. Aluminium pipe for transporting or placing concrete shall not be
used. Intervals between batch deliveries for a single pour on a structure shall not exceed 20 minutes,
unless suitable concrete admixtures are used. The formation of cold joints shall be strictly avoided.
Placement of concrete shall conform to the requirements of Section 21.6, Protection of Concrete,
when there is a forecast of air temperatures above 32 degrees Celsius.
Water shall not be supplied to plastic concrete finishes during finishing operations.
21.27.4 Curing of Concrete

Minor concrete shall be cured a minimum of seven days. Curing shall be according to Section 21.11,
Curing Concrete.
21.27.5 Acceptance
Concrete for minor structures will be subject to acceptance or rejection by visual inspection and
review of the load certification at the placement site. Re-tempering of concrete shall not be permitted.
Quality control shall be as per Chapter 4, Concrete Works, of these standard specifications.
Page 21-100
INDEX
abutments, 21-46, 21-73 couplers, 21-67, 21-79, 21-82

Accessories, 21-11 crack controlling additive, 21-28
additional testing, 21-10 cracks, 21-22, 21-24, 21-39, 21-61, 21-66, 21-
anchorages, 21-50, 21-55, 21-67, 21-70, 21- 71, 21-73, 21-84, 21-86
79 culverts, 21-1, 21-9, 21-12, 21-24, 21-93
anodic, 21-16 dead-load deflection, 21-66
Approach slabs, 21-27 deck girder spans, 21-23
Arch ring, 21-23 deck panels, 21-27, 21-50, 21-51, 21-54, 21-
architectural rustication, 21-46 55, 21-63, 21-66
armour, 21-32, 21-33, 21-35 defects, 21-33, 21-45, 21-61, 21-66, 21-74,
autoclave, 21-86 21-86, 21-98
backfill, 21-75, 21-96, 21-97, 21-100 Design calculations, 21-78
base slab, 21-24, 21-33, 21-36, 21-73 Dewatered excavations, 21-97
beams, 21-20, 21-23, 21-27, 21-49, 21-50, 21- dimensional tolerances, 21-51, 21-61, 21-62,
55, 21-62, 21-95 21-63, 21-64, 21-65
Bituminous protective coating, 21-67 Dry excavations, 21-96
Blinding concrete, 21-27, 21-28 ducts, 21-59, 21-66, 21-67, 21-68, 21-69, 21-
bonding agents, 21-11, 21-55, 21-56, 21-57, 74, 21-77, 21-78, 21-79, 21-83
21-58, 21-59 embedded items, 21-11, 21-48, 21-69, 21-77
bridge decks, 21-1, 21-20, 21-21, 21-37, 21- enclosures, 21-20
38, 21-39, 21-41, 21-42, 21-44, 21-71, 21- environmental conditions, 21-20, 21-88, 21-90
75 epoxy-coated, 21-11, 21-25
bridges, 21-1, 21-9, 21-12, 21-23, 21-37, 21- equipment loads, 21-75
38, 21-40, 21-44, 21-76, 21-77, 21-84 existing concrete, 21-32, 21-95, 21-99
brooming, 21-40, 21-41, 21-49, 21-99 Existing slabs, 21-27
burlap, 21-40, 21-42, 21-45 existing structures, 21-93, 21-94
camber, 21-27, 21-38, 21-40, 21-49, 21-54, expansions joints, 21-37
21-61, 21-63, 21-64, 21-65, 21-66, 21-68, exposed slabs, 21-20
21-76, 21-78 falsework, 21-19, 21-23, 21-38, 21-39, 21-66,
cathodic, 21-16 21-68, 21-71, 21-78, 21-94, 21-95
Cementitious materials, 21-9, 21-10 Falsework, 21-1, 21-68
Ceramic, 21-2, 21-7, 21-85 fascia elements, 21-55
Certificates, 21-67 fascia members, 21-10
chairs, 21-11, 21-60 filled joints, 21-32, 21-35
chemical admixtures, 21-9 fine aggregate, 21-9, 21-18, 21-72
Coarse aggregate, 21-10 fire protection, 21-89, 21-90
coated reinforcement, 21-11 flexural strength, 21-33, 21-36, 21-57, 21-74,
columns, 21-22, 21-50 21-87
compaction, 21-29, 21-60, 21-61, 21-69, 21- fog sprayers, 21-21
97 footings, 21-22, 21-24, 21-73, 21-95, 21-96,
Concrete classes, 21-9 21-98
concrete placement plan, 21-22 frequency, 21-10, 21-17
Concrete sequence placement, 21-23 galvanic corrosion, 21-11
concrete surface, 21-20, 21-26, 21-36, 21-38, gel time, 21-56, 21-59
21-39, 21-41, 21-43, 21-44, 21-49, 21-59, geometric control, 21-76
21-68, 21-73, 21-79, 21-89, 21-90 girders, 21-23, 21-44, 21-49, 21-52, 21-53, 21-
construction joints, 21-22, 21-23, 21-31, 21- 54, 21-55, 21-60, 21-63, 21-68, 21-69, 21-
32, 21-36, 21-37, 21-42, 21-81 71, 21-76
contraction joints, 21-32, 21-33, 21-34, 21-39, grout, 21-9, 21-10, 21-25, 21-32, 21-35, 21-37,
21-99 21-45, 21-50, 21-51, 21-54, 21-55, 21-67,
copper, 21-35 21-70, 21-71, 21-73, 21-74, 21-75, 21-78,
core temperature, 21-28, 21-29 21-79, 21-88, 21-92
Page 21-101
grouting, 21-66, 21-67, 21-70, 21-71, 21-75, protection, 21-16, 21-19, 21-20, 21-21, 21-22,
21-79, 21-81, 21-88, 21-95 21-36, 21-44, 21-55, 21-77, 21-83, 21-85,
Grouting, 21-70 21-89, 21-90
hardboard, 21-33, 21-36, 21-74 pumps, 21-25, 21-26
high performance, 21-28 railing, 21-2, 21-93
high temperatures, 21-21, 21-43 ramps, 21-98, 21-99
high-performance concrete, 21-41 reinforced-concrete bridge slabs, 21-26
high-strength, 21-11 Re-injectable, 21-36
hold-down devices, 21-11 retaining walls, 21-46, 21-73, 21-99
honeycombed areas, 21-66 risks, 21-29
horizontal joints, 21-31 Rock surfaces, 21-24
hot-dipped galvanized, 21-11 sag, 21-27, 21-56, 21-92
immersion-type vibrators, 21-25 salt water, 21-21, 21-22
inaccessible, 21-39 Sampling, 21-2, 21-4, 21-16, 21-17, 21-51, 21-
incremental launching, 21-84 85
independent laboratory, 21-10, 21-56, 21-75 scarifying, 21-92, 21-93
injection, 21-37, 21-70, 21-84 Screed concrete, 21-28
keys, 21-24, 21-31 sealants, 21-32, 21-33, 21-35, 21-99
Laboratory tests, 21-12 segmental construction, 21-76, 21-79, 21-80
Launching forces, 21-84 settlement, 21-16, 21-23, 21-24, 21-38, 21-39,
lifting devices, 21-11, 21-52, 21-79, 21-83 21-82
Lifting devices, 21-52 shoring, 21-68, 21-96
Liquid concrete admixture, 21-16 Shrinkage, 21-10, 21-18
low humidity, 21-21 sidewalks, 21-35, 21-41, 21-99
low-alloy carbon steel, 21-11 skid-resistant surface, 21-37
low-density, 21-9, 21-12 slip form, 21-2
masonry plates, 21-41, 21-74 smoothness, 21-39, 21-40, 21-61, 21-64, 21-
Mass concrete, 21-28 65, 21-66, 21-72
match-cast segments, 21-56, 21-76, 21-80, solvent, 21-55
21-83 Spacers, 21-11
mineral admixtures, 21-9, 21-15, 21-44 spread footing, 21-95, 21-96
minor concrete structures, 21-99 stainless steel, 21-11, 21-36, 21-90
miscellaneous, 21-1, 21-9, 21-12, 21-81, 21- stainless-steel, 21-11, 21-51
90 standard deviation, 21-13
mix designs, 21-10, 21-14 standard test cubes, 21-14
mortar, 21-9, 21-10, 21-22, 21-24, 21-25, 21- Stay-in-place (SIP) form, 21-66
35, 21-36, 21-39, 21-40, 21-41, 21-45, 21- steel shapes, 21-11, 21-71
46, 21-49, 21-54, 21-55, 21-66, 21-70, 21- Steel shims, 21-51
71, 21-74, 21-75, 21-79, 21-88, 21-91 Steps, 21-98, 21-99
mortar-tight, 21-49, 21-54, 21-71, 21-75 straightedge, 21-39, 21-40, 21-41, 21-61, 21-
natural sand, 21-9, 21-10, 21-91 62
non-shrink, 21-10, 21-51, 21-74 strands, 21-19, 21-50, 21-51, 21-60, 21-61,
Open time, 21-56, 21-57 21-62, 21-65, 21-66, 21-67, 21-70
pedestrian, 21-41, 21-98 Stressing operations, 21-69
permanent, 21-27, 21-77, 21-79, 21-80, 21- Stuttgart, 21-16
81, 21-82, 21-87 substructure, 21-22, 21-23, 21-73, 21-76
pier shafts, 21-2 sulphate soils, 21-22
piers, 21-44, 21-46, 21-73, 21-82, 21-84 sulphate water, 21-22
pigments, 21-43, 21-55 superstructure, 21-23, 21-67, 21-69, 21-71,
pipe sleeves, 21-11 21-73, 21-76, 21-77, 21-78, 21-79, 21-80,
plant batches, 21-12 21-81, 21-82
Post-tensioned, 21-66, 21-67 supports, 21-11, 21-38, 21-49, 21-52, 21-60,
Pre-moulded, 21-32 21-78, 21-80, 21-94
prestressed members, 21-10, 21-44, 21-49, surface mortar, 21-20
21-61 surface treatment, 21-85
prestressing forces, 21-19 T-beam, 21-23
Page 21-102
Temperature deflection tests, 21-58 variations, 21-13, 21-14, 21-41

test specimens, 21-9, 21-10, 21-26, 21-57, 21- Vehicles, 21-75
58, 21-60 vertical joints, 21-31
testing, 21-9, 21-10, 21-16, 21-17, 21-19, 21- Vibrators, 21-25
27, 21-40, 21-48, 21-51, 21-56, 21-57, 21- Water absorption, 21-10, 21-18
58, 21-60, 21-71, 21-86 waterproof, 21-19, 21-35, 21-36, 21-42, 21-43,
texture, 21-12, 21-40, 21-41, 21-45, 21-46, 21- 21-51, 21-74, 21-90
49, 21-54, 21-55, 21-72, 21-73, 21-74, 21- water-reducing admixtures, 21-15
75 Waterstops, 21-32, 21-33, 21-34, 21-35, 21-
thermal control, 21-28, 21-29 36
threaded inserts, 21-51 water-tightness, 21-1
ties, 21-11, 21-45, 21-49, 21-50 Welding electrodes, 21-12
time-dependent, 21-76, 21-89 Wet excavations, 21-97
trial batches, 21-12 windbreaks, 21-20
tunnels, 21-1 wingwalls, 21-46, 21-73
underpasses, 21-1 wires, 21-70, 21-84
underwater, 21-25, 21-26 Workability, 21-12
Page 21-103

PART 2
ROAD STRUCTURES
CHAPTER 22 - PRESTRESSING SYSTEMS
DOCUMENT NO: TR-

FIRST EDITION
JANUARY 2018
Chapter 22: Prestressing Systems

TABLE OF CONTENTS
List of Figures ................................................................................................................................. iii
List of Tables .................................................................................................................................. iii
22 Prestressing Systems ...................................................................................................... 22-1
22.1 Prestressing Definitions ............................................................................................... 22-1
22.2 Details of Prestressing Design ..................................................................................... 22-1
22.4 Prestressing Quality Assurance ................................................................................... 22-5
22.4.1 Qualifications of Prestressing Subcontractor ......................................................... 22-5
22.4.1.1 Precast Prestressed Girder ............................................................................ 22-6
22.4.1.2 Post-tensioned Concrete ............................................................................... 22-6
22.4.1.3 Supervision of Prestressing Operations ......................................................... 22-6
22.5 Supplementary Drawings ............................................................................................. 22-7
22.5.1 Working Drawings ................................................................................................. 22-7
22.5.2 Shop Drawings ..................................................................................................... 22-7
22.5.3 Composite Placement Drawings ........................................................................... 22-8
22.6 Submittals .................................................................................................................... 22-8
22.6.1 Qualification Details .............................................................................................. 22-9
22.6.2 Working Drawings................................................................................................. 22-9
22.6.3 Certificates............................................................................................................ 22-9
22.6.4 Test Reports ......................................................................................................... 22-9
22.7 Materials for Prestressing Operations .......................................................................... 22-9
22.7.1 Prestressing System Materials .............................................................................. 22-9
22.7.1.1 Post-tensioning Systems ............................................................................... 22-9
22.7.1.2 Prestressing Steel and Anchorage ............................................................... 22-10
22.7.1.3 Post-tensioning Anchorage and Couplers .................................................... 22-11
22.7.2 Grout .................................................................................................................. 22-14
22.7.2.1 Approval ...................................................................................................... 22-14
22.7.2.2 Mixing .......................................................................................................... 22-14
22.7.2.3 Grout Physical Properties ............................................................................ 22-15
22.7.3 Ducts for Prestressing Operations ...................................................................... 22-17
22.7.3.1 Metal Ducts for Prestressing ........................................................................ 22-18
22.7.3.2 Plastic Ducts for Prestressing ...................................................................... 22-18
22.7.3.3 Duct Area .................................................................................................... 22-19
22.7.3.4 Duct Fittings................................................................................................. 22-19
22.8 General Prestressing Requirements .......................................................................... 22-19
22.8.1 Concrete Strength............................................................................................... 22-20
22.8.2 Prestressing Equipment ...................................................................................... 22-20
22.8.2.1 Cutting ......................................................................................................... 22-20
22.8.2.2 Sequence of Stressing ................................................................................. 22-21
22.8.2.3 Measurement of Stress ................................................................................ 22-21
22.8.3 Pretensioned Members ....................................................................................... 22-21
22.8.3.1 Pre-tensioning Requirements....................................................................... 22-21
22.8.3.2 Placement of Prestressing Steel .................................................................. 22-23
22.8.3.3 Releasing of Prestressing Steel ................................................................... 22-24
22.8.4 Post-tensioned Members .................................................................................... 22-24
22.8.4.1 Post-tensioning Requirements ..................................................................... 22-24
22.8.4.2 Placement of Ducts...................................................................................... 22-24
22.8.4.3 Placement of Concrete ................................................................................ 22-26
22.8.4.4 Placement of Post-tensioning Steel ............................................................. 22-27
22.8.4.5 Placement of Anchorage.............................................................................. 22-28
Page i
CHAPTER 22: PRESTRESSING SYSTEMS First Edition -January 2018
22.8.4.6 Record of Stressing Operation ..................................................................... 22-28

22.8.5 Identification and Testing .................................................................................... 22-29
22.8.5.1 Pre-tensioning Strands ................................................................................ 22-29
22.8.5.2 Post-tensioning Tendons ............................................................................. 22-30
22.8.5.3 Anchorage Assemblies and Couplers .......................................................... 22-30
22.8.6 Protection of Prestressing Steel .......................................................................... 22-30
22.8.7 Corrosion Inhibitor .............................................................................................. 22-31
22.8.8 Grouting .............................................................................................................. 22-31
22.8.8.1 Preparation of Ducts .................................................................................... 22-32
22.8.8.2 Equipment ................................................................................................... 22-32
22.8.8.3 Batching and Mixing of Grout ....................................................................... 22-33
22.8.8.4 Injection of Grout ......................................................................................... 22-33
22.8.8.5 Grouting During Adverse Weather ............................................................... 22-35
22.8.8.6 Vertical Grouting .......................................................................................... 22-35
22.8.8.7 Post-grouting Inspection .............................................................................. 22-35
22.8.8.8 Finishing ...................................................................................................... 22-35
22.8.8.9 Protection of End Anchorages ..................................................................... 22-36
22.8.8.10 Construction Traffic and Operations Causing Vibrations .............................. 22-36
22.8.8.11 Grouting Trials ............................................................................................. 22-37
22.8.8.12 Field Testing of Grout for Quality Control ..................................................... 22-37
22.8.8.13 Admixtures................................................................................................... 22-40
22.9 Structural Cable Members ......................................................................................... 22-41
22.9.1 Description of System and General Requirements.............................................. 22-41
22.9.2 Strand for Structural Cables ................................................................................ 22-41
22.9.2.1 Materials ...................................................................................................... 22-41
22.9.2.2 Production Testing of Strand ....................................................................... 22-43
22.9.2.3 Testing of HDPE Coating ............................................................................. 22-43
22.9.2.4 Petroleum Wax Filling .................................................................................. 22-44
22.9.2.5 Delivery and Storage of Strand .................................................................... 22-44
22.9.3 Outer Casing ...................................................................................................... 22-44
22.9.3.1 HDPE Pipe .................................................................................................. 22-44
22.9.3.2 Stainless Steel Pipe ..................................................................................... 22-45
22.9.4 Anchorages and Transition Zones ...................................................................... 22-45
22.9.5 Stay Cable Testing ............................................................................................. 22-46
22.9.5.1 Strand Acceptance Tests ............................................................................. 22-46
22.9.5.2 Cable Acceptance Tests .............................................................................. 22-46
22.9.5.3 Acceptance of Prior Tests of Cables ............................................................ 22-46
22.9.6 Installation .......................................................................................................... 22-47
22.9.6.1 Handling and Installation.............................................................................. 22-47
22.9.6.2 Stressing ..................................................................................................... 22-47
22.9.6.3 Finishing Operations .................................................................................... 22-48
22.9.6.4 Re-stressing ................................................................................................ 22-48
22.9.7 Vibration Damping .............................................................................................. 22-48
Index ...................................................................................................................................... 22-49
Page ii
LIST OF FIGURES
Figure 22-1: Cone for Fluidity Test. .......................................................................................... 22-38
LIST OF TABLES
Table 22-1: Designations and titles for AASHTO and ASTM standards that apply to prestressing
steel works ................................................................................................................................. 22-3
Table 22-2: Designations and titles for BS and BS EN standards that apply to prestressing steel
works ......................................................................................................................................... 22-5
Table 22-3: Grout classes ........................................................................................................ 22-16
Table 22-4: General grout properties ....................................................................................... 22-17
Table 22-5: Ducts thickness ..................................................................................................... 22-18
Table 22-6: Duct position tolerances ........................................................................................ 22-25
Table 22-7: Acceptable values of primary properties for the PE material ................................. 22-44
Page iii
22 PRESTRESSING SYSTEMS
This chapter outlines requirements with which the Contractor shall comply when prestressing precast
or cast-in-place concrete by furnishing, placing, and tensioning prestressing steel. Such work shall
also comply with the particular specifications and details. This chapter applies to prestressing by
either the pre-tensioning method, the post-tensioning method, or a combination of these methods.
Work for which the specifications in this chapter apply includes furnishing and installing items that
are necessary to complete the prestressing system as part of the construction of the Project. Such
items may include, but are not limited to, ducts, anchorage assemblies, grout used for pressure
grouting ducts, and gauges and testing equipment for assessing various prestressing parameters.
When a structural member, such as a beam, girder, slab, or column, contains both pre-tensioned
steel and post-tensioned steel, both methods shall comply with the applicable requirements of this
chapter’s specifications.
This chapter of the standard specifications also include requirements for the supply, fabrication,
delivery, testing, installation, stressing, and permanent corrosion protection of structural cable
members such as hanger cables and transverse tie cables.
22.1 Prestressing Definitions

Pretensioned prestressed concrete is concrete in which prestressing strands or wire are tensioned
before placing the concrete and released after the concrete has gained sufficient strength to retain
the prestressing force by bond.
Post-tensioned prestressed concrete refers to concrete in which the stressing steel is placed in voids
or ducts installed within the concrete member, and is stressed and anchored after the concrete has
developed a specified strength. As a final operation, the voids or ducts are filled with grout under
pressure. For cast-in-place prestressed concrete, the term member, as used in this chapter, shall
mean the concrete that is to be prestressed.
22.2 Details of Prestressing Design

When the Contract plans do not fully detail the design for the prestressing work, the Contractor shall
furnish the details or type of prestressing system for use and select materials and details that conform
to these specifications, as needed, to satisfy the specified prestressing requirements. Each selected
system shall provide the magnitude and distribution of prestressing force and ultimate strength
required by the Contract plans without exceeding allowable temporary stresses. Unless otherwise
shown in the Contract plans, all design procedures, coefficients and allowable stresses, friction, and
prestress losses — as well as tendon spacing and clearances — shall be in accordance with the
American Association of State Highway and Transportation Officials (AASHTO) Load and
Resistance Factor Design (LRFD) Bridge Design Specifications, the AASHTO Guide Specifications
for Design and Construction of Segmental Concrete Bridges, and the Road Structures Design
Manual (ADQCC TR-516) as applicable.
Prestressing may be performed by either the pre- or post-tensioning methods. If the Contract plans
show only pre-tensioning details, the use of a post-tensioning system will be allowed only if the
Engineer approves the complete details of any necessary modifications.
When the effective or working force — or stress — is shown in the Contract plans, it shall be
considered to be the force or stress remaining in the prestressing steel after all losses, including
creep and shrinkage of concrete, elastic shortening of concrete, relaxation of steel, friction and take
up or seating of anchorages, and all other losses particular to the method or system of prestressing
have taken place or have been accounted for. When the jacking force is shown in the Contract plans,
it shall be considered to be the force applied to the tendon prior to anchorage and the occurrence of
any losses, including the anchor set loss.
Page 22-1

AASHTO LRFD American Association of State Highway and Transportation Officials - load and
resistance factor design, Bridge Construction Specifications;
resistance factor design, Bridge Design Specifications;
AASHTO Guide Specifications for Design and Construction of Segmental Concrete
Bridges;
ACI 503 (1997) Standard Specification for Bonding Hardened Concrete, Steel, Wood, Brick,
and Other Materials to Hardened Concrete with a Multi-Component Epoxy
Adhesive;
CCRL Cement and Concrete Reference Laboratory;
CEB-FIP Model Code1990;
FDOT New Direction for Florida Post-Tensioned Bridges, Florida Department of
Transportation;
FS Federal Specification MIL-P-3420F-87;
PCI Precast/Prestressed Concrete Institute;
PCI MNL-116-99 Manual for Quality Control for plants and production of Structural Precast
Concrete Products;
PCI MNL-117-77 Manual for Quality Control for Plants and Production of Architectural Precast
Concrete Products (1977);
PTI Post-Tensioning Institute - Guide Specification for Grouting of Post-Tension
Structures, Post-Tensioning Institute;
PTI Post-Tensioning Institute - Recommendations for Stay Cable Design, Testing,
and Installation;
U.S. Army Corps of Engineers Method CRD C79;
U.S. Military Specification and Standards MIL-P-24441/20.Table 22-1 and
Page 22-2
Table 22-2 presents American Association of State Highway and Transportation Officials (AASHTO),
American Society for Testing and Materials (ASTM), British (BS), and European (BS EN) Standards
that are related to materials for prestressing steel works. It also includes designations and titles.
Table 22-1: Designations and titles for AASHTO and ASTM standards that apply to
prestressing steel works
AASHTO ASTM
Title
AASHTO M ASTM A722/ Standard Specification for Uncoated, High-Strength

275M/M 275-08 A722M - 12 Steel Bars for Prestressing Concrete
AASHTO M
ASTM A421/ Standard Specification for Uncoated, Stress-Relieved
204M/M 204-06
A421M - 10 Steel Wire for Prestressed Concrete
(2010)
AASHTO M ASTM A 416/ Standard Specification for Steel Strand, Uncoated

203M/M 203-12 A416M - 12 Seven-Wire for Prestressed Concrete
ASTM C1152/ Standard Test Method for Acid-Soluble Chloride in

C1152M - 04e1 Mortar and Concrete
ASTM C33 /
Standard Specification for Concrete Aggregates
C33M - 11a
Standard Test Method for Measuring Changes in

ASTM C1090 -
Height of Cylindrical Specimens of Hydraulic-Cement
10
Grout

ASTM C942 - 10 Grouts for Preplaced-Aggregate Concrete in the
Laboratory
Standard Test Method for Time of Setting of Grouts for

ASTM C953 - 10
Preplaced-Aggregate Concrete in the Laboratory
Standard Test Method for Flow of Grout for Preplaced-

ASTM C939 - 10
Aggregate Concrete (Flow Cone Method)
Standard Test Method for Expansion and Bleeding of

ASTM C940 –
Freshly Mixed Grouts for Preplaced-Aggregate
10a
Concrete in the Laboratory
AASHTO T 277- ASTM C1202 - Standard Test Method for Electrical Indication of
07 (2011) 12 Concrete's Ability to Resist Chloride Ion Penetration
ASTM D3895 - Standard Test Method for Oxidative-Induction Time of

07 Polyolefins by Differential Scanning Calorimetry
ASTM D4101 - Standard Specification for Polypropylene Injection and

11 Extrusion Materials
ASTM D3350 - Standard Specification for Polyethylene Plastics Pipe

12 and Fittings Materials
Page 22-3
AASHTO ASTM
Title
ASTM F714 - Standard Specification for Polyethylene (PE) Plastic

12e1 Pipe (DR-PR) Based on Outside Diameter
ASTM G14-88 Standard Test Method for Impact Resistance of

(1996)e1 Pipeline Coatings (Falling Weight Test)
Standard Practice for Operating Salt Spray (Fog)

ASTM B117 - 11
Apparatus
ASTM A90/ Standard Test Method for Weight [Mass] of Coating on

A90M - 11 Iron and Steel Articles with Zinc or Zinc-Alloy Coatings
ASTM D2657 - Standard Practice for Heat Fusion Joining of Polyolefin

07 Pipe and Fittings
ASTM C150/
AASHTO M 85-12 Standard Specification for Portland Cement
C150M - 12

AASHTO T ASTM C109 /
Hydraulic Cement Mortars (Using 2-in. or [50-mm]
106M/T 106-12 C109M - 11b
Cube Specimens)
ASTM D1505 - Standard Test Method for Density of Plastics by the

10 Density-Gradient Technique
ASTM D1238 - Standard Test Method for Melt Flow Rates of

10 Thermoplastics by Extrusion Plastometer
Standard Test Methods for Flexural Properties of

ASTM D790 - 10 Unreinforced and Reinforced Plastics and Electrical
Insulating Materials
ASTM D1639 - Standard Test Method for Acid Value of Organic

90(1996)e1 Coating Materials
Standard Test Method for Obtaining Hydrostatic Design

ASTM D2837 -
Basis for Thermoplastic Pipe Materials or Pressure
11
Design Basis for Thermoplastic Pipe Products
Page 22-4
Table 22-2: Designations and titles for BS and BS EN standards that apply to prestressing
steel works
BS
Designation
Specification for hot rolled and hot rolled and processed

BS 4486:
high tensile alloy steel bars for the prestressing of
1980
concrete
BS EN 197- Cement. Composition, specifications and conformity

1:2011 criteria for common cements
Mixing water for concrete. Specification for sampling,

testing and assessing the suitability of water, including
BS EN 1008:2002
water recovered from processes in the concrete industry,
as mixing water for concrete
BS EN 12390- Testing hardened concrete. Shape, dimensions and

1:2000 other requirements for specimens and moulds
BS EN 12390- Testing hardened concrete. Making and curing

2:2009 specimens for strength tests
BS High tensile steel wire and strand for the prestressing of

5896:2012 concrete. Specification
BS EN ISO
Quality management systems. Requirements
9001:2015
Concrete admixtures. Specification for accelerating

BS 5075-
admixtures, retarding admixtures and water reducing
1:1982
admixtures
BS 5075- Concrete admixtures. Specification for superplasticizing

3:1985 admixtures
EN 10138 Prestressing Steel
BS EN ISO 527- Plastics. Determination of tensile properties. General

1:2012 principles
BS EN ISO 4892- Plastics. Methods of exposure to laboratory light sources.

2:2006+A1:2009 Xenon-arc lamps
22.4 Prestressing Quality Assurance

Prestessing work shall comply with the requirements for quality assurance outlined in this section.
22.4.1 Qualifications of Prestressing Subcontractor

The subcontractor who performs prestressing work on the Project shall meet the qualifications
outlined in this section.
Page 22-5
22.4.1.1 Precast Prestressed Girder

Before a precast, prestressed girder subcontract is awarded, the Contractor shall submit the pre-
qualification document of the proposed organisation or subcontractor to the Engineer for approval
for the performance of the prestressing works.
Each proposed organisation to perform the prestressed concrete works under these specifications
shall be certified by the Precast/Prestressed Concrete Institute (PCI), Plant Certification program
prior to start of production of works.
The subcontractor approval by the Engineer for the performance of the prestressing work as
specified in these specifications shall not relieve the Contractor of overall responsibility for such work.
If the subcontractor cannot perform the prestressing work in a manner acceptable to the Engineer,
the Contractor shall replace such subcontractor in accordance with the Contract documents. This
alternate subcontractor and the Contractor shall comply with paragraphs 1, 2, and 3 of this section.
22.4.1.2 Post-tensioned Concrete

If the Contractor proposes to perform the post-tensioned concrete work with its own forces, the
Contractor shall submit all details of its qualifications, as specified herein, and as required by the
Engineer, for approval by the Engineer of the Contractor to perform the work.
If the Contractor cannot provide acceptable and adequate information on its qualifications and is
rejected by the Engineer for the post-tensioned concrete work, the Owner shall require the
Contractor to subcontract such work.
The Owner shall require the Contractor to submit the following information regarding its
qualifications, or those of the proposed subcontractor, to the Engineer for review and approval:
a. For the performance of post-tensioned concrete work, the Contractor shall submit the pre-
qualification document of the proposed organisation or subcontractor, along with a complete
and detailed description of its qualifications and experience.
b. Acceptable evidence shall be submitted by the proposed organisation or subcontractor
proving to the Engineer that the organisation or subcontractor is experienced in the field of
prestressing systems. Further, the Contractor or proposed subcontractor shall submit data
acceptable to the Engineer that it has, within the last five years, performed construction work
comparable to the post-tensioned concrete work as specified in these standard specifications
and indicated in the Contract plans. This experience shall be confirmed by the Contractor by
citing a minimum of two comparable projects that have been successfully accomplished.
c. Approval of the Contractor’s organisation or the subcontractor by the Engineer for the
performance of the post-tensioned concrete work shall not relieve the Contractor of overall
responsibility for such work.
d. If, after the approval by the Engineer, the Contractor — or an approved subcontractor —
demonstrates an inability to perform the work as specified in this section, the Engineer
reserves the right to rescind such approval and require the Contractor to submit the name of
another subcontractor to perform the work. All resubmittals shall comply with the
requirements specified herein and in the Contract documents.
22.4.1.3 Supervision of Prestressing Operations

Prestressing and grouting operations shall be under the charge of a supervisor with appropriate
knowledge, training and experience in carrying out similar operations. That person shall be present
during all procedures and shall be responsible for all safety precautions relating to the operations.
The Contractor shall employ this supervisor and ensure that he is aware of the required tendon
loads, order of stressing, extensions, allowance for losses and all other particulars relating to the
operations.
The appointment of the responsible person shall be subject to the approval of the Engineer.
Page 22-6
The supervisor and all operatives shall be certified under a recognized certification scheme as having
the necessary qualifications such as CARES Product Installation Certification.
In addition, for each jacking operation, one technical representative of the approved post-tensioning
system as per Article 22.7.1.1 shall be present through the whole prestressing installation and
operation process. The technical representative shall provide guidance during the installation of the
ducts, anchorages, anchorage reinforcement, and actual post-tensioning operation. The technical
representative shall sign all post-tensioning loading, stressing, and elongation records with the
Contractor’s supervisor and the Engineer.
22.5 Supplementary Drawings

Supplementary drawings including working drawings, shop drawings and composite placement
drawings shall meet the requirements outlined in this section.
22.5.1 Working Drawings

Where the Contract documents do not include complete details of the prestressing system and its
method of installation, or when complete details are provided in the Contract plans and the
Contractor wishes to propose changes, the Contractor shall prepare and submit working drawings
of the prestressing system proposed for use to the Engineer. Fabrication or installation of
prestressing material shall not begin until the Engineer has approved the working drawings.
Working drawings of the prestressing system shall show complete details and substantiating
calculations of the method and materials proposed by the Contractor, including any additions or
rearrangement of reinforcing steel and any revision in concrete dimensions from that shown in the
plans. Such details shall outline the method and sequence of stressing and shall include complete
specifications and details of the prestressing steel and anchoring devices; working and anchoring
stresses; stress-strain curves of the prestressing steel; anticipated gauge pressures; cable profiles;
elongation of prestressing cables; and type of ducts and all other data pertaining to the prestressing
operation, including the proposed arrangement of the prestressing steel in the members.
The working drawing shall include as well erection and handling procedures and sequence for all
precast members.
Designs shall be prepared by a Specialty Engineer who has been approved in advance by the
Engineer.
Working drawings shall be submitted four weeks in advance of the start of the affected work to allow
time for review by the Engineer and correction by the Contractor of the drawings without delaying
the work.
Where required by the Contract plans, or in the Contract documents, the Contractor shall prepare
composite placement drawings for all items embedded in the concrete. If this provision includes a
requirement for additional engineering or design detailing, these requirements shall be clearly stated,
as noted in Section 22.2.
22.5.2 Shop Drawings

The Contractor shall submit shop drawings to the Engineer for approval in accordance with the
requirements of the Contract documents and as specified herein.
The shop drawings shall indicate the complete fabrication, profile, and placement details for all
tendons and strands, including types, locations, anchorages, couplings and methods of support, as
well as, computations for the prestressing of each post-tensioned tendon or all pre-tensioning
strands. The shop drawings shall also show, in addition to the tendons and strands, the placement,
sizes, and details of the reinforcement steel in the prestressed concrete work. Shop drawings shall
be prepared showing formwork and method and types of bracing.
Page 22-7
All shop drawings shall be submitted for review and approval in accordance with the requirements
specified herein. Prints of the final approved shop drawings shall be furnished by the Contractor for
the Engineer's use.
The shop drawings and computations shall be checked by the Contractor before submittal to the
Engineer. All shop drawings, computations and related data shall be accompanied by design data
confirming that the forces indicated on the Contract plans are obtainable and that all prestressing
hardware is adequate to transmit these forces. All shop drawings and computations shall be
approved by the Engineer before commencing any fabrication or delivery of material. No deviations
from the approved shop drawings shall be made by the Contractor without written approval of the
Engineer. Any fabrication by the Contractor without such written approval shall be at the Contractor's
risk. Any girders not fabricated in accordance with approved shop drawings will be rejected by the
Engineer.
The Engineer's approval of any proposed methods, materials, or equipment shall not relieve the
Contractor of full responsibility for the successful completion of all work specified in these Standard
Specifications and all related Contract documents.
Shop drawings for post-tensioning and other embedments and attachments, such as expansion
joints, bearings, and anchor bolts submitted by suppliers, shall be reviewed for conformance with
the design concept and compliance with the Contract plans and specifications; and then approved
by the Engineer. Where the Contract document information on the post-tensioning system is
modified by the Contractor, or where the Contract plans do not provide detailed dimensional
information on the post-tensioning system, it is the Contractor's responsibility to coordinate the
placement of the post-tensioning system with other embedments, and to correct any interferences
created by the Contractor-supplied post-tensioning system or other substitutions. Post-tensioning
layouts shall govern the layout of the secondary nonprestressed reinforcement. Where necessary,
location of nonprestressed reinforcement should be adjusted to clear tendons, subject to the
Engineer’s approval.
22.5.3 Composite Placement Drawings

Where required by the Contract documents, in addition to all required working drawings, the
Contractor shall prepare composite placement drawings to scale and in sufficient detail to show the
relative positions and depths of all items embedded in the prestressed concrete portions of the
structure. Such embedded items shall include the prestressing ducts, vents, anchorage
reinforcement and hardware, reinforcing steel, anchor bolts, earthquake restrainers, deck joint seal
assemblies, drainage systems, and utility conduits. These drawings shall ensure that the planned
positions of embedded items do not conflict with one another and that concrete cover is adequate.
Working drawings shall be developed and prepared by the Contractor for embedded items or
proposed changes in the dimensions of the post-tensioning systems work — as required by the
Contract. This will eliminate conflicts and provide proper cover wherever conflicts arise with or due
to the post-tensioning system. Resolution of the conflicts should follow the provision of Section 22.2.
Before work can begin on any affected item, the Engineer shall approve any revision. All costs
involved with the preparation of drawings and with making necessary modifications to the work
resulting there from shall be borne by the Contractor. This will require composite placement drawings
to be detailed to a scale and sufficient quality to show double-line reinforcement and post-tensioning
tendon details in either 2D or in complete 3D drawings.
22.6 Submittals
The Contractor shall submit the supplementary drawings to the Engineer for approval in accordance
with the requirements of Section 22.5. In addition, submittals shall comply with the requirements
Page 22-8
22.6.1 Qualification Details

Experience records and qualification details of the Contractor’s key structural design, fabrication,
installation, and quality control (QC) personnel who will work on the prestressing and concrete
operations shall be submitted by the Contractor. Once approved, the Contractor shall not change or
substitute any of the personnel without the Engineer’s prior approval.

Working drawings of the proposed prestressing system shall be submitted by the Contractor to the
Engineer for review and approval. For the initial review, six sets of such drawings shall be submitted.
One approved set or one set with corrections and modifications shall be returned by the Engineer.
After modification, six sets of the drawings and their associated calculations, if any, showing any
required corrections shall be submitted for final approval. Working drawings shall be submitted
sufficiently in advance of the start of the affected work to allow time for review and correction without
delaying the approved programmed commencement of the work. Such time shall be proportional to
the complexity of the work but, in no case, shall be less than two months.
Approval of working drawings and other submittals does not absolve the Contractor of the
responsibility for any contractual obligations. No additional payment will be made to the Contractor
for changes required as a result of reviews or approvals. Proper material submittals shall be made
as per Section 1.15, Submittal Procedures, outlined in Chapter 1, General Requirements, of these
standard specifications, for all materials involved.
22.6.3 Certificates
Certificates from the manufacturer, in quantities as directed by the Engineer, shall be furnished to
the Engineer certifying that the materials and equipment to be provided comply with the requirements
of these Standard Specifications, referenced codes and standards and approved shop drawings.
22.6.4 Test Reports

The Contractor shall furnish to the Engineer six (6) copies of test reports and certificates as specified
herein, unless otherwise directed by the Engineer.
22.7 Materials for Prestressing Operations

Materials for prestressing operations shall comply with the requirements outlined in this section.
Samples shall be submitted in the quantities as directed by the Engineer. Sampling and testing shall
be in general compliance with provisions of PCI MNL-117-77. After the Engineer has approved the
shop drawings, a full sized sample shall be prepared for the precast members for final approval of
the Engineer.
22.7.1 Prestressing System Materials

Materials for a prestressing system shall comply with the requirements outlined in this section.
22.7.1.1 Post-tensioning Systems

The post-tensioning system shall comply with latest international standards and the requirements of
these standard specifications, and shall be produced under a permanent system of factory
production control which shall ensure the same level of confidence in the conformity of the finished
product, whatever the manufacturing process.
The post-tensioning system shall subject to an official certification such as BS EN ISO 9001:2015
and CARES certificate relating to factory production control and product conformity.
Except as otherwise specified herein or specifically approved by the Owner, the post-tensioning
system including strands, ducts, anchorages, couplers, installation machines, wedges, stressing
Page 22-9
jacks and pump machine, gauges, grouting equipment, etc. shall be one of the following
manufacturers or systems or equivalent:
1. Bureau BBR Ltd.
2. DYWIDAG System Int.
3. Freyssinet System
4. VSL Corporation
5. Tensacciai System
6. CLL System
7. VLM System
Where a specific item of one of the manufacturers or systems is indicated on the Contract plans or
specified in these standard specifications or the particular specifications, comparable items of other
manufacturers are acceptable, if proven to be of internationally recognized types acceptable to the
Owner/Engineer. The Owner/Engineer shall be the sole judge as to whether or not any proposed
alternative system of post-tensioning is comparable and equal to the specified systems.
22.7.1.2 Prestressing Steel and Anchorage

Prestressing reinforcement shall be high-strength seven-wire strand, high-strength steel wire, or
high-strength alloy bars of the grade and type called for in the Contract plans or in a particular
specification; and, shall conform to the requirements of the following specifications.
a. Strands
Strands shall be uncoated, seven-wire, high-tensile, cold-drawn, stress-relieved low relaxation steel
conforming to the requirements of AASHTO M 203M/M 203-12 (ASTM A416/ A416M - 12),
Supplement S1 (low relaxation) Grade 1860 MPa, or BS 5896:2012 Grade 1770 MPa. Unless
otherwise specified, the Contractor shall furnish 12.7 mm or 12.5mm diameter strands for all pre-
tensioned members, and 15.24 mm or 15.7 mm diameter strands for all post-tensioned members.
Prestressing strand, however manufactured, shall be in coils of a large enough diameter to ensure
that the strand pays off straight.
Prior to shipment of the strands from the Manufacturer's plant, the Contractor shall submit typical
stress-strain curves obtained from the mill — or approved independent laboratory — based on test
performance of the strands proposed for use for approval by the Engineer. For each lot of maximum
10-ton, or fractions thereof, of strands produced specifically for this Contract, certified copies of the
Manufacturer's test reports shall be submitted to the Engineer. In addition to the mill certificates, for
every three coils or reels, one set of three specimens, as selected by the Engineer, shall be tested
for tensile strength and elongation at a laboratory approved by the Engineer. Upon building
confidence in the quality of the delivered strength, the Engineer may relax the aforementioned testing
requirement. This testing including samples shall be performed by the Contractor at no cost to the
Owner. Specimens may be cut from the starting end of any length of strand or wire by the Contractor.
All strands accepted and approved shall have affixed to each coil, reel, or reel-less pack a tag
certifying that it has been tested and/or approved by the Engineer.
b. Wires
Uncoated stress-relieved low relaxation steel wires shall conform to the requirements of AASHTO M
204M/M 204-06 (2010) (ASTM A421/ A421M - 10). Unless otherwise agreed by the Engineer, low
relaxation wires shall be in coils of sufficiently large diameter to ensure that the wire pays off straight.
The quality requirements performed on strands shall be applied on the wires to be used in the
Project.
Page 22-10
c. Bars
Bars shall be Grade 1035 MPa uncoated high-strength bars conforming to the requirements of
AASHTO M 275M/M 275-08 (ASTM A722/ A722M - 12) or BS 4486: 1980. Bars with greater
minimum ultimate strength, but otherwise produced and tested in accordance with AASHTO M
275M/M 275-08 (ASTM A722/ A722M - 12), may be used provided they have no properties that
make them less satisfactory than the specified material. Prestressing bars shall be straight upon
delivery. Three randomly selected samples, per size of bar, per heat of steel with a minimum of one
sample per shipment shall be tested for tensile strength and elongation at a laboratory approved by
the Engineer.
d. Assemblies
Anchorage assemblies, jacks, gauges, grout fittings, and other related equipment and accessories
shall be standard with the system’s Manufacturer and approved by the Engineer. Post-tensioning
ducts shall be as approved by the Engineer.
22.7.1.3 Post-tensioning Anchorage and Couplers

Anchorage assemblies shall be cast units that are standard with the prestressing Manufacturer's
system for the intended purpose (type of anchorages) and to the approval of the Engineer.
All anchorages and couplers shall develop at least 96 percent of the actual ultimate strength of the
prestressing steel, when tested in an unbonded state, without exceeding anticipated set. The
coupling of tendons shall not reduce the elongation at rupture below the requirements of the tendon
itself. Couplers, or coupler components, shall be enclosed in housings long enough to permit
necessary movements. Couplers for tendons shall be used only at locations specifically indicated or
approved by the Engineer. Couplers shall not be used at points of sharp tendon curvature.
Anchorages and couplers shall be handled and used strictly in accordance with the Manufacturer's
instructions and recommendations.
a. Bonded System
Bond transfer lengths between anchorages and the zone where full prestressing force is required,
under service and ultimate loads shall normally be sufficient to develop the minimum specified
ultimate strength of the prestressing steel. When anchorages or couplers are located at critical
sections under ultimate load, the ultimate strength required of the bonded tendons shall not exceed
the ultimate capacity of the tendon assembly, including the anchorage or coupler, tested in an
unbonded state.
Housings shall be designed so that complete grouting of all of the coupler components will be
accomplished when grouting the tendons.
b. Unbonded System
For unbonded tendons, a dynamic test shall be performed on a representative anchorage and
coupler specimen and the tendon shall withstand, without failure, 500,000 cycles from 60 percent to
66 percent of its minimum specified ultimate strength, and also 50 cycles from 40 percent to 80
percent of its minimum specified ultimate strength. The period of each cycle involves the change
from the lower stress level to the upper stress level and back to the lower. The specimen used for
the second dynamic test need not be the same used for the first dynamic test. Systems utilising
multiple strands, wires, or bars may be tested utilising a test tendon of smaller capacity than the full-
sized tendon. The test tendon shall duplicate the behaviour of the full-sized tendon and generally
shall not have less than 10 percent of the capacity of the full-sized tendon. Dynamic tests are not
required on bonded tendons, unless the anchorage is located or used in such manner that repeated
load applications can be expected on the anchorage.
Anchorages for unbonded tendons shall not cause a reduction in the total elongation under ultimate
load of the tendon to less than 2 percent measured in a minimum gauge length of 3 metres.
Page 22-11
All the coupling components shall be completely protected with a coating material prior to final
encasement in concrete.
c. Special Anchorage Device Acceptance Test

1. Test Block Requirements
Test blocks shall be a rectangular prism and shall contain those anchorage components that will
also be embedded in the structure's concrete. Their arrangement must comply with the practical
application and the supplier’s specifications. Test blocks shall contain an empty duct of an
appropriate size for the maximum tendon size that can be accommodated by the anchorage device.
2. Test Block Dimensions
Dimensions for the test block perpendicular to the tendon in each direction shall be the smaller of
the minimum edge distance or the minimum spacing specified by the anchorage device supplier;
with the stipulation that the cover over any confining reinforcing steel or supplementary skin
reinforcement be appropriate for the particular application and environment. The length of the block
along the axis of the tendon shall be at least two times the larger of the cross section dimensions.
3. Local Zone Reinforcement (Anchorage Zone)
The confining reinforcing steel in the local zone shall be the same as that specified by the anchorage
device supplier for the particular system.
4. Skin Reinforcement
In addition to the anchorage device and its specified confining reinforcement steel, supplementary
skin reinforcement may be provided throughout the specimen. This supplementary skin
reinforcement shall be specified by the anchorage device supplier. Similar reinforcement in the actual
structure shall be furnished to achieve an equivalent action.
5. Concrete Strength
The concrete strength at the time of stressing shall be greater than the concrete strength of the test
specimen at time of testing.
6. Test Procedure
Any of the following three test procedures described below is acceptable:
• Cyclic loading
• Sustained loading
• Monotonic loading
Loads specified for the tests are given in fractions of the ultimate load, or Fpu, of the largest tendon
that the anchorage device is designed to accommodate. Specimens shall be loaded in accordance
with normal usage of the device in post-tensioning applications, except that load can be applied
directly to the wedge plate or equivalent area.
7. Cyclic Loading Test
In a cyclic loading test, the load shall be increased to 0.8 Fpu, and then cycled for not less than 10
cycles between 0.1 Fpu and 0.8 Fpu until crack widths stabilize. Crack widths are considered
stabilized if they do not change by more than 0.025 mm over the last three readings. Upon
completion of the cyclic loading the specimen shall be preferably loaded to failure or, if limited by the
capacity of the loading equipment, to at least 1.1 Fpu.
Crack widths and crack patterns shall be recorded at the initial load of 0.8 Fpu at least at the last
three consecutive peak loadings before termination of the cyclic loading, and at 0.9 Fpu. The
maximum load shall also be reported.
8. Sustained Loading Test
Page 22-12
In a sustained loading test, the load shall be increased to 0.8 Fpu and held constant for not less than
48 hours until crack widths stabilize. Crack widths are considered stabilized if they do not change by
more than 0.025 mm over the last three readings. After sustained loading is completed, the specimen
shall be preferably loaded to failure or, if limited by the capacity of the loading equipment, to at least
1.1 Fpu.
Crack widths and crack patterns shall be recorded at the initial load of 0.8 Fpu at least three times at
intervals of not less than four hours during the last 12 hours before termination of the sustained
loading, and during loading to failure at 0.9 Fpu. Maximum loads shall also be reported.
9. Monotonic Loading Test
In a monotonic loading test, the load shall be increased to 0.9 Fpu and held constant for one hour.
Specimen shall then be preferably loaded to failure or, if limited by the capacity of the loading
equipment, to at least 1.2 Fpu.
Crack widths and crack patterns shall be recorded at 0.9 Fpu after the one-hour period, and at 1.0
Fpu. Maximum loads shall also be reported.
10. Anchorage Zone Requirement
Anchorage zone strengths must exceed the following:
• Specimens tested under cyclic or sustained loading: 1.1 Fpu
• Specimens tested under monotonic loading: 1.2 Fpu
Maximum crack width criteria, specified below, must be met for moderately aggressive
environments:
• No cracks greater than 0.25 mm at 0.8 Fpu after completion of the cyclic or sustained loading,
or at 0.9 Fpu after the one-hour period for monotonic loading
• No cracks greater than 0.4 mm at 0.9 Fpu after completion of the cyclic or sustained loading,
or at 1.0 Fpu for monotonic loading
For high-aggressive environments the crack width criteria shall be reduced by at least 50 percent.
11. Test Series Requirement
A test series shall consist of three test specimens. Each specimen must meet the acceptance criteria.
If one of the three specimens fails to pass the test, a supplementary test of three additional
specimens is allowed. The three additional test specimen results must meet all acceptance criteria
of Paragraph 10 of Sub-article c.
For a series of similar special anchorage devices, tests are only required for representative samples,
unless tests for each capacity of the anchorages in the series are required by the Engineer.
12. Records of the Anchorage Device
Records of the anchorage device acceptance test shall include the following:
• Dimensions of the test specimen
• Drawings and dimensions of the anchorage device, including all confining reinforcing steel
• Amount and arrangement of supplementary skin reinforcement
• Type and yield strength of reinforcing steel
• Type and compressive strength at time of testing of concrete
• Type of testing procedure and all measurements required in Paragraphs 7 through 10 of sub-
article c for each specimen
Page 22-13
22.7.2 Grout
The properties of the grout made with the materials and proposed plant and personnel shall be
assessed by the Contractor for suitability for the intended purpose sufficiently in advance of grouting
operations to enable adjustments to be made in use of materials or plant or personnel. All retrials
shall be at the Contractor's expense.
The materials assessment shall consist of the preparation of the grout, made with the materials and
using the plant and personnel proposed for use on site, and the testing of it in accordance with Article
22.8.8.12. The preparation shall be carried out under conditions of temperature expected on site. If
grouting operations are likely to cover different seasons, the assessment shall include the range of
expected temperatures.
The sources of materials and procedures approved as a result of satisfactory trials shall not be
departed from without the written approval of the Engineer.
Unless otherwise instructed or agreed by the Engineer as a result of grouting trials, the grout shall
consist only of Portland cement complying with BS EN 197-1:2011 Class 42.5N, admixtures
complying with Article 22.8.8.13 and water complying with BS EN 1008:2002.
The age, chemical composition, fineness and temperature of the cement shall be subject to close
control.
The materials used shall be such that the chloride ion content of the grout shall not exceed 0.06%
chlorides by mass of the cement.
The post-tensioning grout shall meet the grout physical properties stated in Article 22.7.2.3, Grout
Physical Properties. Grouts may be either a unique design for the Project or supplied in a prebagged
form by the grout Manufacturer. For uniquely designed grouts, the cement and admixtures utilised
in the laboratory trial batches of the proposed grout shall not be changed during construction without
retesting. Cement freshness shall be in accordance with AASHTO M 85-12 (ASTM C150/ C150M -
12), except as specified herein. Daily field testing of the grout for the following properties shall be
required:
• Fluidity
• Bleed at three hours
• Volume change test
Prebagged grout supplied by a grout manufacturer shall be prebagged in plastic-lined or plastic-
coated containers and stamped with date of manufacture, lot number, and mixing instructions. Any
change of materials or material sources shall require retesting and certification of the conformance
of the grout with the physical properties requirements. Grout suppliers shall provide the Contractor
with a copy of the QC data sheet for each lot number and shipment sent to the jobsite; these data
shall also be furnished to the Engineer. Materials with total time from manufacture to usage in excess
of six months shall be removed from the jobsite and replaced.
22.7.2.1 Approval
Manufacturers of post-tensioning grout shall submit certified test reports from an independent
cement and concrete laboratory for approval. These tests shall show that the material meets all the
requirements specified herein.
22.7.2.2 Mixing
Materials shall be mixed in accordance with the manufacturer's recommendations. Water used in
the grout shall be potable, clean, and free of injurious quantities of substances known to be harmful
to Portland cement or prestressing steel.
Page 22-14
22.7.2.3 Grout Physical Properties

Grouts shall achieve a nonbleeding characteristic. Grout shall contain no aluminium powder or gas-
generating system that produces hydrogen, carbon dioxide, or oxygen. Cementitious grout shall
meet or exceed the specified physical properties stated herein, as determined by the following
standard ASTM test methods.
Grout classes shall be taken as specified in Table 22-3, general grout properties for the Engineer’s
approval in principle shall be as specified in Table 22-4, and field testing of grout for quality control
shall be as per Article 22.8.8.12.
a. Fluidity
The fluidity of the grout during the injection period shall be high enough for it to be pumped effectively
and adequately to fill the duct, but low enough to expel the air and any water in the sheath. Field
testing of grout fluidity for quality control shall be as per Article 22.8.8.12. The fluidity at the duct
outlets shall not exceed that of the injected grout by more than 10%.
b. Bleeding
The bleeding of the grout shall be sufficiently low to prevent excessive segregation and settlement
of the grout materials. Field testing of grout bleeding for quality control shall be as per Article
22.8.8.12. The bleeding shall be less than 2% of the initial volume of the grout and the average of
four successive results shall be less than 1%. The water shall be reabsorbed by the grout during the
24 hours after mixing.
c. Volume Change
The volume change assessed may be either an increase or decrease. Field testing of grout volume
change for quality control shall be as per Article 22.8.8.12. The volume change of the grout shall be
within the range 0% to +5%. For grouts with expanding agents there shall be no decrease in volume.
d. Strength
The compressive strength of 100mm cubes made of the grout shall exceed 27 MPa at 7 days and
at least 62 MPa after 28 days. Cubes shall be made, cured and tested in accordance with BS EN
12390-1:2000 and BS EN 12390-2:2009 or AASHTO T 106M/T 106-12.
e. Sieve Test
The grout shall contain no lumps. This shall be verified by checking the sieving medium on the fluidity
test cone.
Page 22-15
Table 22-3: Grout classes
Constituent materials
Silica High-range
Fly ash Water to
Slag fume Calcium
Class Exposure Cement (type F) cementitious water Other
b Required
percent (dry) reducer nitritec
kg material ratio admixtures d testing
percent ª (type F or G) kg/m
ª [W/(c+m)]
percentª gm/kg
Nonaggressive:
Article
A Indoor or 100 0 0 0 0.45 max 0 0 -
22.7.2.3
outdoor
Aggressive:
0 min 0 min 0 min 0 min 0 min As per
Subject wet or Article
B 100 Manufacturers
dry cycles, 25 max 55 max 15 max 0.45 max 29 max 25 max 22.7.2.3
recommendation
marine environ.
C Aggressive or Article
- - - - 0.45 max - - -
Prepackaged nonaggressive 22.7.2.3
D Article
Determined by the Engineer
Special 22.7.2.3
Notes:
a. Percent of cement substitute.
b. Types D and E admixtures may be permitted with approval of the Engineer.
c. Alternate corrosion inhibitors may be used.
d. Other admixtures, such as anti-bleed admixtures, pumping aids, and air-entraining agents.
Page 22-16
Table 22-4: General grout properties
Property Test value Test method
Max.0.06 percent by weight of ASTM C1152/ C1152M -

Total chloride ions
cementitious material 04e1
Fine aggregate (if utilised) Max. Size <No. 50 Sieve ASTM C33 / C33M - 11a
Min. 0.0 percent at 24 hours

Volume change at 28 days ASTM C1090 - 10
and 28 days
Expansion ≤2.0 percent for up to 3 hours ASTM C940 – 10a
Min. 3 hours
Initial set of grout ASTM C953 - 10
Max. 12 hours
Fluidity test
Efflux time from flow cone Min. 11 seconds
immediately after mixing Max. 30 seconds
ASTM C 939 – 10
30 minutes after mixing with
remixing for 30 seconds Max. 25 seconds
At duct outlet time ≥ 10 seconds
Bleeding at 3 hours Max. 0.0 percent ASTM C940 – 10a
Rapid chloride permeability at Max. 2,500 coulombs at 30 AASHTO T 277-07(2011)

28 days volts for 6 hours (ASTM C1202 - 12)
22.7.3 Ducts for Prestressing Operations

Ducts used to provide holes or voids in the concrete for the placement of post-tensioned bonded
tendons may be either formed with removable cores or may consist of rigid or semi-rigid ducts that
are cast into the concrete.
Ducts formed with removable cores shall be formed with no constrictions that could block the
passage of grout. All coring materials shall be removed.
Ducts formed by sheaths left in place shall be a type that will not permit the intrusion of cement
paste. They shall transfer bond stresses, as required, and shall retain their shape under the weight
of the concrete while having sufficient strength to maintain their correct alignment without visible
wobble during concrete placement.
The system of ducts, duct connectors grouting connections, vents, vent connections, drains,
transitions to anchorage and caps for anchorages shall form a complete air and water-tight
encapsulation for the tendons. Ducts shall be of corrosion resistant durable material such as high
density corrugated polyethylene or polypropylene. Galvanized ferrous metal ducts will be permitted.
Ducting which may degrade or corrode during the expected life of the structure in the presence of
contaminants permeating the surrounding concrete is not permitted. The system shall be fully
compatible with the prestressing anchorages, and other details.
Page 22-17
22.7.3.1 Metal Ducts for Prestressing

Sheathing for ducts shall be metal, except as provided herein. Such ducts shall be galvanized ferrous
metal and shall be fabricated with either welded or interlocked seams. Galvanizing of welded seams
will not be required. Rigid ducts shall have smooth inner walls and shall be capable of being curved
to the proper configuration without crimping or flattening. Semi-rigid ducts shall be corrugated and,
when tendons are to be inserted after the concrete has been placed, their minimum wall thickness
shall be as follows:
• 0.45 mm for ducts less than or equal to 66.7 mm in diameter
• 0.60 mm for ducts greater than 66.7 mm in diameter
When bar tendons are preassembled with such ducts, the duct thickness shall not be less than 0.25
mm.
22.7.3.2 Plastic Ducts for Prestressing

For locations in saltwater environment, plastic duct material shall be considered and is
recommended.
Corrugated plastic duct completely embedded in concrete shall be constructed from either high
density polyethylene or polypropylene. The minimum acceptable radius of curvature shall be
established by the duct supplier, according to standard test methods. The duct shall have a thickness
as shown in Table 22-5.
Ducts shall have a white coating on the outside or shall be of white material with ultraviolet (UV)
stabilizers added. Polyethylene duct shall be fabricated from resins meeting or exceeding the
requirements of ASTM D3350 - 12, with a cell classification of 345464A.
Polypropylene duct shall be fabricated from resins meeting or exceeding the requirements of ASTM
D4101 - 11, with a cell classification range of PP0340BI4541 to PP0340B67884.
Resin containing antioxidants with a minimum oxidation induction time (OIT) of not less than 20
minutes, in accordance ASTM D3895 - 07, shall be used. OIT tests shall be performed on samples
taken from the finished product.
Rigid, smooth, black polyethylene ducts used where the tendon is not embedded in concrete shall
be rigid pipe manufactured from 100 percent virgin polyethylene resin meeting the requirements of
ASTM D3350 - 12, with a minimum cell class of 344464C. A resin containing antioxidants with a
minimum OIT of not less than 40 minutes shall be used in accordance with ASTM D3895 - 07. OIT
tests shall be performed on samples taken from the finished product. Ducts shall be manufactured
with a dimensional ratio (DR) of 17, as established by either ASTM D 3350 - 12 or ASTM F714 –
12e1, and as appropriate for the manufacturing process used.
Table 22-5: Ducts thickness
Duct shape Duct diameter (mm) Duct thickness (mm)
Flat any size 2.0
Round 23 2.0
Round 60 2.0
Round 75 2.5
Round 85 2.5
Page 22-18
Duct shape Duct diameter (mm) Duct thickness (mm)
Round 100 3.0
Round 115 3.5
Round 130 4.0
Round 145 4.0
22.7.3.3 Duct Area

The provisions of Article 5.4.6.2, Size of Ducts, of the AASHTO LRFD Bridge Design Specifications,
latest edition, shall apply.
22.7.3.4 Duct Fittings

Coupling and transition fittings for ducts formed by sheathing shall be of either ferrous metal
polyolefin (polyethylene or polypropylene), and shall be air- and watertight and of sufficient strength
to prevent distortion or displacement of the ducts during concrete placement and tendon grouting.
All ducts or anchorage assemblies shall be provided with pipes or other suitable connections at each
end of the duct for the injection of grout after prestressing. As specified in Sub-article a, Duct Inlets
and Outlets, of Article 22.8.4.2, ducts shall be provided with ports for venting or grouting at high
points and for draining at intermediate low points.
Vent and drain pipes shall be at least 20 mm in diameter for strand and at least 12 mm in diameter
for single-bar tendons and three- or four-strand flat-duct tendons. Connection to ducts shall be made
with metallic or plastic structural fasteners. Vents and drains shall be mortar tight, taped as
necessary, and constructed with either mechanical or shrink-wrap connections. Vents and drains
shall provide means for injection of grout through the vents and for sealing to prevent leakage of
grout.
22.8 General Prestressing Requirements

A skilled technician supervisor experienced in the prestressing system as required in Article 22.4.1.3
and specified herein shall be employed by the Contractor. This technician supervisor shall be
capable of directing operations and of providing aid and instruction in the use of tensioning and
grouting equipment. This assistance shall be available as long as necessary to assure satisfactory
results in all phases of the tensioning and grouting work.
Prestressing may be accomplished by pre- and post-tensioning, or by combining the two methods
— as specified in the Contract documents, in the approved working drawings, or approved in writing
by the Engineer.
Prestressing steel shall be tensioned by hydraulic jacks so as to produce the forces shown in the
Contract documents or on the approved working drawing with appropriate allowances for all losses.
Losses to be provided for shall be as specified in Article 5.9.5, Loss of Prestress, of the AASHTO
LRFD Bridge Design Specifications, latest edition.
For post-tensioned work, the losses shall also include the anchor set loss appropriate for the
anchorage system employed, and actual wobble and friction losses of ducts.
For pretensioned members, the strand stress prior to seating (jacking stress), shall not exceed 80
percent of the minimum ultimate tensile strength of the prestressing steel (0.8 fs'). This allowable
stress slightly exceeds the values allowed in Article 5.9.3, AASHTO LRFD Bridge Design
Page 22-19
Specifications, and it may be permitted to offset seating losses and to accommodate compensation
for temperature differences specified in Article 22.8.3.1, Pre-tensioning Requirements.
For post-tensioned members, the standard stress prior to seating (jacking stress) and the stress in
the steel immediately after seating shall not exceed the values allowed in AASHTO LRFD Bridge
Design Specifications, Article 5.9.3, and the Road Structures Design Manual (ADQCC TR-516).
The method of tensioning employed shall be one of the following as specified or approved:
1. Pre-tensioning; in which the prestressing strand or tendons are stressed prior to being
embedded in the concrete placed for the member. After the concrete has attained the
required strength, the prestressing force is released from the external anchorages and
transferred, by bond, into the concrete.
2. Post-tensioning; in which the reinforcing tendons are installed in within the concrete and are
stressed and anchored against the concrete after the development of the required concrete
strength. As a final operation under this method, the voids or ducts are pressure-grouted.
3. Combined Method; in which part of the reinforcement is pre-tensioned and part post-
tensioned.
Under this method all applicable requirements for pre-tensioning and for post-tensioning shall apply
to the respective reinforcing elements using these methods.
During strand stressing, individual wire failures may be accepted by the Engineer, provided not more
than one wire in any strand is broken and the area of broken wires does not exceed 2 percent of the
total area of the prestressing steel in the member.
22.8.1 Concrete Strength

Prestressing forces shall not be applied or transferred to the concrete until the concrete has attained
the strength specified for initial stressing. The Contractor shall cast and test sufficient cubes to
demonstrate this to the approval of the Engineer. Additionally, for bridges not constructed
segmentally, cast-in-place concrete shall not be post-tensioned until at least 10 days after the last
concrete has been placed in the member to be post-tensioned, and the minimum required cube
strength gained for post tensioning.
22.8.2 Prestressing Equipment

Hydraulic jacks used to stress tendons shall provide and sustain the necessary forces and shall be
equipped with either a pressure gauge or a load cell for determining the jacking stress. Jacking
systems shall provide an independent means by which the tendon elongation can be measured. The
pressure gauge shall have an accurately reading dial at least 150 mm in diameter or a digital display,
and each jack and its gage shall be calibrated as a unit with the cylinder extension in the approximate
position that it will be at final jacking force, and shall be accompanied by a certified calibration chart
or curve. The load cell shall be calibrated to an accuracy within ± 2 percent and checked at intervals
to the approval of the Engineer; and shall be provided with an indicator by means of which the
prestressing force in the tendon may be determined. The range of the load cell shall be such that
the lower 10 percent of the manufacturer's rated capacity will not be used in determining the jacking
stress. When approved by the Engineer, calibrated proving rings may be used in lieu of load cells.
Recalibration of gauges shall be repeated at least annually and whenever gauge pressures and
elongations indicate materially different stresses.
22.8.2.1 Cutting
Only oxygen flame or mechanical cutting devices shall be used to cut wire, strands, or bars after
installation in the member or after stressing. All cutting shall be carried out using either of the
following:
Page 22-20
a. A high-speed abrasive cutting wheel or friction saw at not less than 1 diameter from the
anchor, or any other mechanical method approved by the Engineer.
b. An oxy-acetylene cutting flame, using excess oxygen to ensure a cutting rather than a melting
action, not less than 75 mm from the anchor. Temperatures of the tendon adjacent to the
anchor shall not be greater than 200 degrees Celsius. Care shall be taken that neither the
flame nor splashes come into contact with the anchorages or tendons.
Electric arc welders shall not be used.
22.8.2.2 Sequence of Stressing

When the sequence of stressing individual tendons is not specified in the Contract documents, or in
the approved working drawings, the stressing of post-tensioning tendons and the release of
pretensioned tendons shall be done in a sequence that produces a minimum of eccentric force in
the member.
22.8.2.3 Measurement of Stress

A record of gauge pressures and tendon elongations for each tendon shall be provided by the
Contractor for review and approval by the Engineer. Elongations shall be measured to an accuracy
of 1.5 mm. The corresponding wobble and friction coefficients of ducts shall be calculated
accordingly to verify the assumed coefficients used in the design. Stressing tails of post-tensioned
tendons shall not be cut until the stressing records and elongation calculation have been approved.
A facility to measure any movement of the tendon in the gripping devices shall also be provided.
Stresses in the tendons during tensioning shall be determined by the gage or load-cell readings and
shall be verified with the measured elongations. Calculations of anticipated elongations shall utilise
the modulus of elasticity, based on nominal area, as furnished by the manufacturer for the lot of steel
being tensioned, or as determined by a bench test of strands used in the work.
All tendons shall be tensioned to a preliminary force, as necessary, to eliminate any take-up in the
tensioning system before elongation readings are started. This preliminary force shall be between 5
percent and 25 percent of the final jacking force. The initial force shall be measured by a
dynamometer, or by other approved method, so that its amount can be used as a check against
elongation — as computed and as measured. Each strand shall be marked prior to final stressing to
permit measurement of elongation and to ensure that all anchor wedges set properly.
It is anticipated that there may be discrepancy in indicated stress between jack gage pressure and
elongation. In such event, the load used, as indicated by the gage pressure, shall produce a slight
overstress rather than understress. When a discrepancy between gage pressure and elongation of
more than 5 percent in tendons more than 15 m long or 7 percent in tendons of 15 m or less in length
occurs, the entire operation shall be carefully checked and the source of error determined and
corrected before proceeding further. When provisional ducts are provided for the addition of
prestressing force in event of an apparent force deficiency in tendons more than 15 m long, the
discrepancy between the force indicated by gage pressure and elongation may be increased to 7
percent before investigation into the source of the error.
22.8.3 Pretensioned Members

Pretensioned members of concrete structures shall comply with the requirements and specifications
22.8.3.1 Pre-tensioning Requirements

Stressing shall be accomplished by multiple-strand stressing method subject to approval by the
Engineer. Tensioning of an individual strand is not permitted unless approved by the Engineer. Pre-
Page 22-21
tensioning shall comply with PCI MNL-116 requirements. The amount of stress to be given to the
strands shall be as shown in the Contract documents or in the approved working drawings.
All strands to be stressed in a group (multiple-strand stressing) shall be brought to a uniform initial
tension prior to a full pre-tensioning. The amount of the initial tensioning force shall be within the
range specified in Article 22.8.2.3, Measurement of Stress, and shall be the minimum required to
eliminate all slack and to equalise the stresses in the tendons as determined by the Engineer. The
amount of this force will be influenced by the length of the casting bed and the size and number of
tendons in the group to be tensioned.
When straight tendons are used in the long-line method of pre-tensioning, sufficient locator plates
shall be distributed throughout the length of the bed to ensure that the wires or strands are
maintained in their proper position during concreting. Where a number of units are made in line, they
shall be free to slide in the direction of their length and thus permit transfer of the prestressing force
to the concrete along the whole line.
In the individual mould system, the moulds shall be sufficiently rigid to provide the reaction to the
prestressing force without distortion.
Draped pretension tendons shall either be tensioned partially by jacking at the end of the bed and
partially by uplifting or depressing tendons, or they shall be tensioned entirely by jacking, with the
tendons being held in their draped positions by means of rollers, pins, or other approved methods
during the jacking operation.
Approved low-friction devices shall be used at all points of change in slope of tendon trajectory when
tensioning draped pretension strands, regardless of the tensioning method used. For single tendons
the deflector in contact with the tendon shall have a radius of not less than five times the tendon
diameter for wire or 10 times the tendon diameter for strand, and the total angle of deflection shall
not exceed 15 degrees.
If the load for a draped strand, as determined by elongation measurements, is more than 5 percent
less than that indicated by the jack gages, the strand shall be tensioned from both ends of the bed,
and the load as computed from the sum of elongation at both ends shall agree within 5 percent of
that indicated by the jack gages.
When ordered by the Engineer, prestressing steel strands in pretension members, if tensioned
individually, shall be checked by the Contractor for loss of prestress not more than three hours prior
to placing member concrete. Methods and equipment for checking the loss of prestress shall be
subject to approval by the Engineer. All strands that show a loss of prestress in excess of 3 percent
shall be retensioned to the original computed jacking stress.
Stress on all strands, including hold-down and hold-up forces shall be maintained between
anchorages until the concrete has reached the compressive strength required at the time for the
transfer of stress to concrete, which shall take place slowly to minimize shock.
When prestressing steel in pretensioned members is tensioned at a temperature more than 14
degrees Celsius lower than the estimated temperature of the concrete and the prestressing steel at
the time of initial set of the concrete, the calculated elongation of the prestressing steel shall be
increased to compensate for the loss in stress due to the change in temperature, but in no case shall
the jacking stress exceed 80 percent of the specified minimum ultimate tensile strength of the
prestressing steel.
Strand splicing methods and devices shall be approved by the Engineer. When single-strand jacking
is used, only one splice per strand will be permitted. When multi-strand jacking is used, either all
strands shall be spliced or no more than 10 percent of the strands shall be spliced. When more than
a strand are spliced, the splice location should be staggered. Spliced strands shall be similar in
physical properties, from the same source, and shall have the same twist or lay. All splices shall be
located outside of the prestressed units.
Page 22-22
Side and flange forms that restrain deflection shall be removed before release of pre-tensioning
reinforcement.
Except when otherwise shown in the Contract documents, all pretensioned prestressing strands shall
be cut flush to the end of the member and the exposed ends of the strand. A 25-mm strip of the
adjoining concrete shall be cleaned and painted. Cleaning shall be by wire brushing or abrasive blast
cleaning to remove all dirt and residue that is not firmly bonded to the metal or concrete surfaces,
which shall be coated with one thick coat of zinc-rich paint conforming to the requirements of U.S.
Military Specification MIL-P-24441/20. Paints shall be thoroughly mixed at the time of application,
and shall be worked into any voids in the strands.
22.8.3.2 Placement of Prestressing Steel

Prestressing steel that resides in a stressing bed shall be protected from corrosion if the stressing
bed is to be exposed to weather for more than 36 hours before encasement in concrete.
Anchor plates and anchorages shall be accurately located and securely fastened to the forms or
held in place by approved methods; they shall be of such nature that strands will not kink, break
down, or be otherwise damaged; and such anchorages shall ensure proper distribution of the load
to the concrete-bearing surfaces between anchorages. Concrete shall be perpendicular and
concentric with the strands and the line of action of the pre-tensioning. Moulding lengths, as indicated
in the approved shop drawings, shall be verified and recorded for each strand after anchorages are
met. Anchorage devices shall hold the pre-tensioning steel without slip of more than 3 mm at a load
equal to the applied load of the strands at pre-tensioning. If grip type anchorages are used, provisions
shall be made for observation of possible slip. Strands shall be allowed to extend beyond anchorages
at an amount sufficient to permit retensioning before placement of concrete.
Strands shall be carefully handled when removed from storage, uncoiled, placed, and protected from
damage or the intrusion of foreign material.
All strands shall be tensioned according to Article 22.8.3.1. Strands shall not be allowed to unwind
more than one turn. Jacking force records and elongation measurements shall be kept after the
strands are tensioned to 20 percent of final jacking force.
Prestressing steel shall be tensioned to the required stress. Elongation computations shall include
strand anchorage slippage, splice slippage, in place horizontal movement of the structural member
during prestressing operations, and prestressing steel temperature changes between the time of
tensioning and the time when the concrete takes its initial set. All computations must be prepared by
a Professional Engineer.
Prestress bed forms, strands, and reinforcement bar temperatures shall be maintained by the
Contractor within 15 degrees Celsius of the temperature of the concrete to be placed in the forms.
Strands shall be supported with rollers at points of direction change when strands are tensioned in
a draped position. Free-running rollers with minimal friction shall be used. Initially, when strands are
tensioned and then pulled into the draped position, the Contractor shall tension to no more than the
required tension minus the increased tension due to forcing the strand to a draped profile. If the load
in a draped strand at the dead end, as determined by elongation measurements, is less than 95
percent of the jack load, the strand shall be tensioned from both ends of the bed. The load shall be
made, as computed from the sum of elongations produced by jacking at both ends, agree within 5
percent of the jack load.
Within three hours before placing concrete, the tension on the prestressing strands shall be checked.
The method and equipment for checking the loss of prestress shall be subject to approval by the
Engineer. If strands are tensioned individually, each strand shall be checked for loss of prestress.
Strands that show a loss of prestress in excess of 3 percent shall be retensioned by the Contractor
to the original computed jacking stress. If strands are tensioned in a group, the entire group for total
loss of prestress shall be checked. If the total prestress shows a loss in excess of 3 percent, or if any
Page 22-23
individual stand appears significantly different from the rest of the strands in a group, the Contractor
shall release and retension the entire group.
22.8.3.3 Releasing of Prestressing Steel

Transferring of prestressing force from the strands to the concrete shall be performed simultaneously
and in a controlled manner, as approved by the Engineer. Releasing the force by cutting individual
prestressing strands shall not be permitted. No bond stress shall be transferred to the concrete, nor
shall end anchors be released, until the concrete has attained a compressive strength as indicated
by standard cubes made and cured identically with the members, of at least the minimum strength
indicated in the approved shop drawings or in the specifications for such transfer of load. Elements
shall be cut or released in such an order that lateral eccentricity of prestress will be a minimum.
In cases where several beams cast in one continuous line and stressed at one time, elements shall
be cut or released in such an order that lateral eccentricity of prestress will be a minimum.
22.8.4 Post-tensioned Members

Post-tensioned members of concrete structures shall comply with the requirements and
specifications outlined in this section.
22.8.4.1 Post-tensioning Requirements

Prior to post-tensioning any member, the Contractor shall demonstrate to the satisfaction of the
Engineer that the prestressing steel is free and unbonded in the duct.
All strands in each tendon, except for those in flat ducts with not more than four strands, shall be
stressed simultaneously with a multi-strand jack. Tensioning shall be accomplished so as to provide
the forces and elongations specified in Article 22.8.5.1, Pre-tensioning tendons.
Except as provided herein, or when specified in the Contract documents, or in the approved working
drawings, tendons in continuous post-tensioned members shall be tensioned by jacking at each end
of the tendon. For straight tendons, and when one end stressing is shown in the Contract documents,
tensioning may be performed by jacking from one end or both ends of the tendon at the option of the
Contractor.
Deflectors in contact with tendons shall have a radius of not less than 50 times the diameter of the
tendon, and the total angle of deflection shall not exceed 15 degrees unless otherwise agreed by
the Engineer.
Stressing shall continue until the required extension and tendon load are reached or are approved
by the Engineer.
After the tendons have been anchored, the force exerted by the jack shall be decreased gradually
and steadily so as to avoid shock to the tendon or the anchorage. Full records shall be kept of all
tensioning operations, including the measured extensions, pressure gauge, or load-cell readings;
and the amount of anchors set at each anchorage. Copies of these records shall be supplied to the
Engineer within 24 hours of each tensioning operation.
Unless otherwise agreed by the Engineer, tendons shall not be cut less than three days after
grouting.
22.8.4.2 Placement of Ducts

Internal and external surfaces of ducts shall be clean and sound at the time of incorporation in the
work.
Ducts shall be rigidly supported at the proper locations in the forms by ties to reinforcing steel, which
are adequate to prevent displacement during concrete placement. Supplementary support bars
Page 22-24
epoxy coated shall be used, where needed, to maintain proper alignment of the duct. Hold-down ties
shall be used when the buoyancy of the ducts in the fluid concrete will lift the reinforcing steel.
Polyethylene duct and metal duct for longitudinal or transverse post-tensioning in the flanges shall
be supported at intervals not to exceed 600 mm. Polyethylene duct in webs for longitudinal post-
tensioning shall be tied to stirrups at interval not to exceed 600 mm and metal duct for longitudinal
post-tensioning in webs shall be tied to stirrups at interval not to exceed 1.2 metres.
Joints between sections of duct shall be coupled with positive connections that do not result in angle
changes at the joints and will prevent the intrusion of cement paste.
After placing that ducts and reinforcement and forming is complete, an inspection shall be made to
locate possible duct damage.
All unintentional holes or openings in the duct must be repaired prior to concrete placing.
Grout openings and vents must be securely anchored to the duct and to either the forms or to
reinforcing steel to prevent displacement during concrete placing operations.
After installation in the forms, the ends of ducts shall be at all times covered, as necessary, to prevent
the entry of water or debris.
During concrete placement for precast segments, mandrels shall be used as stiffeners in each duct
and shall extend throughout the length of the segment being cast and at least 0.6 m into the
corresponding duct of the previously cast segment. The mandrels shall be of sufficient rigidity to
maintain the duct geometry within the tolerances shown in Table 22-6.
Table 22-6: Duct position tolerances
Vertical position Lateral position

Tolerances
(mm) (mm)
Horizontal tendons in slabs or in slab regions of

±6 ±12
larger members
Longitudinal draped superstructure tendons in

webs ±6 ±6
Tendon over supports or in middle third of span
Tendon in middle-half of web depth ±12 ±6
Longitudinal, generally horizontal superstructure

±6 ±6
Tendons usually in top or bottom of member
Horizontal tendons in substructures and

±12 ±12
foundations
Longitudinal Position Transverse Position

(mm) (mm)
Vertical tendons in webs ±6 ±6
Vertical tendons in pier shafts ±6 ±6
Additionally, the following shall apply:

• In all other cases, locate tendons within ±6 mm in any direction.
Page 22-25
• Entrance and exit angles of tendon paths at anchorages or at faces of concrete shall be within
±3 degrees of desired angle measured in any direction and any deviations in the alignment
are accomplished with smooth transitions without any kinks.
• Angle changes at duct joints shall not be greater than ±3 degrees in any direction and must
be accomplished with smooth transitions without any kinks.
• Locate anchorages within ±6 mm of desired position laterally and ±25 mm along the tendon
except that minimum cover requirements shall be maintained.
• Position anchorage confinement reinforcement in the form of spirals, multiple V-shaped bars,
or links, to be properly centred on the duct and to start within 12 mm of the back of the main
anchor plate.
• If conflicts exist between the reinforcement and post-tensioning duct, position the post-
tensioning duct and adjust the reinforcement locally with the Engineer's approval.
a. Duct Inlets and Outlets

All ducts for continuous structures shall be supplied with outlets at the high and low points of the
duct profile, except where the profile changes are small, as in continuous slabs, and at additional
locations, as specified the Contract documents. Low-point outlets shall remain open until grouting is
started.
b. Proving of Post-tensioning Ducts

Upon completion of concrete placement, the Contractor shall prove that post-tensioning ducts are
free and clear of any objections or damage and can accept the intended post-tensioning tendons by
passing a torpedo through the duct. The torpedo shall have the same cross-sectional shape as the
duct, and 6 mm smaller than the clear nominal inside dimensions of the duct. No deductions shall
be made to the torpedo section dimensions for tolerances allowed in the manufacture or fixing of the
ducts. For straight ducts, a torpedo at least 0.6 m long shall be used. For curved ducts, the length
shall be determined so that when both ends touch the outermost wall of the duct, the torpedo is 6
mm clear of the innermost wall. If the torpedo will not travel completely through the duct, the Engineer
shall reject the member, unless through workable repairs the torpedo shall pass through the duct
easily, by hand, and without resorting to excessive effort or mechanical assistance.
c. Duct Pressure Field Test

Before stressing and grouting internal or external tendons, the Contractor shall install all grout caps,
inlets, and outlets and test the duct with compressed air to determine if duct connections require
repair. In the presence of the Engineer, the duct shall be pressurized to 345 kPa and the outside air
source shall be locked off. Pressure loss shall be recorded for one minute. A pressure loss of 170
kPa is acceptable for ducts that are 45 metres or shorter and a pressure loss of 100 kPa is acceptable
for ducts that are longer than 45 metres. If the pressure losses exceed allowable thresholds, the
Contractor shall repair leaking connections using methods approved by the Engineer and then test
duct pressure again.
22.8.4.3 Placement of Concrete

Where the end of a post-tensioned assembly will not be covered by concrete, the Contractor shall
recess the anchoring devices so that the ends of the prestressing steel and all parts of the anchoring
devices are at least 51 mm inside the end surface of the members.
Before placing concrete, the Contractor shall demonstrate that all ducts are unobstructed.
Immediately after concrete placement, the Contractor shall blow out the conduit with compressed,
oil-free air to break-up and remove all mortar in the conduit before it hardens. Approximately 24
hours after the concrete placement, the Contractor shall flush the conduits with water that may
Page 22-26
contain lime or calcium oxide, or slaked lime or calcium hydroxide, in the amount of 12 gm per liter.
Water shall be blown out with compressed, oil-free air.
For post-tensioned members that are to be steam cured, the Contractor shall not install prestressing
steel until curing is complete.
22.8.4.4 Placement of Post-tensioning Steel

Unless otherwise directed by the Engineer, prestressing steel installed in members prior to placing
and curing of the concrete, is not acceptable.
When accepted by the Engineer, all prestressing steel preassembled in ducts and installed prior to
the placement of concrete shall be accurately placed and held in position during concrete placement.
Locations and support of each tendon shall be within a tolerance of ±6 cm. Tendons shall be securely
tied in place or supported to prevent their dislocation during the concreting operation.
When the prestressing steel is installed after the concrete has been placed, the Contractor shall
demonstrate to the satisfaction of the Engineer that the ducts are free of water and debris
immediately prior to installation of the steel. At this point, the total number of strands in an individual
tendon may be pulled into the duct as a unit, or individual strands may be pulled or pushed through
the duct.
Anchorage devices or block-out templates for anchorages shall be set and held so that their axis
coincides with the axis of the tendon and anchor plates are normal in all directions to the tendon.
Prestressing steel shall be distributed so that the force in each girder stem is equal or as required
by the Contract plans, except as provided herein. For box girders with more than two girder stems,
at the Contractor's option, the prestressing force may vary up to 5 percent from the theoretical
required force per girder stem provided the required total force in the superstructure is obtained and
the force is distributed symmetrically about the centre line of the typical section.
a. Protection of Steel After Installation

When prestressing steel, used in post-tensioned concrete members, is installed prior to placing and
curing of the concrete and is not grouted within the time limit specified below, a corrosion inhibitor
placed in the ducts or directly applied to the steel may only be used when directed by the Engineer
to continuously protect the prestressing steel against rust or other corrosion until grouted or encased
in concrete. Otherwise, removal, replacement and reinstallation of strands may be required at the
direction of the Engineer.
Prestressing steel installed and tensioned in members after placing and curing of the concrete and
grouted within the time limit specified below will not require a corrosion inhibitor, as described herein.
Rust that may form during the interval between tendon installation and grouting will not be cause for
rejection of the steel.
Permissible intervals between tendon installation and grouting without use of a corrosion inhibitor for
various exposure conditions shall be as follows:
• Very damp atmosphere or over saltwater (Humidity >70 percent): 7 days
• Moderate atmosphere (Humidity from 40 percent to 70 percent): 15 days
• Very dry atmosphere (Humidity <40 percent): 20 days
After tendons are placed in ducts, the openings at the ends of the ducts shall be sealed to prevent
entry of moisture.
When steam curing is used, steel for post-tensioning shall not be installed until the steam curing is
completed.
Page 22-27
Such tendons shall be protected against corrosion by means of a corrosion inhibitor placed in the
ducts or on the steel, or shall be stressed and grouted within seven days after steam curing.
Whenever electric welding is performed on or near members containing prestressing steel, the
welding ground shall be attached directly to the steel being welded. All prestressing steel and
hardware shall be protected from weld spatter or other damage.
b. Protection of Tendons
Within four hours after stressing and prior to grouting, tendons shall be protected against corrosion
or harmful effects of debris by temporarily plugging or sealing all openings and vents; cleaning rust
and other debris from all metal surfaces that will be covered by the grout cap; and placing the grout
cap, including a seal, over the wedge plate until the tendon is grouted.
22.8.4.5 Placement of Anchorage

Proper placement of all materials shall be the responsibility of the Contractor, according to the
Contract documents, and the requirements stipulated by the anchorage device supplier. Due care
and attention shall be exercised by the Contractor in the placement of anchorage hardware,
reinforcement, concrete, and consolidation of concrete in anchorage zones. Modifications to the local
zone details, verified under provisions of Article 5.10.9.7.3 of the AASHTO LRFD Bridge Design
Specifications and Sub-article c, Special Anchorage Device Acceptance Test, of Article 22.7.1.3,
shall be approved by both the Contractor’s supervisor and the technical representative of the
approved post-tensioning system.
22.8.4.6 Record of Stressing Operation

A record of the following post-tensioning operations shall be kept for each tendon installed:
• The Project name and number
• The Contractor and/or subcontractor
• Tendon location, size, and type
• Date tendon was first installed in ducts
• Coil or reel number for strands or wires and heat number for bars and wire
• Assumed and actual cross-sectional area
• Assumed and actual modulus of elasticity
• Date stressed
• Jack and gage numbers per end of tendon
• Required jacking force
• Gage pressures
• Elongations, anticipated and actual
• Anchor sets, anticipated and actual
• Stressing sequence, including tendons before and after this tendon
• Stressing mode, such as one end, two ends, simultaneous
• Witnesses to stressing operation, the Contractor and inspector
• Date grouted, days from stressing to grouting, grouting pressure applied, and injection end
• Record any other relevant information, including pour back and bitumastic installation dates
Page 22-28
A complete copy of all stressing operations, and the jack calibration forms, shall be provided to the
Engineer.
22.8.5 Identification and Testing

All wire, strand, or bars shipped to the site shall be assigned a lot number and tagged for identification
purposes. Anchorage assemblies shall be likewise identified. Each cable shall be tagged with its
number from which the coil numbers of the steel used can be identified.
Cables shall not be kinked or twisted. Individual wires and strands for which extensions are to be
measured shall be readily identifiable at each end of the member. No strand that has come
unravelled shall be used.
Each lot of wire or bars and each reel of strand reinforcement shall be accompanied by a
manufacturer's certificate of compliance, a mill certificate, and a test report. The mill certificate and
test report shall include the following:
• Chemical composition, not required for strands
• Cross-sectional area
• Yield and ultimate strengths
• Elongation at rupture
• Modulus of elasticity
• Stress strain curve for the actual prestressing steel intended for use
All values certified shall be based on test values and nominal sectional areas of the material being
certified.
Samples described in the following subsections selected from each lot shall be furnished by the
Contractor to the Engineer for verification testing. Selection of samples shall be made at the
manufacturer’s plant by the inspector, if ordered by the Engineer.
All samples submitted to the Engineer shall be accompanied by a certification from the supplier or
subcontractor certifying that the samples were taken from, and are representative of, the lot of reels
to be furnished. In the case of wire or strand, samples shall be taken from the same master roll.
Actual strengths of the prestressing steel shall not be less than specified by the applicable ASTM or
British standard, and shall be determined by tests of representative samples of the tendon material
in conformance with ASTM or British standards.
If it is proposed to use super strand complying with BS 5896: 2012 Table 6 or other than the lowest
strength 3, 4, 5, 6 or 7mm diameter wires complying with BS 5896: 2012 Tables 4 and 5, reels will
only be accepted if both the breaking load and the 0.1% proof load of the sample exceeds the
specified characteristic loads given in the above Tables 4 or 6. In the case of Table 5 this requirement
shall apply to the breaking load and the load at 1% elongation.
The Contractor shall employ the services of an independent testing laboratory to design the concrete
mixes and test the cement and aggregates, concrete, reinforcing steel, pre-stressing steel, and such
other materials as directed by the Engineer. All of the materials specified for testing shall be furnished
free of cost and shall be delivered in time for tests to be made well in advance of anticipated time of
use.
22.8.5.1 Pre-tensioning Strands

For each certificate furnished for pretensioned strands, one sample at least 5 m long near ends of
fittings shall be furnished in accordance with the requirements of paragraph 9.1 of AASHTO M
203M/M 203-12 (ASTM A416/ A416M - 12).
Page 22-29
22.8.5.2 Post-tensioning Tendons

The following lengths shall be furnished for each 10,000 kg, or portion thereof, lot of material used
in the work:
• For wires not requiring heading-sufficient length to make up one parallel-lay cable, 1.5 m long
consisting of the same number of wires as the cable to be furnished.
• For strands to be furnished with fittings, 1.5 m between near ends of fittings.
• For bars to be furnished with threaded ends and nuts, 1.5 m between threads at ends.
22.8.5.3 Anchorage Assemblies and Couplers

One specimen of each size of the prestressing tendon, including couplings, at the selected type, with
end fittings and anchorage assembly attached, shall be furnished by the Contractor for strength tests
only. These specimens shall be 1.5 m in clear length, measured between ends of fittings. If the
results of the test indicate the necessity of check tests, additional specimens shall be furnished
without cost.
When dynamic testing is required, the Contractor shall perform the testing and shall furnish certified
copies of test results that indicate conformance with the specified requirements prior to installation
of anchorages or couplers. Costs of such testing shall be borne by the Contractor.
For prestressing systems previously tested and approved on projects having the same tendon
configuration, the Engineer may not require complete tendon samples, provided there is no change
in the material, design, or details previously approved. Shop drawings or prestressing details shall
identify the Project on which approval was obtained; otherwise testing shall be conducted.
22.8.6 Protection of Prestressing Steel

All prestressing steel shall be protected against physical damage and rust or other results of
corrosion at all times from manufacture to grouting. Prestressing steel shall also be free of
deleterious material, such as grease, oil, wax, or paint. Prestressing steel that has sustained physical
damage at any time shall be rejected. Development of pitting or other results of corrosion, other than
rust stain, shall be cause for rejection.
Prestressing steel shall be stored clear of the ground and be protected from the weather, from
splashes from any other materials, and from splashes from the cutting operation of an oxyacetylene
torch or arc welding activity. In no circumstances shall prestressing steel, after manufacture, be
subjected to any welding operation, or heat treatment or metallic coating, such as galvanising. This
does not preclude cutting as described in Article 22.8.2.1.
Prestressing steel shall be packaged in containers or shipping forms for the protection of the strand
against physical damage and corrosion during shipping and storage. A corrosion inhibitor that
prevents rust or other results of corrosion shall be placed in the package or form, or shall be
incorporated in a corrosion inhibitor carrier type packaging material. When permitted by the
Engineer, a corrosion inhibitor may also be applied directly to the steel. Corrosion inhibitors shall
have no deleterious effect on the steel, concrete, or bond strength of steel to concrete or grout.
Packaging or forms damaged from any cause shall be immediately replaced or restored to their
original condition.
Shipping packages or forms shall be clearly marked with a statement that the package contains high-
strength prestressing steel, and the type of corrosion inhibitor used, including the date packaged.
All pre- or post-tensioning steel shall be satisfactorily stored and protected from excessive rust or
other corrosion prior to placing. Such steel shall be free from deleterious substances when placed.
Ample protection shall also be provided for all exposed steel at the ends of prestressed concrete
bridge members to prevent deterioration by rust and corrosion.
Page 22-30
All anchorages, end fittings, couplers, and exposed tendons, which will not be encased in concrete
or grout in the completed work, shall be permanently protected against corrosion.
22.8.7 Corrosion Inhibitor

Corrosion inhibitors shall consist of a vapour-phase inhibitor (VPI) powder conforming to the
provision of Federal Specification MIL-P-3420F-87 or as otherwise approved by the Engineer.
Corrosion inhibitors shall only be used at the direction of the Engineer. When approved, water-
soluble oil may be used on prestressing steel as a corrosion inhibitor.
22.8.8 Grouting
The Contractor shall undertake grout trials in accordance with the details described in Article
22.8.8.11. The trials are required to demonstrate that the grouting methods and procedures
proposed by the Contractor will ensure that grout completely fills the ducts and surrounds the
prestressing steel.
The Contractor shall submit at least 4 weeks before on-site trials a detailed method statement or
grouting operation plan covering proposed materials, duct, anchorage and vent arrangements,
personnel, equipment grouting procedures and quality control for the approval of the Engineer.
When the post-tensioning method is used, the prestressing steel shall be provided with permanent
protection and shall be bonded to the concrete by completely filling the void space between the duct
and the tendon with grout. Grout should be injected from low points pumping toward the high-point
vent. For segmental, span-by-span construction, grout shall be injected through a grout inlet at mid-
span.
All grouting operations shall be carried out by experienced superintendents and foremen that have
received instructional training and have at least three years of experience on previous projects
involving grouting of similar type and magnitude.
A grouting operation plan shall be submitted for approval at least 45 days in advance of any
scheduled grouting operations. Written approval of the grouting operation plan by the Engineer shall
be required before any grouting of the permanent tendons in the structure takes place.
Tendons shall be grouted at not less than eight hours to 12 hours, but within the number of days
specified in Article 22.8.4.4 after tendon installation. The tendons shall be protected against
corrosion by a plug at each end to prevent the passage of air, and such plugs shall be left in place
until the tendon is grouted.
At a minimum, the following items shall be provided in the grouting operation plan:
1. Provide names, and proof of training and experience records for the grouting crew and the
crew supervisor in conformance with this specification
2. Type, quantity, and brand of materials used in grouting including all required certifications
3. Type of equipment furnished, including capacity in relation to demand and working condition,
as well as back-up equipment and spare parts
4. General grouting procedure
5. Duct pressure test and repair procedures
6. Method to be used to control the rate of flow within ducts
7. Theoretical grout volume calculations
8. Mixing and pumping procedures
9. Direction of grouting
Page 22-31
10. Sequence of use of the inlets and outlet pipes

11. Procedures for handling blockages
12. Procedures for possible post grouting repair
13. Grout trials
Before grouting operations begin, a joint meeting of the Contractor, grouting crew, and the Engineer
shall be conducted. At the meeting, the grouting operation plan, required testing, corrective
procedures, and any other relevant issues shall be discussed.
22.8.8.1 Preparation of Ducts

Each duct shall be air-pressure tested prior to the installation of the prestressing steel into the ducts.
If leaks are indicated during the test, the duct shall be repaired to eliminate the leakage or minimize
the consequences of the leakage.
All ducts shall be clean and free of deleterious materials that would impair bonding or interfere with
grouting procedures.
Ducts with concrete walls, or cored ducts, shall be flushed to ensure that the concrete is thoroughly
wetted. Metal ducts shall be flushed, if necessary, to remove deleterious material.
Water used for flushing ducts may contain slack lime or calcium hydroxide, or quicklime (or calcium
oxide, in the amount of 0.012 kg/L.
After flushing, all water shall be blown out of the duct with oil-free compressed air.
22.8.8.2 Equipment
Grouting equipment shall include a high-speed shear mixer capable of continuous mechanical
mixing, which will produce a grout free of lumps and undispersed cement; a storage reservoir; a
grout pump with all the necessary connection hoses, valves, measuring devices for water, cement
and admixtures and testing equipment; and stand-by flushing equipment with water supply. The
equipment shall pump the mixed grout in a manner that will comply with all requirements.
Accessory equipment that will provide for accurate solid and liquid measures shall be provided to
batch all materials.
The mixing equipment shall be capable of producing a grout of homogeneous consistency and shall
be capable of providing a continuous supply to the injection equipment.
The capacity of the equipment shall be such that the duct can be filled and vented without interruption
and at the required rate of injection.
The injection equipment shall be capable of continuous operation with little variation of pressure and
shall include a system for recirculating the grout while actual grouting is not in progress.
The equipment shall have a constant delivery pressure of less than 1 MPa, it shall be equipped with
a pressure gauge and shall prevent pressures above 2 MPa. The pressure gage shall be placed at
some point in the grout line between the pump outlet and the duct inlet. Pumps shall have seals
adequate to prevent introduction of oil, air, or other foreign substance into the grout, and to prevent
loss of grout or water. All piping to the grout pump shall have a minimum number of bends, valves
and changes in diameter and shall incorporate a sampling Tee with stop cock.
The equipment shall be capable of maintaining pressure on completely grouted ducts and shall be
fitted with a valve that can be locked off without loss of pressure in the duct.
Grouting equipment shall contain a screen having clear openings of 3.35 mm maximum size to filter
the grout prior to its introduction into the grout pump. If a grout with a thixotropic additive is used, a
Page 22-32
screen opening of 4.75 mm is satisfactory. This screen shall be easily accessible for inspection and
cleaning.
Grouting equipment shall utilise gravity feed to the pump inlet from a hopper attached to and directly
over it. Hoppers must be kept at least partially full of grout at all times during the pumping operation
to prevent air from being drawn into the post-tensioning duct.
Under normal conditions, the grouting equipment shall be capable of continuously grouting the
largest tendon on the Project in no more than 20 min.
During the grouting operation, the Contractor shall provide adequate flushing-out plant to facilitate
complete removal of the grout in the event of a breakdown of the grouting equipment or other
disruption before the grouting operation has been completed and shall demonstrate that this
equipment is in full working order.
All equipment shall be kept free from build-up of adhering materials by washing as required.
22.8.8.3 Batching and Mixing of Grout

All materials shall be batched by weight except the mixing water and liquid admixtures which may
be batched by weight or volume. The accuracy of batching shall be:
• ± 2% for cement and admixtures
• ± 1% for mixing water
of the quantities specified. The mixing water shall include the water content of liquid admixtures.
Depending upon environmental or materials influence (e.g. temperature, configuration of the tendon
and properties of the cement used), the water/cement ratio shall be kept as low as possible having
regard to the required plastic properties of the grout.
The maximum w/c ratio shall be 0.40. The material shall be mixed to produce a homogeneous grout
and kept in slow continuous agitation until pumped into the duct. Water shall be added to the mixer
first, followed by the cement and admixtures. The batch quantities of cement and admixture may be
added as a whole or in part in sequence until the total quantities are added. The minimum mixing
time determined from grouting trials shall be adhered to.
The temperature of freshly mixed grout shall be between 5°C and 25°C.
Grout shall be mixed in accordance with the manufacturer's instructions using a colloidal mixer to
obtain homogeneous mixture. A fluidity test shall be performed on the mixed grout prior to beginning
the injection process. Target flow rates, as a function of mixer type used and ambient temperatures,
shall be obtained from the grout manufacturer. The grouting process shall not be started until the
proper grout properties have been obtained.
Mixing shall be of such duration as to obtain a uniform, thoroughly blended grout, without excessive
temperature increase or loss of expansive properties of the admixture. Grout shall be continuously
agitated until it is pumped.
Water shall not be added to increase grout flow, which has been decreased by delayed use of the
grout.
22.8.8.4 Injection of Grout

Grouting operations shall be carried out by operatives with appropriate knowledge, training and
proven experience in carrying out similar operations and certified under an approved scheme.
A check shall be made to ensure the ducts, vents, inlets and outlets are capable of accepting injection
of the grout. This shall be done by blowing through the system with dry, oil-free air and proving each
vent in turn.
Page 22-33
Where there is water in the duct, it shall be removed through outlets at the lowest points. Dry, oil-
free compressed air may be used for this purpose.
Grouting of the ducts shall be carried out as soon as is practicable after the tendons in the ducts
have been stressed and the Engineer's written agreement to commence has been obtained. All grout
vents shall be opened before grouting starts. Injection and ejection vents with positive shut-offs shall
be provided. Grout shall be allowed to flow from the first injection vent until any residual flushing
water or entrapped air has been removed prior to closing that vent. Remaining vents shall be closed
in sequence in the same manner. Injection shall be continuous, and it shall be slow enough to avoid
producing segregation of the grout. Unless otherwise agreed by the Engineer, grout injection shall
be at the rate of between 10 and 15 metres of duct per minute as per CEB-FIP Model Code1990.
Pumping pressure at the injection vent should not exceed 1 MPa. Normal operations shall be
performed at approximately 0.5 MPa. If the actual grouting pressure exceeds the maximum allowed,
the injection vent shall be closed and the grout shall be injected at the next vent that has been, or is
ready to be, closed; as long as a one-way flow is maintained. Grout shall not be injected into a
succeeding vent from which grout has not yet flowed.
The method of injecting grout shall ensure complete filling of the ducts and complete surrounding of
the steel. Grout shall be allowed to flow from each vent and the free end of the duct until its
consistency is equivalent to that of the grout injected and no visible slugs of water or air are ejected.
Following this, a further 5 litres at each vent shall be vented into a clean receptacle, tested in
accordance with Article 22.8.8.12 and then discarded. The opening shall be firmly closed. All vents
shall be closed in a similar manner one after another in the direction of the flow except that at
intermediate crests the vents 400mm downstream shall be closed before their associated crest vent.
The injection tubes shall then be sealed off under pressure. A pressure of 0.5 MPa shall be
maintained for at least one minute.
Grout vents at high points shall be reopened 10 minutes after completion of grouting and any escape
of air, water or grout recorded and reported immediately to the Engineer. A further pumping of grout
may be required at this stage to expel bleed water and/or entrapped air. This shall be carried out
with only the high points open one at a time sequentially in the direction of grouting.
The filled ducts shall not be subjected to shock or vibration within 24 hours of grouting.
Not less than 48 hours after grouting, the level of grout in the injection and the vent tubes shall be
inspected, all defective grout shall be removed from the vent and the level topped up as necessary
with freshly mixed grout.
Not less than 48 hours after grouting, the end caps at anchorages shall be removed and a
photographic record taken, clearly identified.
If, in the opinion of the Engineer, there is cause for doubt that the ducts are completely filled with
grout, the Engineer may require non-destructive testing to be carried out.
The Contractor shall keep full records of grouting for each duct including the date each duct was
grouted, the proportion of the grout and any admixtures used, the pressure, details of any
interruptions and topping up required, and the records shall be in accordance with the
recommendations of the certification scheme. Copies of these records shall be supplied to the
Engineer within 24 hours of grouting.
Grout vents shall be positively sealed to be waterproof on completion of grouting so as to maintain
the encapsulation to the tendons by a means separate from the concrete waterproofing.
The fluidity test shall be performed on each tendon in accordance with Article 22.8.8.12, measuring
the grout fluidity from the discharge outlet. Measured grout efflux times shall not be faster than the
efflux time measured at the inlet or the minimum efflux time established in Article 22.7.2.3. If the
grout efflux time is not acceptable, additional grout shall be discharged from the discharge outlet.
Grout efflux time shall be tested. This cycle shall continue until acceptable grout fluidity is achieved.
Page 22-34
To ensure that the tendon remains filled with grout, the ejection and injection vents shall be closed
in sequence, respectively, under pressure when the tendon duct is completely filled with grout. The
positive shut-offs at the injection and ejection vents shall not be removed or vents opened until the
grout has set.
22.8.8.5 Grouting During Adverse Weather

a. Hot Weather
Grouting in conditions where the shade air temperature exceeds 30o C will only be permitted when
the Contractor's proposals for ensuring that the grout quality will not be impaired have been accepted
by the Engineer.
During hot weather, the Contractor shall ensure that the constituent materials of the grout are
sufficiently cool to prevent the grout from stiffening in the interval between its discharge from the
mixer and compaction in its final position. Cement shall not be allowed to come into contact with
water at a temperature greater than 40°C.
Notwithstanding the above recommendations grouting shall not be carried out when the shade air
temperature exceeds 40° C or during "ghibli" conditions.
b. Cold Weather
When the ambient temperature may be expected to fall below 5°C, accurate temperature records
shall be kept covering maximum and minimum air temperatures, and temperatures of the structures
adjacent to the ducts to be grouted.
No grout shall be placed when the temperature of the structure adjacent to the ducts is below 5°C,
or is likely to fall below 5°C during the following 48 hours, unless the member is heated so as to
maintain the temperature of the placed grout above 5°C for at least 48 hours. Methods of heating
shall be to the approval of the Engineer.
Ducts shall not be warmed with steam.
22.8.8.6 Vertical Grouting

In lieu of a positive shut-off, vertical or near vertical tendon ducts for grouting shall terminate in
reservoirs at the upper-most point. The reservoir shall have sufficient capacity to store excess grout
and bleed water. Visible grout levels shall be maintained in the reservoirs, which shall be maintained
until the grout has set.
Grout shall be injected at a rate of 5 m of duct per minute.
22.8.8.7 Post-grouting Inspection

Vacuum grouting shall be used to fill any voids that expose strands discovered in the grouting
process.
Where possible, all anchorages and high-point vents shall be drilled and probed 48 hours after
grouting, until the Engineer is assured that no bleed water or subsidence, such as settlement, voids
exist. After the Engineer is assured that voids do not exist, only one or two anchorages per span
shall be drilled and probed to ensure quality grouting. Any voids discovered should be filled
immediately with the approved grout.
22.8.8.8 Finishing
The following requirements apply:
a. Valves, caps, and vent pipes shall not be removed or opened until the grout has set.
Page 22-35
b. Vent ends shall be removed at least 25 mm below the concrete surface after the grout has
set.
c. Voids shall be filled with epoxy grout. All miscellaneous material used for sealing grout caps
shall be removed before carrying out further work to protect end anchorages.
22.8.8.9 Protection of End Anchorages

Permanent grout caps constructed from either stainless steel or fibre-reinforced polymer shall be
specified.
The following requirements apply:
a. Within seven days upon completion of the grouting, the anchorage of post-tensioning bars
and tendons shall be protected, as indicated in the Contract documents. The application of
the elastomeric coating may be delayed up to 90 days after grouting. Plastic or stainless steel
threaded caps shall be used to plug all grout in- and outlets. A sand-filled epoxy grout suitable
for machinery base plates shall be used to construct all pour-backs located at anchorages of
expansion joints or other areas exposed to the elements.
b. All laitance, grease, curing compounds, surface treatments, coatings, and oils shall be
removed by grit or water blasting, using a minimum 70 MPa nozzle pressure. The surface
shall be flushed with water and blown dry. Surfaces shall be clean, sound, and without any
standing water. In case of dispute, ACI 503 (1997) shall be followed for substrate testing and
a minimum of 1.2 MPa tension, or pull-off value, is developed.
c. Epoxy shall be mixed and applied as per the manufacturer's current standard technical
guidelines. All pour-backs shall be in leak-proof forms, creating neat lines. Epoxy grout
pumping shall be permitted for proper installation. Forms shall be constructed to maintain a
liquid head to insure intimate contact with the concrete surface. Vents shall be used as
needed to provide for the escape of air to insure complete filling of the forms.
d. Exposed pour-back or group cap surfaces, except on transverse tendons, shall be coated
with an elastomeric coating system having a thickness of 760 μm to 1,140 μm. Concrete,
grout caps, or other substrates shall be structurally sound, clean, and dry. Concrete shall be
a minimum of 28 days old. Laitance, grease, curing compounds, surface treatments,
coatings, and oils shall be removed by grit or water blasting using a minimum 70 MPa nozzle
pressure to establish the anchor pattern. Surfaces shall be blown with compressed air to
remove dust or water.
e. A 0.6 m by 1.2 m concrete test block shall be constructed with a similar surface texture to the
coated surfaces and a vertical face shall be coated with the elastomeric coating system
chosen. To achieve a coating thickness between 760 μm to 1,140 μm, without runs and drips,
the Contractor shall have to determine the number of coats needed. Elastomeric coatings
shall be mixed and applied as per the manufacturer's current standard technical
specifications. Spray or roller application may be permitted; spray application is preferred.
Coatings shall be applied using approved and experienced personnel with a minimum of
three years experience applying similar polyurethane systems. Credentials of these persons
shall be submitted to the Engineer for review and consideration for approval.
22.8.8.10 Construction Traffic and Operations Causing Vibrations

For the designated period of time after grouting of a tendon begins, vibrations from all sources —
such as moving vehicles, jackhammers, compressors, and generators — that are operating within
the affected bridge superstructure shall be eliminated and pile-driving and soil compaction within 90
m of the affected superstructure shall not be permitted. The designated period of time shall be taken
as four hours for prequalified anti-bleed grout and 24 hours for plain grout. The affected bridge
Page 22-36
superstructure shall be taken as that portion of the total superstructure that is 90 m up- or down-
station of the ends of the span in which grouting is taking place.
22.8.8.11 Grouting Trials

At least 56 days before the planned commencement of fixing ducts for the post-tensioning permanent
works, the Contractor shall carry out full-scale grouting trials. The trial shall comprise a 25m long
concrete beam 350mm wide and 1500mm deep, incorporating one tendon with a high point and a
low point in a profile to be instructed by the Engineer. All relevant details of ducts, vents, duct
supports, prestressing anchorages, prestressing strands, grout inlets and outlets shall be
incorporated.
The tendons shall be sufficiently tensioned such that the strands within the duct take up a
representative alignment. All personnel, system methods and materials are to be those proposed for
the permanent works, and shall have been submitted to the Engineer as part of the detailed method
statement required in Section 22.8.8.
Grouting and testing shall be carried out in accordance with the specification in this chapter.
After 3 days the Contractor shall carefully cut and expose cross-sections and longitudinal sections
of the duct and anchorages where directed by the Engineer to demonstrate that the duct is fully
grouted.
A report shall be prepared by the Contractor giving full details of the trial, testing results and
photographs of the cut sections.
Grouting of the ducts shall be shown to leave no void which has a radial dimension greater than 5%
of the diameter of the duct or which poses a risk to the protective system. The location of the voids
with respect to grout vents and their adequate grouting and subsequent sealing, and the disposition
of the steel tendons within the body of the grout shall be reported.
Post-tensioning of the permanent works will not be permitted without the written approval of the
Engineer to the grouting procedures and formal acceptance of the results of the grouting trial.
22.8.8.12 Field Testing of Grout for Quality Control

a. General Conditions
Field testing shall comprise suitability testing of the materials assessment, and acceptance testing
of the grouting trials and actual works operations.
Suitability testing shall wherever possible be carried out in the conditions of temperature and
humidity expected on site but in the absence of this data the conditions of temperature and relative
humidity at test shall be as follows:
• Temperature: 20°C ± 2°C
• Relative humidity: > 65%
Variations in temperature and humidity on site are likely to cause variations in the test results and
shall be reported.
The temperature of the freshly mixed grout shall be given in all test reports.
b. Fluidity Test
1. Principle
The fluidity of the grout, expressed in seconds, is a measure of time necessary for a stated quantity
of grout to pass through the orifice of the cone, under stated conditions.
2. Apparatus
Page 22-37
The following apparatus is required for the test:

I. Cone - A cone of the dimensions given in Figure 22-1. It shall be robust and manufactured
from materials not reactive with any materials specified. A tap shall be fitted at the lower cone
orifice.
II. Sieving medium - The sieving medium aperture shall be 1.5mm and the sieving medium shall
be fitted as shown in Figure 22-1, and be removable.
III. Stopwatch - The stopwatch shall be accurate to 0.2 seconds in 60 seconds and shall show
time to 0.1 seconds.
IV. Graduated cylinder of minimum 1 litre capacity.
3. Test Procedure
Mount the cone with its axis vertical and its largest diameter uppermost. Fix the sieving medium at
the position indicated in Figure 22-1: Cone for Fluidity Test. During the test, prevent the cone from
vibrating. Place the cylinder under the cone outlet. All surfaces of the cone shall be clean and shall
be dampened so that the surfaces are moist but without free water. Close the lower cone orifice.
Pour the grout through the sieving medium to fill the conical section of the cone. Pouring shall be
sufficiently slow to prevent the build-up of air in the grout in the cone. Open the lower cone orifice
and, at the same time, start the stopwatch. Measure the time taken to the nearest 0.5s to fill the
cylinder to 1 litre. The presence of lumps on the sieving medium shall be reported. For suitability
testing three tests shall be carried out, the first immediately after the grout is mixed and the remaining
two tests 30 minutes after the grout is mixed. The grout shall be kept agitated while awaiting testing.
Figure 22-1: Cone for Fluidity Test.

4. Reporting of Results
Page 22-38
Report the time to the nearest 0.5 s. Report also the presence of lumps. Report the result as the
average of the times determined to the nearest 0.5 of the second and third tests, separately from the
results of the first test.
For acceptance testing, the test shall be performed on grout from each anchorage outlet and from
the mixer at the start and end of grouting of each duct.
c. Bleeding Test
1. Principle
The test consists of measuring the quantity of water remaining on the surface of the grout which has
been allowed to stand protected from evaporation.
2. Apparatus
A transparent cylinder 50mm internal diameter and 200mm in height graduated in mm.
3. Test Procedure
Place the cylinder on a surface free form shocks or vibration. The grout used should be from the
same batch as that used for the fluidity test.
Pour grout into the cylinder to a height of approximately 150mm and seal the cylinder to prevent
evaporation. Note the height to the top of the grout (h) ignoring the meniscus. After 3 hours, measure
the depth of water on top of the grout (h1). After 24 hours, check whether the water has been
reabsorbed. The test is carried out on one sample of grout.
Bleeding at the end of 3 hours is given by:
h1 × 100(%)
h
where:
h1 is the height in mm of water on the surface of the grout after 3 hours.
h is the initial height in mm of grout.
The report shall state the range of air temperatures and the grout temperature at the time of test, the
bleeding at 3 hours and whether the water has been reabsorbed after 24 hours.
For acceptance testing, a minimum of two tests per day shall be performed.
d. Volume Change Test

1. Principle
The volume change is measured as a percentage of the volume of grout between the start and the
end of the test. The test measures mainly the volume change caused by segregation, contraction or
expansion.
The volume change test may be a continuation of the bleeding test.
2. Apparatus
A transparent cylinder 50mm internal diameter and 200mm in height graduated in mm.
3. Test procedure
Place the cylinder on a surface free from shocks or vibration. Fill it with grout to approximately
150mm and seal the cylinder to prevent evaporation. Note the height to the top of the grout h ignoring
the meniscus. 24 hours after filling the cylinder measure the height of the grout in the cylinder (h2).
Page 22-39
Volume change at the end of 24 hours given by:
(h2 − h) × 100(%)
h
where:
h is the initial height in mm of grout
h2 is the height in mm of grout after 24 hours.
The report shall state the range of air temperatures during the test and the volume change.
For acceptance testing the test shall be performed twice each day.
22.8.8.13 Admixtures
a. General
Admixtures shall be used to achieve a low water/cement ratio and impart good fluidity, minimum
bleed and volume stability or expansion to the grout to comply with Article 22.7.2.3. They should be
added on site during the mixing process and used in accordance with the manufacturer's
recommendations.
b. Types
Admixtures are divided into two types - expanding and non-expanding.
Expanding grout admixtures are supplied as powders which expand to ensure there is no decrease
in the volume of grout at the end of the hardening period. Non-expanding grout admixtures are
supplied in liquid or powder form and shall not exhibit any measurable decrease in volume after
curing.
Both types of grout admixture may also permit a reduction in water/cement ratio, improve fluidity,
reduce bleeding and retard the set of the grout.
Admixtures may be used singly or in combination to obtain the required grout performance.
Admixtures used in combination shall be checked for compatibility.
c. Chemical Composition
Admixtures shall not contain substances in quantities which will adversely affect the grout or the
corrosion protection of the prestressing steel. Thiocyanate, nitrates, formate, fluorides and sulphides
shall not be used in admixtures.
d. Material Requirements
The admixture shall not segregate and shall be uniform in colour. The composition shall not change
and the supplier shall operate a quality system complying with BS EN ISO 9001:2015. Where
appropriate, admixtures shall comply with BS 5075-1:1982 and BS 5075-3:1982.
Other admixtures shall be permitted provided they satisfy Sections 6, 7.1 and 7.3 of BS 5075-1:1982
and full account is taken of their effects on the finished product and their fitness for purpose. Data
on their suitability, including previous experience with such materials, shall be made available and
records of the details and performance of such materials shall be maintained.
e. Corrosion
Grout admixtures shall not cause the grout to promote corrosion of the prestressing steel by rusting,
pitting, stress corrosion or hydrogen embrittlement.
Page 22-40
f. Dosage
The optimum dosage of the admixture shall be determined by trial mixes with the cement to be used
in the grout. This dosage shall be expressed as percent by mass of cement. It shall be within the
range recommended by the supplier and shall not exceed 5% by mass of the cement.
The method of measuring dosage and checking weights of pre-packed dry materials shall be agreed
with the Engineer.
22.9 Structural Cable Members

This section of the specification shall apply to the supply, fabrication, delivery, testing, installation,
stressing, and permanent corrosion protection of the hanger cables forming the structural connection
between the concrete deck and the supporting structures, and any transverse tie cables connecting
the supporting structures.
Forming tubes, anchorage bearing plates together with any other material necessary to form a
complete hanger or tie system in accordance with the Contract plans and Contract documents, shall
also be subject to the requirements of this section.
The arrangement and details of the cables shown on the Contract plans are indicative only. Final
details and dimensions are to be determined by the Contractor and shall be subject to the approval
of the Engineer.
22.9.1 Description of System and General Requirements

The general arrangement of the cable systems shall be as shown on the Contract plans. Each cable
shall be comprised of an assembly of parallel, individually protected seven wire strands with wedge
anchorages, contained within an additional outer casing. The cable members shall be arranged to
enable the replacement of any cable, if required, on a strand by strand basis, with minimum
disruption to traffic using the bridge. To permit this, the space between the individual strands and
the outer casing shall not contain any filler material in the free length between the anchorage zones.
The design and arrangement of the cables shall include provision for the measurement and final
adjustment of their tension under full permanent loading. However, during construction, initial
installation and tensioning of multi-strand cable members may be carried out on a strand by strand
basis by a method approved by the Engineer. After completion of construction, and with all
permanent dead load in place, the load in each complete hanger member shall be measured, and if
necessary adjusted using a calibrated hydraulic jack or equivalent device. The associated fine
adjustment of cable length shall be by means of a securing nut on an externally threaded anchor
member. The use of shimming to provide cable length adjustment shall not be permitted.
22.9.2 Strand for Structural Cables

22.9.2.1 Materials
The individual strands for cables shall be 15.24mm diameter seven wire low relaxation prestressing
strands conforming to AASHTO M 203M/M 203-12 (ASTM A416/ A416M - 12) Grade 1860 MPa or
15.7mm diameter seven wire low relaxation prestressing strands conforming to EN 10138 – BS
5896:2012 Grade 1770 MPa, together with the following additional requirements:
a. Zinc Coating
Before the final wire drawing operation, the wire for the strands shall be galvanized to give a uniform
zinc coating with an average weight of 280g/m2 on the finished wires. The weight of zinc coating
shall have a minimum value of 220g/m2 and a maximum value of 350g/m2.
Page 22-41
b. High Density Polyethylene (HDPE) Coating to Strand

The strand shall be completely coated with an HDPE sheath extruded over the strand and protective
filler material. The HDPE sheath shall have a minimum thickness of 1.5mm (thickness tolerance -0,
+0.25mm), and shall tightly follow the outer contours of the strand, so that the outer surface of the
HDPE sheath need not necessarily be circular. The HDPE coating material shall be virgin high
density polyethylene complying with the requirements of Article 22.9.3.1, and shall be coloured black.
The minimum longitudinal bond strength between the sheath and the strand wires shall be 1.0kN
per 300mm length of strand. The Manufacturer shall provide the Engineer with an evidence of having
such bond strength.
c. Protective Filler
All strands shall be further protected against corrosion by the application during fabrication of an
approved petroleum wax material containing anti-corrosive additives. This material shall have a
melting point of between 100o C and 120o C, and shall fill both the inter-wire voids, together with any
spaces between the wires and the HDPE sheath. Sufficient filler material shall be incorporated in the
strand to prevent the flow of water along it should the HDPE sheath be locally damaged.
d. Resistance of the HDPE Sheath to Accidental Damage

The HDPE sheath shall have a resistance to accidental damage determined by a falling weight test,
using a test apparatus and procedure similar to that described in ASTM G14-88 (1996)e1, but with
a specially shaped cup nose. This nose shall be wedge shaped with an included angle of 90o, an
edge radius of 1.0mm, and a length of 20mm. The edge of the nose shall be arranged to fall
perpendicular to the axis of the strand, which shall be positioned such that impact occurs on a single
wire. Perforation of the sheath shall not occur under an impact of 6.0 Newton metres.
e. Fatigue Resistance
Unless otherwise specified in the Contract documents, the strands shall have a fatigue resistance of
2 million cycles with a maximum force applied to the strands representing half its rated rupture load
and with a stress range of 280 MPa.
f. Ductility
The strand ductility shall be measured by the one-pin test specified in Appendix C of the Post
Tensioning Institute publication “Recommendations for Stay Cable Design, Testing, and Installation”.
The pin test efficiency (PTE) as measured by this deflected tensile test shall not be less than 80%.
g. Free Curvature of Strand

With a length of strand freely lying on a smooth flat surface, the maximum deviation from a one metre
long gauge length, measured on the inside of the strand shall not exceed 15 mm.
h. Environmental Resistance
The resistance to environmental exposure shall be such that after a 7000 hours duration xenon-arc
exposure to UV radiation:
• No degradation in mechanical properties shall occur when tested in accordance with BS EN
ISO 527-1:2012.
• The HDPE envelope shall completely prevent any penetration when exposed for 1000 hours
to salt mist as per ASTM B117 - 11.
• The shore D hardness shall not be increased by more than 20 %.
Page 22-42
i. Protective Filler
The weight of wax per unit length of strand shall be specified by the stay cable Supplier, who shall
propose the range of permitted maximum and minimum values. The minimum value shall ensure
that any possible water flow or passage is prevented, and the maximum value shall provide for
sufficient bond between the wires and the protective coating. The test procedure shall consist of
weighing a suitable length of complete strand, followed by longitudinal cutting and removal of the
HPDE sheath. The weight of wax shall then be established by further weighing of the cleaned and
degreased wires and HDPE sheath. The stay cable supplier shall propose a water tightness test to
the approval of the Engineer at no cost to the Owner.
22.9.2.2 Production Testing of Strand

a. Unit of Production for Sampling
The unit of production shall be defined as a production lot of maximum 10-ton or fractions thereof
from which test pieces shall be selected.
b. Standard Properties
Tests for standard properties shall be carried out in accordance with AASHTO M 203M/M 203-12
(ASTM A416/ A416M - 12) or BS 5896:2012 and the requirements of Article 22.7.1.2.
c. Particular Properties
1. Weight of Galvanising
The weight of galvanizing shall be determined as per the ASTM A90/ A90M – 11 method. The
frequency of testing shall be not less than one test per five production units.
2. Fatigue
Unless agreed otherwise, one fatigue test shall be carried out for each five units of production or
fraction thereof. For each test, 3 samples shall be taken. If the test fails two more tests are to be
done. If one of the two additional tests fails the quantity of strand represented by the 3 samples shall
be rejected.
3. Ductility
A "One-pin deflected tensile test" in accordance with Appendix C of the Post Tensioning Institute
publication “Recommendations for Stay Cable Design, Testing, and Installation” shall be carried out
for each five units of production.
4. Curvature of Strand
A straightness check shall be made for every unit of production.
22.9.2.3 Testing of HDPE Coating

a. Mechanical Resistance Test
One mechanical resistance test as per Sub-article d, Resistance of the HDPE sheath to accidental
damage, of Article 22.9.2.1 shall be carried out for each unit of production. The stay cable supplier
shall further demonstrate to the satisfaction of the Engineer that no cracking of the HDPE will occur
due to the calculated in service stress variations in the HDPE.
b. Resistance to Environment
At least one 7000 hours duration xenon-arc exposure test in accordance with BS EN ISO 4892-
2:2006+A1:2009 at a temperature of 60o C shall be carried out in a suitable chamber (Weather-0-
Page 22-43
meter or equivalent) to demonstrate compliance with the requirements of Sub-article h,

Environmental Resistance, of Article 22.9.2.1.
22.9.2.4 Petroleum Wax Filling

One test of void filling as per Sub-article i, Protective filler, of Article 22.9.2.1 shall be carried out for
each unit of production or fraction thereof unless otherwise directed by the Engineer.
22.9.2.5 Delivery and Storage of Strand

For delivery to the bridge site, lengths of strand shall preferably be supplied on either wooden or
steel reels. Supply of strand in unreeled coils shall only be acceptable provided the Contractor has
demonstrated to the satisfaction of the Engineer that the methods used for transport, unloading, and
handling of the coils will not cause any damage or deterioration of the strands.
The minimum diameter of reeled or coiled strand shall not be less than 50D, where D is the outside
diameter of the strand outer coating.
22.9.3 Outer Casing

The outer casing for the cables shall consist of a circular cross-section high density polyethylene
(HDPE) or stainless steel pipe conforming to the requirements of the following sections. The pipe
materials and dimensions shall be as shown in the Contract plans.
22.9.3.1 HDPE Pipe

HDPE casing pipe shall be manufactured from virgin HDPE material, and shall meet the specific cell
category requirements for PE 3408 material as defined by table X1 of ASTM D3350-12. The resultant
acceptable values of primary properties for the PE material shall be as follows.
Table 22-7: Acceptable values of primary properties for the PE material
Property ASTM Test Method Value
Density, g/cc ASTM D1505 - 10 0.941 - 0.955
Melt Index ASTM D1238 - 10 Max. of 1
Flexural modulus, Mpa ASTM D790 - 10 550 ≤ 1100
Tensile Strength at Yield, Mpa ASTM D638 - 10 21 ≤ 28
Environmental Stress Crack ASTM D1639 - 90(1996)e1

192
Resistance, F20, hrs., min. (Condition C)
Hydrostatic Design Basis, Mpa ASTM D2837 - 11 8.62 (A)
• Verification tests for mechanical and other properties on each size of pipe required shall be
carried out in accordance with ASTM D3350 - 12. The material shall meet the requirement of
a class C material: it shall be black, weather resistant, and contain not less than 2.3 percent
of carbon black and 1000 ppm of antioxidant.
The required length of the HDPE pipe shall be obtained by continuous extrusion or by fusion welding
of shorter lengths performed in accordance with ASTM D2657 - 07. The Contractor shall produce
sample welds to demonstrate the adequacy of the proposed fusion welding procedure. At least three
sample welds shall be made for each pipe size and wall thickness.
Page 22-44
The Contractor shall demonstrate the durability of the HDPE pipe by carrying out an accelerated
aging test of at least 7000 hours duration xenon-arc exposure test in accordance with BS EN ISO
4892-2:2006+A1:2009 at a temperature of 60o. The test shall be carried out in a suitable chamber
(Weather-0-meter or equivalent) to demonstrate that:
• No degradation in mechanical properties shall occur when tested in accordance with BS EN
ISO 527-1:2012.
• The HDPE envelope shall completely prevent any penetration when exposed for 1000 hours
to salt mist as per ASTM B117 - 11.
• The shore D hardness shall not be increased by more than 20 %.
Procedures for packaging, handling and shipping the pipe shall ensure the pipe will not be damaged
when delivered to the site. A certificate of analysis shall be furnished for each shipment stating the
material meets this specification and showing results of tests.
22.9.3.2 Stainless Steel Pipe

Stainless steel casing pipe shall be Grade 316L. Pipe joints shall be welded before installation of the
cable strands. Pipe ends and details shall incorporate insulating devices to prevent bimetallic
contact. The Contractor shall propose suitable details for the pipe including jointing and installation
procedures which shall be subject to the Engineer’s approval. The pipe shall incorporate fixing
devices at intervals to allow for the possible installation of anti-vibration dampers.
22.9.4 Anchorages and Transition Zones

The cable anchorages shall be designed to anchor each strand individually by means of conical steel
wedges. These anchorages shall meet the acceptance criteria as specified in Section 6.1 of the 1993
edition of the Post-Tensioning Institute (PTI) "Recommendations for Stay Cable Design, Testing and
Installation" except as otherwise required by the Contract particular specifications.
Apart from the wedge anchor jaws, the steel wires of the strands shall not be in contact with any
other steel elements.
The angle of deviation of any strand in the anchorage or in the transition zone shall not be more than
0.025 radians. The anchorage and/or the transition zone shall include means to reduce the flexural
stress variations in the strand at the jaw due to cable oscillations and movement. The supplier of the
cable shall demonstrate the adequacy of such means to the satisfaction of the Engineer.
After completion of cable installation, and final adjustment of load, the anchor zones shall be
completely filled with a petroleum wax filler containing corrosion inhibiting additives. The type and
details of the filler material shall be proposed by the Contractor and shall be subject to the approval
of the Engineer.
The Contractor shall submit all material specifications, not specified herein or on the Contract plans,
to the Engineer for review and approval. The components of the assembly shall have, whenever
possible, an AASTHO or ASTM material and test designation numbers.
The Supplier of the stay cable system shall submit to the Engineer for review and approval assembly
drawings for each size and type of anchorages required by the Project, showing all dimensions and
materials of the main components.
All other components such as bearing plates, recess tubes, steel flanges, deviators and guides
shown on the Contract plans shall be of a type and strength suitable for the intended use. The
Contractor shall submit to the Engineer calculations for the justification of these components.
Page 22-45
22.9.5 Stay Cable Testing

The Contractor shall provide all materials, anchorages, stay cable specimens, strand specimens and
all labour and equipment, and carry out fatigue, ultimate strength, ductility and strand endurance
testing as follows.
Fatigue and ultimate strength of fully assembled cables for acceptance of the anchorage system,
unless evidence of previous testing is submitted and accepted by the Engineer, shall be as permitted
by Article 22.9.5.3.
Acceptance and other testing of individual strands and/or sheathing specimens shall be as required
by Article 22.9.2.2 and Article 22.9.2.3.
The specimen assemblies shall be tested by a recognized independent testing laboratory approved
by the Engineer. The Engineer shall be notified a minimum of 30 days in advance of any fabrication
or testing so that a representative of the Engineer may be present when the respective work is being
performed.
All testing data and testing results shall be submitted to the Engineer for approval.
Fabrication of anchorages or stay cable strands shall not begin until the required tests (or previous
tests reports) have been successfully completed and submitted and written approval has been given
by the Engineer.
22.9.5.1 Strand Acceptance Tests

The strand acceptance tests and frequency shall be as specified in Article 22.9.2.2.
22.9.5.2 Cable Acceptance Tests

Unless otherwise accepted by the Engineer, three complete fully assembled cable specimens shall
be fabricated for testing. One specimen shall be made representing the smallest cable required, a
mid-range cable and a large (the largest when the testing machine is of sufficient capacity) cable.
Each specimen shall be fully representative of all details and manufacturing processes for production
anchorages.
Cables shall be tested with their entire load bearing appurtenances. They shall include an active
anchorage and a passive anchorage. Strand deviations shall be representative of the actual installed
cable deviations. At the discretion of the Engineer, the anchorages of the test specimens may not
be injected with wax for the tests.
Test parameters and acceptance criteria shall be as detailed in Section 6.1 of the 1993 edition of the
Post-Tensioning Institute (PTI) "Recommendations for Stay Cable Design, Testing and Installation",
except that, in order to be consistent with the fatigue safety philosophy (Figure 5.1 of the above
reference), the stress range shall be equal to 210 MPa, corresponding to the specified component
fatigue stress range of 280 MPa.
22.9.5.3 Acceptance of Prior Tests of Cables

When at least three cable tests with the same specified stress range as in the Project have been
conducted for previous projects on specimens similar to those recommended for the Project (not
necessarily of the same sizes, but at least half the size of the largest for the Project), the previous
tests may be used as the basis for stay cable approval, subject to review and acceptance by the
Engineer. However, the quality control tests required by Article 22.9.2.2 must be carried out to
establish that the strand supplied for the Project has geometrical, mechanical and fatigue
characteristics equal to the strand used in the acceptance tests of the stay cable specimens in the
previous projects. Further, the stay anchorage hardware must be the same as in the previous tests.
Page 22-46
22.9.6 Installation
Cables shall be installed in accordance with procedures prescribed by the cable system Supplier.
The Contractor shall submit for the Engineer’s approval a method statement fully describing the
installation operations. This shall include a description of the main items of the equipment required,
as well as an installation sequence prescribing the force and elongation of each cable.
The cable installation procedure shall be compatible with the bridge construction sequence, and the
Engineer’s approval of the Contractor's erection sequence and equipment shall not relieve the
Contractor from his responsibility for performing the work required by the Contract documents.
Stay cables may be fabricated into fixed length cables or erected in-situ.
The Contractor shall be responsible for the determination of and monitoring of forces, and deflections
in the permanent structure at all erection stages as are caused by his proposed erection process.
22.9.6.1 Handling and Installation

The Contractor shall work in accordance with procedures developed to ensure that the cables and
associated components will not be damaged during handling and installation. These procedures
shall be subject to the approval of the Engineer.
All cables and associated components shall be protected from corrosion, excessive heat, abrasion
and other harmful effects throughout the fabrication and installation.
During fabrication, transport, storage, and installation, HDPE outer casing pipes shall at no stage be
bent to radiuses of less than 60 times their outside diameter.
All damage to cables or associated components shall be evaluated by the Engineer and remedied
prior to installation of the cables. Any damaged strand or load carrying components shall be
replaced. Minor damage to non load-carrying components may be repaired to the Engineer's
satisfaction prior to installation.
22.9.6.2 Stressing
Jacks and gauges for cable installation shall be calibrated using a load cell or calibrated static load
machine within one month prior to the beginning of the cable installation, and every 6 months
thereafter, for the duration of cable installation. The 6-month recalibration may be performed using
a master gauge, provided that the master gauge is calibrated with the field gauges at the time of
initial jack calibration.
Prefabricated cables shall only be tensioned as a full unit. For cables prefabricated at the bridge site,
pre tensioning of individual strands may be allowed up to 10 percent of the final installation force
called for in the cable. Procedures shall be developed to ensure that the pretension in all strands is
equalized within a range of 2.5%.
In-situ installed hanger cables may be tensioned one by one provided that it can be demonstrated,
to the satisfaction of the Engineer, that the final tension and elongation of each strand is equalized
within a range of 2.5 %. Tensioning of strands one by one by applying forces to the strands deduced
from calculations based on the deformation of the structure shall not be permitted. The preferred
method shall be the so-called "isotension" method. All stressing must be recorded automatically with
a computer system connected to load cells. The use of pressure gauges for strand load
measurement will not be permitted.
Cables shall be capable of being tensioned, de-tensioned or re-tensioned more than once during
and after the construction of the structure. These operations may be carried out either by full jacking
of the live anchorage and adjustable ring setting, or strand by strand. If de-tensioning strand by
strand in such a way that the "gripping" zone is incorporated in the stressed portion of the stay, it
shall be demonstrated by testing that a single strand anchored and fitted with the jaws and the strand
Page 22-47
used in the Project can withstand without rupture 0.1 million cycles with a stress range of 350 MPa
and at an upper stress equal to 55 percent of the guaranteed ultimate tensile stress. It is not permitted
to de-tension or re-tension strand by strand in such a way that already "gripped" and newly "gripped"
lengths overlap. No "gripped" lengths of strand shall permanently be left on the stressed portion of
the stay. Maximum cable tension during construction shall not exceed 55 percent of the cable
guaranteed ultimate tensile strength.
22.9.6.3 Finishing Operations

Completion of the anchorage and transition zones (removal of surplus strand length; wax injection
of the anchorage zone; installation of guides, deviators, vibration dampers etc.) shall not be
commenced until the tension of each cable has been finally adjusted to the satisfaction of the
Engineer. The Contractor shall carry out these operations in accordance with a detailed procedure
22.9.6.4 Re-stressing
The cable tensions shall be re-measured and adjusted to the specified tensions at the following times
after the initial installation and tensioning of the cables:
• 1 year after initial installation
• 5 years after initial installation
22.9.7 Vibration Damping

The Contractor shall design, supply and install a suitable number and type of dampers to limit cable
oscillations for the prescribed cable layouts and tensions for the full range of design wind speed from
0 to 45 metre per second. The damping system shall be chosen to have minimum visual impact and
shall be subject to the Engineer’s approval. It shall be easily replaceable during the life of the bridge.
The acceptance criteria for cable vibrations shall be that the maximum amplitude of vibration shall
not exceed the lesser of the following:
• ± 5 cm
• ± L / 500
where L is the free length of the cable between its effective anchor points.
Page 22-48
INDEX
Admixtures, 22-39 gauges, 22-1, 22-10, 22-11, 22-20, 22-45, 22-

allowable stresses, 22-1 46
ambient temperature, 22-34 girder, 22-1, 22-6, 22-26
Anchor plates, 22-22 grout, 22-1, 22-11, 22-14, 22-15, 22-17, 22-19,
anchorage assemblies, 22-1, 22-19 22-26, 22-27, 22-30, 22-31, 22-32, 22-33,
anchorages, 22-1, 22-7, 22-9, 22-11, 22-13, 22-34, 22-35, 22-36, 22-37, 22-38, 22-39
22-17, 22-19, 22-20, 22-22, 22-25, 22-26, Grout openings, 22-24
22-29, 22-30, 22-33, 22-34, 22-35, 22-36, grouting operations, 22-6, 22-14, 22-30, 22-31
22-40, 22-44, 22-45 hanger cables, 22-1, 22-39, 22-46
beam, 22-1, 22-36 HDPE sheath, 22-40, 22-41, 22-42
bleeding, 22-15, 22-38, 22-39 hot weather, 22-34
Bleeding, 22-3, 22-15, 22-17, 22-37, 22-38 humidity, 22-36
Bond transfer lengths, 22-11 hydrogen embrittlement, 22-39
cable vibrations, 22-46 individual mould system, 22-21
Cables, 22-28, 22-40, 22-45, 22-46 injection tubes, 22-33
caps, 22-17, 22-26, 22-33, 22-35 inlets, 22-19, 22-26, 22-31, 22-33, 22-36
CARES certificate, 22-9 jacks, 22-10, 22-11, 22-19, 22-20
cast-in-place, 22-1, 22-20 load cell, 22-20, 22-45
Chemical composition, 22-28 local zone, 22-12, 22-27
coefficients, 22-1, 22-21 lot number, 22-14, 22-28
column, 22-1 low points, 22-19, 22-25, 22-30
concrete placement, 22-17, 22-19, 22-24, 22- mandrels, 22-24
25, 22-26 mechanical resistance, 22-42
cone, 22-15, 22-17, 22-36, 22-37 Moderate atmosphere, 22-27
constant delivery pressure, 22-32 multiple-strand stressing, 22-21
corrosion, 22-1, 22-16, 22-17, 22-22, 22-27, nonbleeding characteristic, 22-15
22-29, 22-30, 22-39, 22-40, 22-44, 22-45 optimum dosage, 22-39
Corrosion inhibitors, 22-30 outlets, 22-15, 22-19, 22-25, 22-26, 22-33, 22-
Coupling, 22-19 35, 22-36
damp atmosphere, 22-27 petroleum wax material, 22-40
dampers, 22-43, 22-46 physical damage, 22-29, 22-30
degradation, 22-41, 22-43 Plant Certification, 22-6
Department of Transport, iii post-tensioning, 22-1, 22-7, 22-8, 22-9, 22-10,
design procedures, 22-1 22-12, 22-14, 22-19, 22-20, 22-22, 22-23,
Draped pretension tendons, 22-21 22-24, 22-25, 22-27, 22-30, 22-32, 22-35,
draped strand, 22-22, 22-23 22-36
duct profile, 22-25 precast, 22-1, 22-6, 22-24
ducts, 22-1, 22-7, 22-8, 22-9, 22-11, 22-17, pressure gauge, 22-20, 22-24, 22-32
22-18, 22-19, 22-21, 22-23, 22-24, 22-25, prestress losses, 22-1
22-26, 22-27, 22-30, 22-31, 22-32, 22-33, prestressing, 22-1, 22-3, 22-5, 22-6, 22-7, 22-
22-34, 22-36 8, 22-9, 22-11, 22-14, 22-17, 22-19, 22-20,
dynamic test, 22-11 22-21, 22-22, 22-23, 22-26, 22-27, 22-28,
elongation measurements, 22-22, 22-23 22-29, 22-30, 22-31, 22-36, 22-39, 22-40
fatigue resistance, 22-41 prestressing strands, 22-23, 22-36, 22-40
Field testing, 22-15, 22-36 prestressing system, 22-1, 22-7
fluidity, 22-15, 22-32, 22-34, 22-36, 22-38, 22- pretensioning, 22-1, 22-21, 22-22
39 rust, 22-27, 22-29, 22-30
friction, 22-1, 22-19, 22-20, 22-21, 22-22, 22- saltwater environment, 22-18
23 Sheathing, 22-17
skin reinforcement, 22-12, 22-13
Page 22-49
slab, 22-1, 22-25 Test blocks, 22-12

stainless steel, 22-35, 22-42 test procedures, 22-12
Stainless steel, 22-43 testing equipment, 22-1, 22-31
Stay cables, 22-45 transverse tie cables, 22-1, 22-39
steam curing, 22-27 ultimate strength, 22-1, 22-11, 22-44
steel wedges, 22-44 unbonded tendons, 22-11
steel wires, 22-10, 22-44 Valves, 22-35
straight tendons, 22-21, 22-24 vents, 22-8, 22-17, 22-19, 22-24, 22-27, 22-
strand ductility, 22-41 33, 22-34, 22-36
Strand splicing, 22-22 Very dry atmosphere, 22-27
subcontractor, 22-5, 22-6, 22-27, 22-28 vibrations from, 22-35
supervisor, 22-6, 22-7, 22-19, 22-27, 22-31 volume change, 22-15, 22-38
tendon elongation, 22-20 written agreement, 22-33
tendon elongations, 22-21 zinc coating, 22-40
Page 22-50
PART 2
ROAD STRUCTURES
CHAPTER 23 - STEEL STRUCTURES
DOCUMENT NO: TR-

FIRST EDITION
JANUARY 2018
Chapter 23: Steel Structures

TABLE OF CONTENTS
23 Steel Structures ............................................................................................................... 23-1
23.1 Terminology for Steel Work.......................................................................................... 23-1
23.2 General Requirements for Steel Structure Work .......................................................... 23-2
23.2.2 Mill Inspection and Tests for Steel Structures ....................................................... 23-9
23.2.3 Notice of Beginning Steel Structure Work ........................................................... 23-10
23.2.4 Shop Inspection for Steel Structures ................................................................... 23-10
23.2.5 Material Traceability and Shipping for Steel Structures ....................................... 23-10
23.2.6 Handling and Storing Materials for Steel Structures ............................................ 23-12
23.2.7 Field Inspection for Steel Structures ................................................................... 23-13
23.2.8 Falsework for Steel Structures ............................................................................ 23-13
23.2.9 Continuous Members of Steel Structures ............................................................ 23-13
23.3 Drawings for Steel Structures .................................................................................... 23-14
23.3.1 Shop Drawings for Steel Structures .................................................................... 23-14
23.3.2 Erection Drawings for Steel Structures ............................................................... 23-14
23.3.3 Camber Diagrams for Steel Structures ............................................................... 23-15
23.3.4 Transportation Drawings for Steel Structures ...................................................... 23-15
23.4 Materials for Steel Structures ..................................................................................... 23-15
23.4.1 Structural Steel ................................................................................................... 23-15
23.4.2 High-strength Fasteners for Steel Structures ...................................................... 23-17
23.4.3 Other Structural Fasteners .................................................................................. 23-19
23.4.4 Welded Stud Shear Connectors.......................................................................... 23-20
23.4.5 Steel Forgings for Steel Structures ..................................................................... 23-21
23.4.6 Cold-finished Carbon Steel Shafting for Steel Structures .................................... 23-21
23.4.7 Mild Steel Castings for Steel Structures .............................................................. 23-21
23.4.8 Chromium Alloy-steel Castings for Steel Structures ............................................ 23-21
23.4.9 Iron Castings for Steel Structures ....................................................................... 23-21
23.4.10 Galvanising Steel Structures ............................................................................... 23-22
23.4.11 Welding Steel Structures .................................................................................... 23-22
23.5 Fabricating Steel Structures ....................................................................................... 23-23
23.5.1 Cutting, Shearing, and Machining for Steel Plates .............................................. 23-23
23.5.2 Cold Bending Steel Plates .................................................................................. 23-24
23.5.3 Straightening Steel ............................................................................................. 23-25
23.5.4 Applying Heat to Steel ........................................................................................ 23-25
23.5.5 Bolt Holes for Steel Structures ............................................................................ 23-31
23.5.6 Contact and Bearing Surfaces for Steel Structures ............................................. 23-34
23.5.7 Cleaning and Coating Steel Structures ............................................................... 23-35
23.5.8 Geometry for Members of Steel Structures ......................................................... 23-35
23.5.9 Surface Condition ............................................................................................... 23-37
23.5.10 Pins and rollers for Steel Structures .................................................................... 23-38
23.5.11 Eye Bars for Steel Structures .............................................................................. 23-38
23.5.12 Stiffeners for Steel Structures ............................................................................. 23-38
23.5.13 Abutting Joints for Steel Structures ..................................................................... 23-39
23.5.14 Fabrication of Stainless Steel.............................................................................. 23-39
23.5.15 Orthotropic-deck Superstructures ....................................................................... 23-39
23.5.16 Full-size Tests for Steel Structures ..................................................................... 23-40
23.6 Assembly of Steel Structures ..................................................................................... 23-40
23.6.1 Shop Assembly for Steel Structures.................................................................... 23-40
Page i
CHAPTER 23: STEEL STRUCTURES First Edition -January 2018
23.6.2 Evaluation of Steel Structure Assemblies............................................................ 23-42

23.6.3 Certification of Members or Components of Steel Structures .............................. 23-42
23.6.4 Bolting Steel Structures ...................................................................................... 23-43
23.6.5 Welded Connections for Steel Structures............................................................ 23-43
23.6.6 Preassembly of Field Connections for Steel Structures....................................... 23-43
23.6.7 Match-marking Connecting Parts for Steel Structures ......................................... 23-45
23.6.8 Steel Structure Connections Using Unfinished, Turned, or Ribbed Bolts ............ 23-45
23.6.9 Steel Structure Connections Using High-strength Bolts ...................................... 23-46
23.6.10 Welding for Steel Structures ............................................................................... 23-56
23.7 Erecting Steel Structures ........................................................................................... 23-59
23.7.1 Pre-erection Requirements ................................................................................. 23-59
23.7.2 Special Requirements to Resist Steel Weathering .............................................. 23-59
23.7.3 Aligning Steel Structure with Substructure .......................................................... 23-60
23.7.4 Placing Anchor Rods for Erection of Steel Structure ........................................... 23-60
23.7.5 Preparing Bearing Areas and Setting Bearings for Erection of Steel Structure .... 23-61
23.7.6 Tightening Anchor Rod Nuts for Erection of Steel Structure ................................ 23-61
23.7.7 Bearings for Erection of Steel Structures ............................................................ 23-61
23.7.8 Procedure to Erect a Steel Structure................................................................... 23-61
23.7.9 Field Assembly for Erection of a Steel Structure ................................................. 23-62
23.7.10 Connection of Pins for an Erected Steel Structure .............................................. 23-62
23.7.11 Correcting Misfits in an Erected Steel Structure .................................................. 23-63
23.8 Expansion Joints for Steel Structures ........................................................................ 23-63
23.9 Inspection and Final Acceptance for Steel Structures ................................................ 23-63
23.10 Additional Provisions for Curved Steel Girders........................................................... 23-64
23.10.1 Contractor’s Construction Plan for Curved Girder Bridge .................................... 23-64
23.10.2 Fabricating Materials for Curved Girder Bridges ................................................. 23-64
23.10.3 Transportation Plan for Curved Girders .............................................................. 23-66
23.10.4 Erecting Steel for Curved Girder Bridges ............................................................ 23-67
23.10.5 Erecting Decks for Curved Girder Bridges .......................................................... 23-67
23.10.6 Reporting Modification to Construction Plan for Curved Girder Bridge ................ 23-68
23.11 Post-weld Treatment for Steel Structures................................................................... 23-68
23.11.1 Ultrasonic Impact Treatment for Steel Structures ................................................ 23-68
23.12 Additional Requirements for Steel Structures ............................................................. 23-69
Index ........................................................................................................................................... 71
Page ii
LIST OF TABLES
Table 23-1: Designations and titles for AASHTO and ASTM standards that apply to steel
structures construction works .............................................................................................. 23-4
Table 23-2: Designations and titles for BS and BS EN standards that apply to steel structures
construction works .............................................................................................................. 23-6
Table 23-3: Tensile Properties of Stud Shear Connectors ................................................ 23-20
Table 23-4: Minimum Cold-bending Radii ......................................................................... 23-24
Table 23-5: Maximum temperature limits for heat applications .......................................... 23-25
Table 23-6: Bolt hole geometry ......................................................................................... 23-33
Table 23-7: Distances of bolt holes from edge of steel structure ....................................... 23-34
Table 23-8: ANSI surface roughness requirements ........................................................... 23-34
Table 23-9: Material and Dimension as per BS & BS EN Standards ................................. 23-37
Table 23-10: Minimum required bolt tension ..................................................................... 23-48
Table 23-11: Nut rotation from snug condition................................................................... 23-48
Table 23-12: Direct tension indicator requirements ........................................................... 23-54
Table 23-13: Acceptance Levels for internal imperfections in steel plates ......................... 23-69
Page iii
23 STEEL STRUCTURES
This chapter outlines standards and requirements for furnishing, fabricating, assembling, and
erecting steel structures and structural steel portions of other structures for the Project. This chapter
also outlines requirements for non-destructive testing for steel structures and structural steel
components of other structures. When performing such work for the Project, the Contractor shall
comply with the specifications in this chapter and in the Contract documents.
The Contractor shall fabricate and test steel structures and structural steel components of other
structures in accordance with these specifications and in compliance with the American Association
of State Highway and Transportation Officials (AASHTO) Standard Specifications for Transportation
Materials and Methods of Sampling and Testing, and the American Society for Testing and Materials
(ASTM), or the British Standards (BS) and European Standards (BS EN). Where steel structures
and steel components are fabricated and tested by standards other than AASHTO/ASTM, products
conforming to equivalent or higher standards will be acceptable if proven to be suitable.
23.1 Terminology for Steel Work

This section defines terminology that occurs throughout this chapter and that applies to work with
steel structures.
Main or Primary Load-Carrying Member or Component: Any part of a steel structure, including
the following, that supports the primary load for such a structure:
• Longitudinal or transverse rolled beams or fabricated girders (I or box, curved or straight)
• All truss members not designated as cross frames
• Cross frames, diaphragms and connection plates of horizontally curved beams or girders
• Rib members of steel arches
• Bracing members subjected to and specifically designed for traffic live load and/or other loads
• Cross frames or diaphragms at pier and abutment supports of tub or box girders (trapezoidal
members) and their connection plates
• Attachments and components of the above such as splice, cover, cross frame and diaphragm
connection and gusset plates, but not transverse and bearing stiffeners (unless acting as a
cross frame or diaphragm)
• Cables, moment release pins and links, and hangers
• All steel substructure members except those designated as secondary in the Contract
documents
• Other members as may be identified in the Contract documents
Miscellaneous Components: Any other components of a steel structure, which includes but is not
limited to the following:
• Ladders
• Platforms
• Bearings
• Railings
• End Wall Grates
• Roadway Gratings
• Metal Drainage Components
• Steel Expansion Joint and Components
Design details shall conform to the requirements for the American Association of State Highway and
Transportation Officials (AASHTO), as outlined in the AASHTO Load and Resistance Factor Design
(LRFD) Bridge Design Specifications, and Road Structures Design Manual (ADQCC TR-516), as
applicable.
Page 23-1
Falsework used in the erection of structural steel shall conform to the provisions of Section 1.20.8 of
Chapter 01, General Requirements.
Welding and weld qualification tests shall conform to the provisions of the current AASHTO/ AWS
D1.5M/D1.5:2010, Bridge Welding Code.
23.2 General Requirements for Steel Structure Work

This section outlines general standards and requirements for steel structure work.

Standards and codes for materials of steel structures and related construction works shall be as
specified in this section, in the Contract documents, if any, and the following, in their latest edition:
AASHTO LRFD American Association of State Highway and Transportation Officials -
Load and Resistance Factor Design, Bridge Construction
Specifications;
AASHTO Standard Specifications for Highway Bridges, 17th Edition, Design
Specifications;
AASHTO Guide Specifications for Highway Bridge Fabrication with HPS70W
Steel, 2nd Edition;
AASHTO/AWS Bridge Welding Code; D1.5M/D1.5:2010
AASHTO Standard Specification for Structural Steel Supports for Highway
Signs, Luminaires and Traffic Signals, 5th Edition;
ANSI ASME Metric Screw Threads: M Profile; B1.13M-2005
ANSI/ASME Square, Hex, Heavy Hex, and Askew Head Bolts and Hex, Heavy
Hex,
B18.2.1-2010 Hex Flange, Lobed Head, and Lag Screws (Inch Series);
ANSI/ASME Nuts for General Applications: Machine Screw Nuts, Hex, Square,
Hex
B18.2.2-2010 Flange, and Coupling Nuts (Inch Series);
ANSI/ASME Surface Texture, Surface Roughness, Waviness and Lay; B46.1-
2009
ANSI/AWS Specification for Carbon Steel Electrodes and Fluxes for Submerged
Arc
A5.17/A5.17M-97 Welding; (R2007)
ANSI/AWS A5.18 Specification for Carbon Steel Electrodes and Rods for Gas Shielded
Arc
/A5.18M:2005 Welding;
ANSI/AWS A5.28 Specification for Low-Alloy Steel Electrodes and Rods for Gas
Shielded
Page 23-2
/A5.28M:2005 Arc Welding;

ANSI/AWS A5.24 Zirconium and Zirconium Alloy Welding Electrodes and Rods;
/A5.24M:2005
ANSI/AWS Structural Welding Code – Steel;
D1.1/D1.1M:2010
API American Petroleum Institute;
API RP 2X:2004 Recommended practice for ultrasonic and magnetic examination of
offshore structural fabrication and guidelines for qualification of
technicians, 4th Edition;
ASME American Society of Mechanical Engineers;
ASME/ANSI Metric Heavy Hex Structural Bolts;
B 18.2.3.7M-2006
ASME/ANSI Metric heavy hex nuts;
B 18.2.4.6M-2010
ASME/ANSI Round head short square neck bolts;
B 18.5-2008
AWS American Welding Society;
AWS A5.1/ Specification for Carbon Steel Electrodes for Shielded Metal Arc
Welding;
A5.1M-2004
AWS A5.5/ Specification for Low-Alloy Steel Electrodes for Shielded Metal Arc
A5.5M:2006 Welding;
AWS A5.23/ Specification for Low-Alloy Steel Electrodes and Fluxes for
Submerged
A5.23M:2011 Arc Welding;
AWS D 1.6/ Structural Welding Code - Stainless Steel;
D 1.6M: 2007
FHWA U.S. Department of Transportation, Federal Highway Administration;
OSHA Occupational Safety and Health Administration;
Report No. Technical Information Guide for Narrow-Gap Improved Electroslag
FHWA-SA- Welding;
96-053
Report No. Process Operational Guide for Narrow-Gap Improved Electroslag
FHWA-SA- Welding;
96-052
SSPC Society for Protective Coatings;
Page 23-3
SSPC-SP 10/ Near-White Blast Cleaning;

NACE No. 2
SSPC-SP 6/ Commercial Blast Cleaning;
NACE No. 3
Table 3.2 Prequalified Minimum Preheat and Interpass Temperature;
ANSI/AWS D1.1
/D1.1M:2010
UNC Unified Coarse Thread;
UNC Thread Specifications of International Thread Standards.
ANSI B1.1
Officials (AASHTO), American Society for Testing and Materials (ASTM), British (BS), and European
(BS EN) Standards that are related to materials for steel structures. It also includes designations and
titles.
Table 23-1: Designations and titles for AASHTO and ASTM standards that apply to steel
structures construction works
AASHTO ASTM
Title
AASHTO M
ASTM A709 /
270M/M 270- Standard Specification for Structural Steel for Bridges
A709M - 11
12
ASTM A675 /
Standard Specification for Steel Bars, Carbon, Hot-
A675M -
Wrought, Special Quality, Mechanical Properties
03(2009)
ASTM A663 / Standard Specification for Steel Bars, Carbon, Merchant

A663M – 12 Quality, Mechanical Properties
ASTM A673 /
Standard Specification for Sampling Procedure for Impact
A673M -
Testing of Structural Steel
07(2012)
ASTM A501 - Standard Specification for Hot-Formed Welded and

07 Seamless Carbon Steel Structural Tubing
Standard Specification for Cold-Formed Welded and

ASTM A500 /
Seamless Carbon Steel Structural Tubing in Rounds and
A500M - 10a
Shapes
AASHTO M ASTM A325 - Standard Specification for Structural Bolts, Steel, Heat
164-05 10 Treated, 120/105 ksi Minimum Tensile Strength
AASHTO M ASTM A490 - Standard Specification for Structural Bolts, Alloy Steel,
253-05 12 Heat Treated, 150 ksi Minimum Tensile Strength
Page 23-4
AASHTO ASTM
Title
Standard Test Methods for Determining the Mechanical

ASTM F606 -
Properties of Externally and Internally Threaded Fasteners,
11a
Washers, Direct Tension Indicators, and Rivets
AASHTO M ASTM A563 -

Standard Specification for Carbon and Alloy Steel Nuts
291-09 07a
AASHTO M ASTM F436 -

Standard Specification for Hardened Steel Washers
293-10 11
ASTM F959 - Standard Specification for Compressible-Washer-Type

09 Direct Tension Indicators for Use with Structural Fasteners
AASHTO M ASTM B695 - Standard Specification for Coatings of Zinc Mechanically

298-10 04(2009) Deposited on Iron and Steel
AASHTO M
232M/M 232-
10
Standard Specification for “Twist Off” Type Tension Control

ASTM F1852 -
Structural Bolt/Nut/Washer Assemblies, Steel, Heat
11
Treated, 120/105 ksi Minimum Tensile Strength
AASHTO M ASTM A108 - Standard Specification for Steel Bar, Carbon and Alloy,
169-09 07 Cold-Finished
ASTM A109 / Standard Specification for Steel, Strip, Carbon (0.25

A109M - 08 Maximum Percent), Cold-Rolled
AASHTO T ASTM A370 - Standard Test Methods and Definitions for Mechanical
244-12 12 Testing of Steel Products
AASHTO M ASTM A668 /

Standard Specification for Steel Forgings, Carbon and
102M/M 102- A668M -
Alloy, for General Industrial Use
06 (R2011) 04(2009)
ASTM A781 / Standard Specification for Castings, Steel and Alloy,

A781M - 12a Common Requirements, for General Industrial Use
AASHTO M
ASTM A27 / Standard Specification for Steel Castings, Carbon, for
103M/M 103-
A27M - 10 General Application
12
AASHTO M ASTM A743 / Standard Specification for Castings, Iron-Chromium, Iron-

163M/M 163- A743M - Chromium-Nickel, Corrosion Resistant, for General
07 (2012) 06(2010) Application
ASTM A48 /
AASHTO M
A48M - Standard Specification for Gray Iron Castings
105-09
03(2008)
Page 23-5
AASHTO ASTM
Title
ASTM A536 -
84(2009)
ASTM A47 /
A47M - Standard Specification for Ferritic Malleable Iron Castings
99(2009)
AASHTO M
111M/M 111-
A123M – 12 Coatings on Iron and Steel Products
11
ASTM A6 / Standard Specification for General Requirements for Rolled

A6M – 12 Structural Steel Bars, Plates, Shapes, and Sheet Piling
ASTM A36 /
A36M – 08

ASTM A588 /
Structural Steel, up to 50 ksi [345 MPa] Minimum Yield
A588M – 10
Point, with Atmospheric Corrosion Resistance
ASTM E165 / Standard Practice for Liquid Penetrant Examination for

E165M – 12 General Industry
ASTM E709 –
Standard Guide for Magnetic Particle Testing
08
ASTM A941 - Standard Terminology Relating to Steel, Stainless Steel,

10a Related Alloys, and Ferroalloys
ASTM A307 – Standard Specification for Carbon Steel Bolts and Studs,
10 60 000 PSI Tensile Strength
ASTM F568M- Standard Specification for Carbon and Alloy Steel

07 Externally Threaded Metric Fasteners (Withdrawn)
ASTM A276 -
Standard Specification for Stainless Steel Bars and Shapes
13
Table 23-2: Designations and titles for BS and BS EN standards that apply to steel
structures construction works
BS BS EN
Title
BS 4-1:2005 Structural steel sections. Specification for hot-rolled sections
General introduction to standards for preparation of steel

BS 7079:2009
substrates before application of paints and related products
Page 23-6
BS BS EN
Title
ISO metric black hexagon bolts, screws and nuts.

BS 4190:2001
Specification
ISO metric precision hexagon bolts, screws and nuts.

BS 3692:2001
Specification
BS 2583:1955 Specification for podger spanners
BS 4872- Specification for approval testing of welders when welding

1:1982 procedure approval is not required. Fusion welding of steel
BS 7419:2012 Specification for holding down bolts
Specification for ISO metric black cup and countersunk

BS 4933:2010
head bolts and screws with hexagon nuts
BS 4929- Specification for steel hexagon prevailing-torque type nuts.

1:1973 Metric series
Specification for metal washers for general engineering

BS 4320:1968
purposes. Metric series
BS EN 10163- Delivery requirements for surface condition of hot-rolled

1:2004 steel plates, wide flats and sections. General requirements
Steel products with improved deformation properties

BS EN
perpendicular to the surface of the product. Technical
10164:2004
delivery conditions
BS EN Ultrasonic testing of steel flat product of thickness equal or

10160:1999 greater than 6 mm (reflection method)
BS EN 10025- Hot rolled products of structural steels. General technical

1:2004 delivery conditions
BS EN 10025- Hot rolled products of structural steels. Technical delivery

2:2004 conditions for non-alloy structural steels
Hot rolled products of structural steels. Technical delivery

BS EN 10025-
conditions for normalized/normalized rolled weldable fine
3:2004
grain structural steels

BS EN 10025-
conditions for thermomechanical rolled weldable fine grain
4:2004
structural steels
Hot rolled products of structual steels. Technical delivery

BS EN 10025-
conditions for structural steels with improved atmospheric
5:2004
corrosion resistance
Page 23-7
BS BS EN
Title

BS EN 10025-
conditions for flat products of high yield strength structural
6:2004+A1:2009
steels in the quenched and tempered condition
BS EN 10210- Hot finished structural hollow sections of non-alloy and fine

1:2006 grain steels. Technical delivery requirements
Hot finished structural hollow sections of non-alloy and fine

BS EN 10210-
grain steels. Tolerances, dimensions and sectional
2:2006
properties
Cold formed welded structural hollow sections of non-alloy

BS EN 10219-
and fine grain steels. Tolerances, dimensions and sectional
2:2006
properties
BS EN Continuously hot-dip coated steel flat products. Technical

10346:2009 delivery conditions
BS EN Continuously hot-dip coated steel sheet and strip.

10143:2006 Tolerances on dimensions and shape
BS EN Hot-rolled steel plates 3 mm thick or above. Tolerances on

10029:2010 dimensions and shape
BS EN 10056- Specification for structural steel equal and unequal angles.

1:1999 Dimensions
BS EN Structural steel I and H sections. Tolerances on shape and

10034:1993 dimensions
Continuously hot-rolled strip and plate/sheet cut from wide

BS EN
strip of non-alloy and alloy steels. Tolerances on
10051:2010
dimensions and shape
BS EN
High-strength structural bolting for preloading.
14399:2005
BS EN 1993-1-
Eurocode 3. Design of steel structures. Design of joints
8:2005
BS EN 1011- Welding. Recommendations for welding of metallic

2:2001 materials. Arc welding of ferritic steels
BS EN 1011- Welding. Recommendations for welding of metallic

8:2004 materials. Welding of cast irons
BS EN 287-
Qualification test of welders. Fusion welding. Steels
1:2011
Page 23-8
BS BS EN
Title
BS EN ISO Specification and qualification of welding procedures for

15614- metallic materials. Welding procedure test. Arc and gas
1:2004+A2:2012 welding of steels and arc welding of nickel and nickel alloys
BS EN ISO Non-destructive testing of welds. Visual testing of fusion-

17637:2011 welded joints
BS EN ISO Non-destructive testing. Magnetic particle testing. General

9934-1:2001 principles
BS EN ISO Non-destructive testing. Penetrant testing. General

3452-1:2013 principles
BS EN ISO Non-destructive testing of welds. Ultrasonic testing.

17640:2010 Techniques, testing levels, and assessment
BS EN ISO Construction drawings. Designation systems. Buildings and

4157-1:1999 parts of buildings
BS EN ISO Construction drawings. Designation systems. Room names

4157-2:1999 and numbers
BS EN ISO
Construction drawings. Indication of limit deviations
6284:1999
BS EN ISO Construction drawings. Representation of modular sizes,

8560:1999 lines and grids
BS EN ISO Construction drawings. Spaces for drawing and for text, and
9431:1999 title blocks on drawing sheets
BS EN ISO Welding and allied processes. Nomenclature of processes

4063:2010 and reference numbers
BS EN Welded, brazed and soldered joints. Symbolic

22553:1995 representation on drawings
BS EN ISO Prevailing torque type all-metal hexagon high nuts. Property

7042:2012 classes 5, 8, 10 and 12
BS EN ISO Prevailing torque type steel nuts. Mechanical and

2320:2008 performance properties
23.2.2 Mill Inspection and Tests for Steel Structures

Unless directed otherwise, the Fabricator of structural steel shall give the Engineer two copies of a
certified report of test or analysis showing both physical and chemical tests of the material for each
heat of material. The Fabricator shall submit these inspection and test reports to the Engineer for
examination and before requesting the fabrication shop inspection.
Page 23-9
23.2.3 Notice of Beginning Steel Structure Work

The Contractor shall give the Engineer ample notice of the beginning of work at the mill or in the
shop to enable inspection. The Contractor shall not manufacture any material or do any work in the
shop until providing such notice to the Engineer.
23.2.4 Shop Inspection for Steel Structures

The Engineer may inspect all structural steel and miscellaneous metals furnished at fabrication site.
Before requesting inspection, the Fabricator shall submit a list of main stress-carrying members and
the heat number of the material from which fabricating the member. The Fabricator shall preserve
the heat number, as marked by the rolling mill, for identification by the Engineer and inspectors. If
fabrication hides, cuts off, or otherwise obliterates the original number or marking, the Fabricator
shall paint the number on the material at a conspicuous location.
The Fabricator shall furnish facilities in the shop for inspecting material and work quality and allow
the Engineer and inspectors necessary access to all parts of the work. Such facilities shall include
adequate office space at the fabricating plant for the inspectors use during fabrication, assembly,
cleaning, and painting. At the plants of all major Fabricators, as the Engineer determines, the
Contractor shall ensure this office space has at least 10 square metres of floor space and at least
two desks (or a desk and table), a file case, and other necessary furniture. The Contractor shall
provide adequate lighting, heating, and ventilation and ensure cleanliness. The Contractor shall
provide office space that is completely partitioned and separated from the Fabricator's activities, with
a separate door equipped with a suitable lock and key. This may be part of a larger facility that is set
aside for the exclusive use of outside inspection personnel.
The Contractor shall make available telephone service and adequate sanitary facilities in the
immediate area. The Engineer may revise the foregoing requirements to accommodate the number
of inspectors necessary to inspect the volume of work. The inspector may reject any material or work
that does not conform to the specification requirements. The inspector’s acceptance of any material
or finished members shall not preclude the rejection of such materials later if they are defective.
Inspection at the mill and shop facilitates the work and avoids error. It shall not relieve the Contractor
of responsibility for imperfect material, or technique, or for replacing the same.
23.2.5 Material Traceability and Shipping for Steel Structures

This section outlines requirements for tracing and shipping materials for steel structures.
23.2.5.1 Marking
The Contractor’s system of assembly-marking individual pieces, and the issuance of cutting
instructions to the shop shall be such as to maintain identity of the original piece.
The Contractor may furnish material that can be identified by heat number and mill test report from
stock.
During fabrication, up to the point of assembling members, each piece of steel, other than Grade 36
(Grade 250) steel, shall show clearly and legibly its specification.
Any piece of steel, other than Grade 36 (Grade 250) steel, which will be subject to fabricating
operations such as blast cleaning, galvanizing, heating for forming, or painting which might obliterate
marking prior to assembling into members, shall be marked for grade by steel die stamping or by a
substantial tag firmly attached. Steel die stamps shall be low stress-type.
The Contractor shall properly identify all materials that arrive at the shop, in accordance with the
requirements of ASTM’s Standard Specification for General Requirements for Rolled Structural Steel
Bars, Plates, Shapes, and Sheet Piling (ASTM A6 / A6M – 12) or BS EN’s General Technical Delivery
Conditions for Hot Rolled Products of Structural Steels (BS EN 10025-1:2004). The Fabricator shall
document all main load-carrying member material, high-strength fastener assemblies, and weld
materials incorporated into the work through the entire fabrication process. The Contractor shall
Page 23-10
document this material traceability in a report that correlates heat numbers to their respective
locations in the completed members. The Contractor shall also provide diagrams and sketches, as
requested by the Engineer for clarity.
At the fabrication facility, the Fabricator shall maintain records of all relevant material testing and
certification processes and identification of all components and parts. The Fabricator shall maintain
such vital project records for at least two years from the latest date on which they shipped such
materials from their facility. The Contractor shall provide a copy of these records to the Engineer.
On any item that weighs more than three tons, the Fabricator shall mark the item’s weight on the
member in a visible location.
The Contractor shall mark matching members and assemblies.
The Fabricator shall match mark all connecting members or parts that have been reamed or drilled
while assembled. The Fabricator shall also provide a diagram showing all marks and clearly indicate
the location of all the marks on the shop drawings.
The Fabricator shall use painted marks, attached metal tags, other durable methods that do not
degrade the finish of the piece, or low-stress type steel die stamps to identify and match mark pieces.
Steel die stamps, if used, shall be blunt nosed or interrupted dot dies, manufactured to produce
impressions that are rounded at the bottom of the impression. Depressions caused by such stamps
shall not exceed 0.8 mm. Character heights from such stamps shall not exceed 12.5 mm. The
Fabricator shall remark coated type markings as necessary to maintain continuity in traceability.
The Fabricator shall mark splice plates and girders so that upon erection, the mark on the splice
plate is located opposite a matching mark on the girder. The Fabricator shall adhere to the following
instructions for marking splice plates:
a. Place the mark on web splice plates, midway down the long side of the plate, on either the
right or left side, to correspond with the girder to which the splice plate will be temporarily
attached for shipping to the erection site. Make a matching stamp on the girder web opposite
the mark on the splice plate.
b. Place the mark on top or bottom flange splice plates, on the right or left end of the plate,
corresponding to the girder to which the plate will be attached for shipment to the erection
site. Place a corresponding mark on the girder flange opposite the mark in the splice plate.
c. As an alternate location for tub girder bottom flange splice plates, place the mark midway
down the long side of the plate, on either the right or left side, to correspond with the girder
to which the splice plate will be temporarily attached for shipping to the erection site. Make a
matching mark on the girder flange opposite the mark on the splice plate.
The Fabricator shall mark girders and beams on the left end, according to the orientation shown in
the shop drawings, near the top flange. Diaphragms shall be marked in the middle upper portion of
the web. Cross frames shall be marked in the middle of the top or bottom horizontal member. The
Fabricator shall not use die stamps on fracture critical members or use die stamps near edges of
members or components subject to tensile stresses as specifically noted in the Contract plans or as
The Fabricator shall ensure that, during fabrication, the heat number remains painted on each
primary load-carrying component until each component is permanently joined into a piece-marked
member or assembly.
Upon request by the Engineer, the Contractor shall furnish an affidavit certifying that throughout the
fabrication operation the identification of steel has been maintained in accordance with this
specification.
23.2.5.2 Shipping Structural Members

The Fabricator shall load structural members on trucks or cars in a way that transport to their
destination and unloading at their destination shall not cause excessive stress, deformation, or
damage. All girders and rolled beams shall be shipped in a standing position. The Contractor shall
Page 23-11
ensure that girders and beams remain in such standing positions in subsequent operations. The
Fabricator may ship haunched sections of built-up girders in inverted positions.
23.2.5.3 Shipping Bulk Materials

The Contractor shall ensure that all bulk materials, such as shear studs, are stored together in
individual LOTs and that the outside of each container has a list and description of the contents.
Maintain a separate list of the weights of all tools and erection materials.
23.2.5.4 Shipping Fastener Assemblies

Either the Contractor or the Fabricator shall transport and store fastener assemblies in sealed,
watertight containers, in accordance with the following procedural directions.
a. Label the side of each container with the supplier’s name and LOT identification number, and
marked to identify the contents and size of the fastener components. Ensure that all surfaces
of the nuts are lubricated before their placement in watertight containers.
b. Provide containers for components that are capable of protecting them from moisture and
other harmful materials. Maintain such containers in their sealed conditions until they are
opened for use at their assembly locations. Do not remove more fastener assemblies from
the protected area than can be installed and tightened during a work shift. Leave the
containers unopened until needed for assembly.
c. At the end of the work shift, return unused fastener assemblies to the protected storage area
for future use. Protect opened storage containers from contamination.
The Fabricator shall separately pack non-high-strength bolts of different lengths and diametres. They
shall also pack the loose nuts and washers supplied for each size of bolt separately, except that zinc
coated bolts, nuts, and washers of the same size shall be shipped in the same containers. Bolts,
nuts, washers, pins, and small parts shall be shipped in boxes, crates, kegs, or barrels. A container’s
gross weight shall not exceed 136 kg.
23.2.5.5 Shipping Anchor Rods and Nuts

The Contractor shall ship anchor rods and nuts as an assembly. Washers may be shipped separate
from an assembly.
23.2.6 Handling and Storing Materials for Steel Structures

When handling, transporting, and storing plates, shapes, assemblies, fastener components and
other parts, the Contractor shall protect such items from damage. They shall also ensure that such
items remain safe during subsequent inspections. The Contractor shall provide storage that keeps
materials, assemblies, parts, and other components clean. While stored, such materials shall remain
free from dirt, grease, other foreign matter, unacceptable corrosion or coating deterioration, and all
other adverse environmental conditions.
The Contractor shall place material to be stored at a job site on platforms, skids, or other supports
above the ground to keep materials clean and properly drained. Girders and beams shall be placed
upright, shored, and tied or braced to prevent high winds from tipping or overturning them. Long
members, such as columns and chords, shall be supported on skids that are near enough to each
other to prevent damage and injury from deflection. If the Contract documents only apply to the
erection of a steel structure, the Contractor shall check the material received against the shipping
lists and promptly report, in writing, any shortage or damage. The Contractor shall be responsible
for any loss of material and for any damage to those materials after receiving them.
The Contractor shall store bolts, nuts, and washers in their original containers and protect them from
dirt and moisture until using them. Storage of high-strength fasteners shall conform to Article
23.6.9.6.
Page 23-12
The Contractor shall store coatings in accordance with Section 24.3.8 of Chapter 24, Painting, and
the Manufacturer’s recommendations. The Contractor shall notify the Engineer if the Manufacturer’s
recommendations vary from those provided in the Contract documents.
23.2.7 Field Inspection for Steel Structures

Erections are subject to inspection and the Contractor shall provide facilities in which the Engineer
can inspect material and work quality. The Engineer shall inspect only material and work quality that
was not already inspected after its delivery to the work site.
23.2.8 Falsework for Steel Structures

Falsework used for the erection of structural steel shall conform to the provisions in Section 1.20.8
of Chapter 1, General Requirements, of these standard specifications, except that dead loads shall
consist of the mass of the structural steel and any other portions of the structure that are supported
by the falsework.
The Contractor shall properly design, construct, and maintain falsework to ensure that it can handle
the loads placed upon it. Falsework shall provide the required construction camber.
If asked to do so, the Contractor shall submit detailed plans for falsework to the Engineer. The
Engineer's approval of these plans, or acceptance of work constructed according to them, however,
shall not relieve the Contractor of responsibility for successful erection of a steel structure and
otherwise satisfactory results.
When building falsework over seawater that is subject to boating use, the Contractor shall construct
such falsework to provide adequate horizontal and vertical clearance for rowboats and small
powerboats to pass. Such clearance shall also comply with the requirements of related authorities.
Falsework that resides over a highway or street that is used by traffic shall provide a minimum
horizontal clearance of 7.5 metres and minimum vertical clearance of 6.5 metres, unless the plans
or special provisions require otherwise.
After completing a steel structure, the Contractor shall remove falsework piles down to at least 600
mm below seabed or finished ground line. The Contractor shall also entirely remove any temporary
bents, mudsills, and footings.
Overhang bracket form supports shall not attach to the girder web.
Falsework and forms that support concrete work on steel structures shall be constructed so that any
loads applied to girder webs shall be applied within 150 mm of a flange or stiffener and shall be
distributed to prevent local distortions of the web. As necessary, temporary struts and ties shall resist
lateral loads that are applied to the girder flanges and shall prevent appreciable relative vertical
movement between the edge of a deck form and the adjacent steel girder.
23.2.9 Continuous Members of Steel Structures

If erection procedures to be used will provide the designed girder continuity for dead load, then the
Contractor shall provide a statement of the intended steel erection procedures to the Engineer for
review and approval. This statement shall include calculations in sufficient detail to substantiate that
girder geometry will be correct. The Contractor shall preassemble members with field joints in a
horizontal or an upright position and with no load.
If erection procedures to be used will result in steel girders not attaining the continuity for dead load
assumed in design, then the Contractor shall provide a statement of steel erection procedures to the
Engineer. This statement shall include calculations in sufficient detail to substantiate that girder
capacity and geometry will be correct.
After erection, a steel structure shall have a load carrying capacity at least equal to the designed
structure, as shown on the Contract plans. With the Engineer’s approval, the Contractor may
increase the cross-sectional area or change the grades of steel to provide the specified load carrying
capacity. The Contractor may also use any additional steel or higher strength steels to accommodate
Page 23-13
the method of erection at their own expense; the Owner will not make additional payment for such
surpluses that the Contractor uses for their own convenience.
23.3 Drawings for Steel Structures

The Contractor shall submit working drawings to the Engineer for approval. Working drawings shall
include shop drawings, erection drawings, and transportation drawings for structural steel. All
working drawings shall be made in accordance with BS EN ISO 4157-1:1999, BS EN ISO 4157-
2:1999, BS EN ISO 6284:1999, BS EN ISO 8560:1999, and BS EN ISO 9431:1999.
All welding symbols shall conform to BS EN ISO 4063:2010 and BS EN 22553:1995.
For the initial review, the Contractor shall submit six sets of such drawings. After the initial review,
the Contractor shall submit from 6 to 12 sets of working drawings for final approval, for use during
construction, and in response to any request for the drawings from the Engineer.
Working drawings shall show the following information:
• Any changes proposed in the work
• Details and calculations for connections not dimensioned on the plans
• Direction of rolling of plates (where specific orientation is required)
• Sequence of shop and field assembly tasks
• Sequence of erection activities
• Welding sequences and procedures
• Locations of all butt welded splices (on a layout drawing of the entire structure)
• Locations of any temporary supports
• Vertical alignment of the girder at each stage of erecting the steel structure
The Contractor shall also submit substantiating camber calculations and diagrams with the working
drawings.
Working drawings shall be submitted sufficiently in advance of the start of the affected work to allow
time for the Engineer to review them and the Contractor to make necessary corrections without
delaying work. Submission time before work commences shall be proportional to the complexity of
the work, but shall never be less than six weeks.
If the Contractor orders any material or the fabrication of any material before receiving the Engineer’s
final approval for the working drawings, they do so at their own risk.
23.3.1 Shop Drawings for Steel Structures

Shop drawings for steel structures shall give full, detailed dimensions and sizes of component parts
of the structure and details of all miscellaneous parts, such as pins, nuts, bolts, and drains.
Where plates require specific orientation, shop drawing shall clearly indicate the direction in which
plates roll.
Unless otherwise specified in the Contract documents, shop drawings shall identify every piece of
steel that will not comply with the requirements for grade 36 steel outlined in AASHTO M 270M/M
270-12 or grade 250 steel outlined in ASTM’s Standard Specification for Structural Steel for Bridges
(ASTM A709 / A709M – 11).
23.3.2 Erection Drawings for Steel Structures

The Contractor shall submit drawings that full illustrate the proposed method of erection. Such
drawings shall show details of all falsework bents, bracing, guys, deadmen, lifting devices, and
attachments to the bridge members, sequence of erection, location of cranes and barges, crane
capacities, location of lifting points on the bridge members, and weights of the members. Such
drawings shall be complete in detail for all anticipated phases and conditions during erection.
Calculations may be required to demonstrate that factored resistances are not exceeded and that
member capacities and final geometry will be correct.
Page 23-14
23.3.3 Camber Diagrams for Steel Structures

The Fabricator shall provide camber diagrams to the Engineer for review. Such diagrams shall show
the camber at each panel point in the cases of trusses or arch ribs, and at the location of field splices
and fractions of span length (quarter points minimum) in the cases of continuous beam and girders
or rigid frames. Camber diagram shall show calculated cambers to be used in preassembly of the
structure in accordance with Section 23.6.6.
23.3.4 Transportation Drawings for Steel Structures

If required, transportation drawings shall be furnished for approval. All support points, tie-downs,
temporary stiffening trusses or beams, and any other details needed to support and brace the
member shall be shown. The Contractor shall provide calculation sheets showing the dead load plus
impact stresses induced by the loading and transportation procedure. Impact stresses to be used
shall be of at least two hundred percent (200%) of the dead load stress. Total load to be used,
including impact, shall not be less than three hundred percent (300%) of the dead load.
All members, both straight and curved, shall be shipped and stored in their upright position.
23.4 Materials for Steel Structures

This section outlines requirements and standards for materials used in steel structures for the
Project.
23.4.1 Structural Steel

The Contractor shall furnish structural steel materials specified in the Contract documents for
highway structures in accordance with (ASTM A6 / A6M – 12) or (BS EN 10025 Parts 1 to 6), and
AASHTO/AWS D1.5M/ D1.5:2010, Bridge Welding Code as supplemented by the AASHTO Guide
Specifications for Highway Bridge Fabrication with HPS70W Steel, 2nd Edition. For material that the
Contract documents do not indicate the ASTM specifications, the Contractor shall furnish structural
carbon steel that conforms to ASTM A709 / A709M - 11 grade 36 (Grade 250). The Contractor shall
fabricate all unpainted steel elements using steels with weathering characteristics as defined in
ASTM A709 / A709M - 11 for grades with a “W” suffix.
Structural components designated as “fracture critical” shall conform to the provisions of the
AASHTO/AWS D1.5M/D1.5:2010, Bridge Welding Code, Section 12, AASHTO/AWS Fracture
Critical Control Plan for Non-Redundant Members, in addition to the requirements of the Contract
documents.
If the Contractor cannot obtain grade 36 (or grade 250) structural carbon steel bar that conforms to
ASTM A709 / A709M - 11 for use in secondary members in structures in the quantity specified in the
Contract documents, they may use either or both of the following alternates:
• ASTM’s Standard Specification for Steel Bars, Carbon, Hot-Wrought, Special Quality,
Mechanical Properties (ASTM A675 / A675M - 03(2009)), grade 60 (Grade 420).
• ASTM’s Standard Specification for Steel Bars, Carbon, Merchant Quality, Mechanical
Properties (ASTM A663 / A663M – 12), grade 60 (Grade 420).
The Contractor shall ensure that girder flange plates, girder web plates, flange splice plates, hanger
bars, links, rolled beams, flange cover plates, and plates and angles connecting floor beams to
girders conform to zone 2 toughness requirements for longitudinal Charpy V-Notch tests specified
in AASHTO M 270M/M 270-12 (ASTM A709 / A709M - 11). The Contractor shall sample and test
according to ASTM’s Standard Specification for Sampling Procedure for Impact Testing of Structural
Steel (ASTM A673 / A673M - 07(2012)) and use the (H) frequency of testing.
The Contractor shall obtain structural steel and miscellaneous metal components and products for
use on the Project from a Fabricator approved by the Owner with Accepted Quality Control Programs
for Metal Fabricators. This Fabricator shall also be certified by the AISC Quality Certification Program
with the following modifications to the AISC categories:
Page 23-15
• Standard for Steel Building Structures - Required for miscellaneous components or as

• Simple Steel Bridge Structures - Required for bolted highway sign, lighting and traffic
structures fabrication, bridge components such as cross-frames and diaphragms not
designated as main or primary load-carrying members, and unspliced rolled beam bridges.
Fabricators qualified under this category are also qualified to perform work as described
under the Conventional Steel Building Structures Category.
• Major Steel Bridges - Required for all steel bridges (including welded or bolted truss
structures), welded truss and pole type highway sign, lighting and traffic structures, and
bridge elements not defined as miscellaneous components or covered by Simple Steel
Bridge Structures in the previous bullet. Fabricators qualified under this category are also
qualified to perform work as described under the Simple Steel Bridge and Conventional Steel
Building Structures Categories.
• Fracture Critical Endorsement - Required for any fabrication conducted on fracture critical
structures or components.
The Contractor shall ensure that structural steel members that contribute to a design’s structural
capacity, if they are to be welded, have a maximum carbon equivalent (CE) of 0.48. Steels that
conform to ASTM A709 / A709M - 11 HPS 50 or 70 (HPS 345 or 485) with carbon contents 0.10 %
or less are exempted from this rule. The Engineer may allow steels with up to CE 0.58 only if the
Contractor uses an adjusted welding procedure that has been approved by the Engineer. The
Contractor shall submit steel mill certifications that indicate that the steel meets the Contract’s
c
o
Equation 23-1 to calculate the carbon equivalent.
m
p (𝐌𝐧 + 𝐒𝐢) (𝐂𝐫 + 𝐌𝐨 + 𝐕) (𝐍𝐢 + 𝐂𝐮)
𝐂𝐄 = 𝐂 + + +
o 𝟔 𝟓 𝟏𝟓
s Equation 23-1: Carbon equivalent
i
t23.4.1.1 Structural Carbon Steel
i
Unless
o otherwise specified in the Contract documents, structural carbon steel for bolted or welded
construction
n shall be grade 250 steel that conforms to Standard Specification for Structural Steel for
Bridges
a (AASHTO M 270M/M 270-12) or (ASTM A709 / A709M - 11).
l
23.4.1.2 High-strength, Low-alloy Structural Steel
r
High-strength, low-alloy steel shall be grade 345, 345S, 345W, or HPS 345W, as defined in Standard
e
Specification for Structural Steel for Bridges (AASHTO M 270M/M 270-12) or (ASTM A709 / A709M
q
- 11).
u
i
23.4.1.3
r
High-strength, Low-alloy, Quenched, and Tempered Structural
e Steel Plate
m
High-strength, low-alloy, quenched, and tempered steel plate shall be grade 485W or HPS 485W
e
steel that conforms to Standard Specification for Structural Steel for Bridges (AASHTO M 270M/M
n
270-12) or (ASTM A709 / A709M - 11).
t
s23.4.1.4 High-yield-strength, Quenched, and Tempered Alloy-steel
.
Plate
T
High-yield-strength, quenched, and tempered alloy steel plate shall have the following properties:
h
e a. Shall be grade 690 or 690W steel as defined in Standard Specification for Structural Steel
for Bridges (AASHTO M 270M/M 270-12) or (ASTM A709 / A709M - 11).
E b. Shall be quenched-and-tempered alloy-steel structural shapes and seamless mechanical
n tubing that meet all of the mechanical and chemical requirements for grade 690 and 690W
g Page 23-16
iCHAPTER 23: STEEL STRUCTURES First Edition -January 2018
n
e
e
steel, as defined in Standard Specification for Structural Steel for Bridges (AASHTO M
270M/M 270-12) or (ASTM A709 / A709M - 11), except that the specified maximum tensile
strength may be 965 MPa for structural shapes and 1000 MPa for seamless mechanical
tubing.
23.4.1.5 Eye Bars for Steel Structures

Steel for eye bars shall be of a grade that enables welding. Applicable structural steel shall conform
to one of the following grades:
a. Grade 250, as defined in Standard Specification for Structural Steel for Bridges (AASHTO M
270M/M 270-12) (ASTM A709 / A709M - 11)
b. Grade 345, 345W, or HPS 345W, as defines in Standard Specification for Structural Steel for
Bridges (AASHTO M 270M/M 270-12) or (ASTM A709 / A709M - 11)
23.4.1.6 Structural Tubing for Steel Structures

Structural tubing shall be either cold-formed welded or seamless tubing conforming to ASTM A500
/ A500M - 10a, Grade B, or hot-formed welded or seamless tubing conforming to ASTM A501 - 07.
23.4.1.7 Stainless Steel

All stainless steel shall be new and shall comply with the following specifications and requirements:
1. All members or parts called for on the Contract plans to be stainless steel shall be AISI Type
316 with a mill finish and complying with ASTM A276 – 13, unless otherwise indicated in the
Contract plans or specified in the particular specifications.
2. If specified, AISI Types 302, 303, 304 shall comply with ASTM A276 – 13.
3. Unless otherwise indicated on the Contract plans or in the Contract particular specifications,
all bolts shall be of the same type of stainless steel as the adjoining parts.
23.4.2 High-strength Fasteners for Steel Structures

High-strength bolts for structural steel joints shall conform to either AASHTO M 164-05 (ASTM A325
- 10) or AASHTO M 253-05 (ASTM A490 - 12). When high-strength bolts are used with unpainted
weathering grades steel, the bolts shall be type 3.
The Contractor shall use (ASTM A325 – 10) bolts in all bolted structural steel connections, unless
the connected assemblies or parts are designated as miscellaneous components and the fastener
assembly is specified elsewhere in the Contract documents.
The Contractor shall use (ASTM A490 – 12) bolts only with approval from the Engineer. The
Contractor shall provide procedures in accordance with for the handling, lubrication, installation,
tightening, and testing of (ASTM A490 – 12) bolts. The Contractor shall not install (ASTM A490 –
12) bolts without the Engineer’s approval of the procedures.
A supplier’s lot number shall appear on the shipping package. A certification shall note when and
where all testing, including rotational capacity tests, were done. For galvanized bolts and nuts, a
certification shall note zinc thicknesses.
Bolts shall not be harder than 33 HRC, as defined in AASHTO M 164-05 or ASTM A325 - 10.
Proof-load tests (ASTM F606 - 11a, Method I) shall be required for bolts. Wedge tests of full-size
bolts are required in accordance with Section 8.3 of AASHTO M 164-05 (ASTM A325 - 10).
Galvanized bolts shall be wedge tested after galvanising. Proof-load tests of AASHTO M 291-09
(ASTM A563 - 07a) are required for nuts. Proof-load tests for nuts to be used with galvanized bolts
shall be performed after galvanising, over tapping, and lubricating, except as noted below:
a. Nuts for AASHTO M 164-05 (ASTM A325 - 10) bolts shall conform to AASHTO M 291-09
(ASTM A563 - 07a), Grades DH, DH3, C, C3, and D (Property Class 8S, 8S3, l0S, or 10S3).
Page 23-17
b. Nuts for AASHTO M 253-05 (ASTM A490 – 12) bolts shall conform to the requirements of
AASHTO M 291-09 (ASTM A563 - 07a), Grades DH and DH3 (Property Class 10S or 10S3).
The exceptions are:
• Nuts to be galvanized (hot-dip or mechanically galvanized) shall be Grade DH (Property
Class 10S).
• Nuts to be used with AASHTO M 164-05 (ASTM A325 - 10) Type 3 bolts shall be Grade C3
or DH3 (Property Class 8S3 or 10S3). Nuts to be used with AASHTO M 253-05 (ASTM A490
– 12), Type 3 bolts shall be Grade DH3 (Property Class 10S3).
All galvanized nuts shall be lubricated with a lubricant containing a visible dye. Black bolts must be
oily to touch when delivered and installed.
Washers shall be hardened steel washers that conform to the requirements outlined in AASHTO M
293-10 or ASTM F436 - 11, and Article 23.6.9.6.
23.4.2.1 Identifying Marks for High-strength Fasteners

AASHTO M 164-05 (ASTM A325 - 10) for bolts and the specifications referenced herein for nuts
require that bolts and nuts manufactured to the specification be identified by specific markings atop
the bolt head and on one face of the nut. Head markings must identify the grade by the symbol
(A325), the Manufacturer, and, for type 3 bolts, the type. Nut markings must identify the property
class, the Manufacturer, and, for type 3 nuts, the type. Markings on direct tension indicators (DTI,
ASTM F959 - 09) must identify the Manufacturer and type (such as "325, Class 8.8"). Other washer
markings must identify the Manufacturer, and, for type 3 washers, the type.
To comply with AASHTO M 253-05 or ASTM A490 – 12, bolts must be identified by specific markings
on the top of the bolt head. Head markings must identify the grade by the symbol (such as “A490"),
the Manufacturer, and, for type 3 bolts, the type.
To comply with AASHTO M 253-05 or ASTM A490 – 12 and the specifications referenced therein
for nuts, nuts must be identified on one face. Nut markings must identify the property class, the
Manufacturer and, for type 3 nuts, the type.
To comply with AASHTO M 253-05 or ASTM A490 – 12, direct tension indicators must have markings
that clearly identify the Manufacturer and Type "490" (Class" 10.9"). Markings on washers must
identify the Manufacturer, and, for type 3 washers, the type.
23.4.2.2 Dimensions of High-strength Fasteners

Bolt and nut dimensions shall conform to the requirements for heavy hexagon structural bolts and
heavy semi-finished hexagon nuts (metric heavy hexagon structural bolts and metric heavy semi-
finished hexagon nuts) given in ANSI/ASME B18.2.1-2010 Standards and B 18.2.2 (ASME/ANSI B
18.2.3.7M-2006 and ASME/ANSI B 18.2.4.6M-2010), respectively.
23.4.2.3 Galvanized High-strength Fasteners

AASHTO M 253-05 (ASTM A490 – 12) bolts shall not be galvanized.
When fasteners are galvanized, they shall be specified to be hot-dip galvanized in accordance with
AASHTO M 232M/M 232-10 (ASTM A153 / A153M - 09), Class C or mechanically galvanized in
accordance with AASHTO M 298-10 (ASTM B695 - 04(2009)), Class 50 (Class 345). Bolts to be
galvanized shall be either AASHTO M 164-05 (ASTM A325 - 10) Type I. Galvanized bolts shall be
tension tested after galvanising. Washers, nuts, and bolts of any assembly shall be galvanized by
the same process. Nuts should be over tapped to the minimum amount required for the fastener
assembly and shall be lubricated with a lubricant containing a visible dye so a visual check can be
made for the lubricant at the time of field installation.
Page 23-18
23.4.2.4 Alternative Fasteners

The Contractor may use other fasteners or fastener assemblies, including the following:
a. Fasteners that conform to the requirements outlined in ASTM’s Standard Specification for
“Twist Off” Type Tension Control Structural Bolt/Nut/Washer Assemblies, Steel, Heat
Treated, 120/105 ksi Minimum Tensile Strength (ASTM F1852 - 11).
b. Fasteners that meet the material, manufacturing, and chemical composition requirements
outlined in the AASHTO’s Standard Specification for High-Strength Bolts for Structural Steel
Joints (AASHTO M 164-05), ASTM’s Standard Specification for Structural Bolts, Steel, Heat
Treated, 120/105 ksi Minimum Tensile Strength (ASTM A325 - 10), or the Standard
Specification for Structural Bolts, Alloy Steel, Heat-Treated, 150 ksi Minimum Tensile
Strength (AASHTO M 253-05) or (ASTM A490 – 12).
c. Fasteners that meet the mechanical property requirements of the same specifications that
apply for full size tests.
d. Fasteners with diametres and bearing areas under the head and nut that are at least
equivalent to those provided by a bolt and nut of the same nominal dimensions outlined in
Article 23.4.2.2.
These fasteners are subject to the approval of the Engineer. Such alternate fasteners may differ in
other dimensions from those of the specified bolts and nuts.
Subject to the approval of the Engineer, the Contractor may use high-strength steel lock-pin and
collar fasteners as an alternative to high-strength bolts. Shanks and heads of high-strength steel
lock-pin and collar fasteners shall meet the requirements of Article 23.4.2.2. Each fastener shall
provide a solid-shank body of sufficient diametre to provide tensile and shear strength equivalent to
or greater than that of the bolt specified in the Contract documents and shall have the following
characteristics:
• Have a cold-forged head on one end
• Be of a type approved by the Engineer
• Have dimensions as approved by the Engineer
• Have a shank length that is suitable for the thickness of fastened material
• Have locking grooves
• Have a breakneck groove
• Have pull grooves (annular grooves) on the opposite end
Each fastener shall provide a steel locking collar of a size that is appropriate for the diameter of the
fastener’s shank. By means of suitable installation tools, a fastener’s steel locking collar shall be
cold-swaged into the locking grooves, forming a head for the grooved end of the fastener after the
pull groove section has been removed. Such steel locking collars shall be a standard product of an
established Manufacturer of lock-pin and collar fasteners, as approved by the Engineer.
23.4.2.5 Load-indicator Devices

Load-indicating devices may be used in conjunction with bolts, nuts, and washers for high-strength
fasteners, as outlined in Section 23.4.2. Load-indicating devices shall conform to the requirements
of ASTM’s Specification for Compressible-Washer Type Direct Tension Indicators for Use with
Structural Fasteners (ASTM F959 - 09), except as provided in the following paragraph.
Subject to the approval of the Engineer, the Contractor may use alternative design direct tension
indicating devices if they satisfy the requirements detailed in of Article 23.6.9.6 or other requirements
detailed in specifications provided by the Manufacturer and have the approval of the Engineer.
23.4.3 Other Structural Fasteners

23.4.3.1 Ordinary Bolt Assemblies
Shop and site bolts and nuts shall be to one the following grades:
Page 23-19
1. Grade 4.6 in accordance with BS 4190:2001

2. Grade 8.8 or 10.9 in accordance with BS 3692:2001.
Dimensions, tolerance and threaded length shall be to BS 4190:2001.
23.4.3.2 High Strength Friction Grip (HSFG) Bolt Assemblies

HSFG bolt assemblies shall be in accordance with BS EN 14399:2005.
23.4.3.3 Foundation Bolts

Holding down bolts shall be in accordance with BS 7419:2012.
23.4.3.4 Cup and Countersunk Bolts

Cup and countersunk bolts shall be in accordance with BS 4933:2010.
23.4.3.5 Washers
Unless otherwise specified metal washers for general engineering purpose shall be made in
accordance with BS 4320:1968, and black steel washers to Form E shall be used.
23.4.3.6 Lock Nuts

Lock nuts shall be in accordance with BS 4929-1:1973, BS EN ISO 7042:2012, and BS EN ISO
2320:2008.
23.4.4 Welded Stud Shear Connectors

Stud shear connectors shall be grade 1015, 1018, or 1020 cold-drawn bars that conform to the
requirements outlined in ASTM’s Standard Specification for Steel Bar, Carbon and Alloy,
Cold-Finished (AASHTO M 169-09) or (ASTM A108 - 07). Such shear connectors shall be either
semi- or fully-killed. If flux retaining caps are used, steel for the caps shall be of a low-carbon grade
suitable for welding and shall comply with ASTM’s Standard Specification for Steel, Strip, Carbon
(0.25 Maximum Percent), Cold-Rolled (ASTM A109 / A109M - 08).
Tensile properties, as determined by tests of bar stock after drawing or of finished studs, shall
conform to the requirements outlined in Table 23-3, in which the yield strength is as determined by
a two-tenth percent (0.2%) offset method.
Table 23-3: Tensile Properties of Stud Shear Connectors
Property Required value
Tensile strength 420 MPa
Yield strength 345 MPa
Elongation 20% in 50 mm
Reduction areas 50%
23.4.4.1 Test Methods for Welded Stud Shear Connectors

Tensile properties shall be determined in accordance with the applicable sections of the Standard
Test Methods and Definitions for Mechanical Testing of Steel Products (AASHTO T 244-12) or
(ASTM A370 - 12). Tensile tests for finished studs shall be made on studs that are welded to test
plates using a test fixture similar to that shown in Figure 7.2 of the current AASHTO/AWS
D1.5M/D1.5:2010, Bridge Welding Code. If fracture occurs outside of the middle half of the gage
length, the test shall be repeated.
Page 23-20
23.4.4.2 Finish for Welded Stud Shear Connectors

Finished studs shall be of uniform quality and condition, free from irregularities such as laps, fins,
seams, cracks, twists, bends, or other injurious defects. Finish shall be as produced by cold-drawing,
cold-rolling, or machining.
23.4.4.3 Certification for Welded Stud Shear Connectors

The Manufacturer shall certify that the studs as delivered are in accordance with the material
requirements outlined in this chapter. Certified copies of in-plant quality-control test reports shall be
furnished to the Engineer upon request.
23.4.4.4 Check Samples for Welded Stud Shear Connectors

At the Contractor's expense, the Engineer may select studs of each type and size for checking as
necessary to validate that they meet the requirements outlined in this chapter.
23.4.5 Steel Forgings for Steel Structures

Steel forgings shall conform to the Standard Specification for Steel Forgings, Carbon and Alloy, for
General Industrial Use, AASHTO M 102M/M 102-06 (R2011) (ASTM A668 / A668M - 04(2009)),
Classes C, D, F, or G.
23.4.6 Cold-finished Carbon Steel Shafting for Steel Structures

Cold-finished carbon steel shafting shall conform to the Standard Specification for Steel Bar, Carbon
and Alloy, Cold-Finished, AASHTO M 169-09 (ASTM A108 - 07). Such steel shall be grades 10160
through 10300, inclusive, unless the Contract document specify otherwise.
23.4.7 Mild Steel Castings for Steel Structures

Steel castings for use in highway bridge components shall conform to Standard Specification for
Castings, Steel and Alloy, Common Requirements, for General Industrial Use, ASTM A781 / A781M
- 12a, Class 70 (Class 485), or Standard Specifications for Steel Castings, Carbon, for General
Application, AASHTO M 103M/M 103-12 (ASTM A27 / A27M - 10), Class 70 or Class 485 or Grade
485-250, unless otherwise specified in the Contract documents.
23.4.8 Chromium Alloy-steel Castings for Steel Structures

Chromium alloy-steel castings shall conform to the Standard Specification for Castings, Iron-
Chromium, Iron-Chromium-Nickel, Corrosion Resistant, for General Application, AASHTO M
163M/M 163-07 (2012) (ASTM A743 / A743M - 06(2010)). Such steel casting shall be grade CA
15M, unless the Contract documents specify otherwise.
23.4.9 Iron Castings for Steel Structures

Gray iron castings shall conform to the Standard Specification for Gray Iron Castings, AASHTO M
105-09 or ASTM A48 / A48M - 03(2008), Class 30, unless otherwise specified in the Contract
documents.
Ductile iron castings shall conform to the Standard Specification for Ductile Iron Castings, ASTM
A536 - 84(2009), Grade 420-280-18, unless otherwise specified in the Contract documents.
Test specimens from parts integral with the castings, such as risers, shall be tested for castings with
a weight more than 4.45 kN to determine that the required quality is obtained in the castings in the
finished condition.
Malleable castings shall conform to the Standard Specification for Ferritic Malleable Iron Castings,
ASTM A47 / A47M - 99(2009). Grade 35018 (Grade 24118) shall be furnished unless otherwise
specified in the Contract documents.
Page 23-21
23.4.9.1 Work Quality and Finish for Iron Castings

Iron castings shall be true to pattern in form and dimensions, free from pouring faults, sponginess,
cracks, blow holes, and other defects in positions that affect their strength and function for the service
intended.
Castings shall be boldly filleted at angles and the arises shall be sharp and perfect.
23.4.9.2 Cleaning Iron Castings

All castings must be sandblasted or otherwise effectively cleaned of scale and sand to present a
smooth, clean, and uniform surface.
23.4.10 Galvanising Steel Structures

When galvanising is specified in the Contract documents, ferrous metal products, other than
fasteners and hardware items, shall be galvanized in accordance with the Standard Specification for
Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel Products, AASHTO M 111M/M 111-11 (ASTM
A123 / A123M - 12). Fasteners and hardware items shall be galvanized in accordance with the
Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware, AASHTO M 232M/M
232-10 (ASTM A153 / A153M - 09), except as noted in Article 23.4.2.3.
23.4.11 Welding Steel Structures

All welding shall comply with all requirements as specified herein and as indicated on the Contract
plans.
23.4.11.1 Materials
a. Before any electrodes or flux-electrode combinations are used for welding steel, the
Contractor shall furnish certified copies of test reports for all the pertinent tests specified in
AWS A5.1/A5.1M-2004, AWS A5.5/A5.5M:2006, ANSI/AWS A5.17/ A5.17M-97 (R2007),
ANSI/AWS A5.18/A5.18M:2005, AWS A5.23/A5.23M: 2011, or ANSI/AWS
A5.28/A5.28M:2005, whichever is applicable, made on electrodes or flux-electrode
combinations of the same class, size and brand as the electrodes to be used. If electrodes
are to be used which are of a size for which tests are not required by the specifications
governing the process applicable to those electrodes, the test reports shall be furnished for
electrodes of the size nearest and of the same classification and brand as those to be used.
The tests may have been made for process qualification or quality control, and shall have
been made within one year prior to the manufacture of the electrodes and fluxes to be used.
The report shall include the manufacturer's certification that the process and material
requirements were the same for manufacturing the tested electrodes and the electrodes to
be used. All pertinent information concerning the tests required by the applicable electrode
specifications shall be reported. The forms and certificates shall be as directed by the
Engineer.
b. Electrodes for manual shielded metal arc welding of structural steel, ASTM A36 / A36M - 08
or ASTM A588 / A588M - 10, shall comply with the requirements of AWS A5.1/A5.1M-2004
or AWS A5.5/A5.5M:2006 for E7016, E7018, E7048, or E7028 electrodes.
c. Electrodes and fluxes for automatic and semi-automatic submerged arc welding of structural
steel, ASTM A36 / A36M - 08 shall comply with the requirements of AWS ANSI/AWS A5.17/
A5.17M-97 (R2007) or AWS A5.23/A5.23M: 2011 for F62, F64, F66, F72, F74, or F76 and
for ASTM A588 / A588M - 10 shall comply with the requirements of ANSI/AWS A5.17/
A5.17M-97 (R2007) or ANSI/AWS A5.24/ A5.24M:2005 for F72, F74 or F76.
d. Solid and composite electrodes for automatic and semi-automatic gas metal-arc welding of
structural steel, ASTM A36 / A36M - 08 shall comply with the requirements of ANSI/AWS
A5.18/A5.18M:2005 or ANSI/AWS A5.28/A5.28M:2005 for ER 70S-2, 3, 6 or 7 electrodes.
Page 23-22
23.4.11.2 Construction Requirements

a. The work methods and procedures shall comply with the AWS specifications, or BS EN 1011-
2:2001 and tested in accordance with BS EN ISO 15614-1:2004+A2:2012 by the Contractor,
except as modified herein.
b. Procedures and tests shall be approved by an independent Inspection Authority. Welding
Procedure sheets shall be made available to the welder prior to the commencement of the
work and shall be available to the Engineer and Inspection Authority on request.
c. All welding shall be performed in such a manner that the Brinnell hardness of the weld metal
and heat-affected zone is within the limits computed from Equation 23-2 and Equation 23-3:
Minimum specified tensile strength of parent metal
Minimum Brinnell Hardness =
500
Equation 23-2: Minimum Brinnell hardness
Max. specified or tested tensile strength of parent metal

Maximum Brinnell Hardness = + 50
500
Equation 23-3: Maximum Brinnell hardness
d. The minimum preheat and interpass temperatures for welding structural steel shall comply
with Table 3.2, Prequalified Minimum Preheat and Interpass Temperature, ANSI/AWS
D1.1/D1.1M:2010, except that the minimum preheat for structural steel 1.8 cm or less in
thickness, shall not be less than 10o C.
e. Automatic vertical shielded metal-arc welding processes, such as electroslag or electrogas,
may be used only on structural steel ASTM A36 / A36M - 08. The impact strength
requirements shall be included in the procedure qualification.
f. All welding shall be protected from air currents or drafts to prevent loss of heat or loss of arc
shielding. The method of protecting the welding area from loss of heat or loss of arc shielding
shall be subject to approval by the Engineer.
g. Areas contiguous to welding operations shall be preheated to a minimum temperature of 150o
C when necessary, in the opinion of the Engineer, to prevent distortion or weld cracking.
Preheating to a temperature in excess of 200o C will not be required by the Engineer.
23.4.11.3 Qualification of Welders

a. Welder qualification tests will be evaluated in accordance with requirements of the current
AASHTO/AWS D1.5M/D1.5:2010, Bridge Welding Code. As an alternative, welders may be
tested to meet the requirements of BS EN 287-1:2011 but, in the case of welders engaged
on fillet welding only, BS 4872-1:1982 is an acceptable alternative.
b. Welder testing shall be witnessed and certificates endorsed by an independent Inspection
Authority.
c. The certification shall remain valid providing it complies with the conditions for re-approval of
certification specified in BS EN 287-1:2011.
d. In lieu of the AWS requirements, qualification tests for tack welding will be the same as the
qualification tests required for butt welding material up to and including 1.8 cm thick.
23.5 Fabricating Steel Structures

This section outlines standards and specifications for fabricating steel structures.
23.5.1 Cutting, Shearing, and Machining for Steel Plates

Cutting (including burning and sawing), shearing, and machining shall be accomplished in
accordance with the AASHTO/AWS D1.5M/D1.5:2010, Bridge Welding Code. In addition, the
Fabricator shall do the following:
Page 23-23
a. Plane, mill, grind, or thermally cut the sheared edges of main load-carrying member plate
components that are greater than 16 mm thick to a depth of 6 mm.
b. Cut and fabricate steel plates so that the primary direction of rolling is parallel to the direction
of the member’s or component’s main stress. For flanges and webs, the direction of rolling
shall be parallel to the flanges, unless the Contract documents note otherwise. With approval
from the Engineer, the Fabricator may roll web splice plates parallel to their length.
Oxygen cutting of structural steel shall conform to the requirements of the current AASHTO/AWS
Visual inspection and repair of plate-cut edges shall be in accordance with the current
AASHTO/AWS D1.5M/D1.5:2010, Bridge Welding Code.
23.5.2 Cold Bending Steel Plates

The Contractor shall submit cold bending procedures to the Engineer for review. Cold bending shall
comply with the specifications in the AASHTO/AWS D1.5M/D1.5:2010, Bridge Welding Code and
the provisions in this section. The Contractor shall not cold bend materials that are fracture-critical.
They shall not cold bend members or components that carry main loads. The Contractor shall visually
inspect all load points. Large dents or upsets will be cause for rejection. The Contractor shall use
magnetic particle examination or ultrasonic examination to discover any potentially damaged areas,
and then shall further inspect such areas.
23.5.2.1 Minimum Bend Radii and Other Requirements

The Contractor shall remove all sharp edges (including edges of holes if affected by the cold bending)
by grinding to a 1.6 mm radius. The Contractor shall submit material preparation procedures to the
Engineer for review.
Unless otherwise approved, the minimum bend radii for cold bending (at room temperature),
measured to the concave face of the plate shall be as given in Table 23-4. If a smaller radius is
required, the Contractor may need to apply heat as part of the bending procedure in accordance with
Article 23.5.4.5. The Contractor shall submit the heating procedure to the Engineer for review.
For materials and grades not shown in Table 23-4, follow the minimum bend radii recommendations
of a plate’s producer.
Table 23-4: Minimum Cold-bending Radii
Steel grades Thickness (t) mm

AASHTO M 270M/M 270-12
Up to 19 mm Over 19 mm Over 25 mm Over 50
(ASTM A709 / A709M - 11), MPa
to 25 mm to 50 mm mm
250 1.50 t 1.50 t 1.50 t 2.00 t
345, 345S, 345W, or HPS 345W 1.50 t 1.50 t 2.00 t 2.50 t
HPS 485W 1.50 t 1.50 t 2.50 t 3.00 t
690, 690W, or HPS 690W 1.75 t 2.25 t 4.50 t 5.50 t
As possible, bend lines shall be perpendicular to the direction of final rolling of the plate. If a bend
line is parallel to the direction of final rolling, multiply the suggested minimum radii in Table 23-4 by
1.5.
Page 23-24
23.5.3 Straightening Steel

When permitted by the Engineer, plates, angles, other shapes, and built-up members shall be
straightened before the parts are assembled. The Fabricator shall perform straightening such that
no fracture, cracking or other damage occurs. If heat is to be used for straightening, such heating
shall comply with the specifications and requirements in Section 23.5.4. Distorted members shall be
straightened by mechanical means or, if approved by the Engineer, by carefully planned procedures
and supervised application of a limited amount of localized heat, except that heat-straightening of
AASHTO M 270M/M 270-12 (ASTM A709 / A709M - 11) (Grades HPS 485W and HPS 690W) steel
members shall be done only under rigidly controlled procedures, each application subject to the
approval of the Engineer. In no case shall the maximum temperature exceed values in Table 23-5.
In all other steels, the temperature of the heated area shall not exceed 649°C as controlled by
temperature indicating crayons, liquids, or bimetal thermometers. Heating in excess of the limits
shown shall be cause for rejection, unless the Engineer allows testing to verify material integrity.
Parts to be heat-straightened shall be substantially free of stress and from external forces, except
stresses resulting from mechanical means used in conjunction with the application of heat.
Evidence of fracture following straightening of a bend or buckle will be cause for rejection of the
damaged piece.
23.5.4 Applying Heat to Steel

At various points during the fabrication of structural steel, applications of heat may be necessary for
hot-bending, cambering, curving, or straightening. The Fabricator shall use the temperature limits
and guidelines given in this section, unless alternate procedures have been approved by the
Engineer. Routine straightening of material other than quenched and tempered material shall be
done in accordance with the temperature limits and guidelines as specified in this section; the Owner
does not require the Contractor to submit a procedure for such routine straightening.
Heat curving may be used in conjunction with a cut-curve procedure, in which a portion of the
curvature is obtained by cutting the plates to all or part of the required radius, except as limited by
Article 23.5.4.2.
23.5.4.1 Equipment and Process for Heating Steel

This section outlines requirements and specifications for the process and equipment used to heat
steel.
a. Maximum Temperatures
Table 23-5 indicates the maximum allowable temperature to which steel can be heated, as measured
by temperature-indicating crayons or other suitable means.
Table 23-5: Maximum temperature limits for heat applications
Steel grades
Maximum temperature
AASHTO M 270M/M 270-12 (ASTM A709 / A709M - 11), MPa
250 649o C
345, 345S, 345W, or

649o C
HPS 345W
HPS 485W 593o C
690 or 690W 593o C
Page 23-25
b. Timing Heat Applications

The Fabricator shall conduct heating operations before the application of coatings.
c. Allowable Preload Stresses

Preload compressive stresses will be permitted up to 0.5 times the minimum specified yield strength
(Fy) of the material. This stress limit is applicable to all steels covered by this specification as listed
in Table 23-5. If jacks are used, the Fabricator shall energize them and lock them off before applying
heat.
d. Heating Tips
The Fabricator shall apply heat using orifice tips only. Select tip sizes proportional to the thickness
of the heated material.
e. Torches
The Fabricator shall manipulate the heating torches to guard against general and surface
overheating. In addition, place heat reflective sheet material against the web before applying heat to
the inside flange surface. When heating the inside flange surface, point the torches to prevent
applying heat directly to the web.
f. Heating Patterns
Fundamental heating patterns (such as vee, line, edge, spot, and strip) may be used separately or
in combination. The Fabricator shall mark vee and strip heat patterns on the material surfaces before
heating. When heating, bring the steel within the planned pattern to the specified heating
temperature as rapidly as possible without overheating the steel. Apply heat in accordance with the
approved procedure.
g. Thin Wide Plates

The Fabricator shall prevent buckling of thin wide plates by not applying excessive heat.
h. Verification of Temperatures
The Fabricator shall use temperature sensitive crayons, pyrometres, or infrared non-contact
thermometres for verifying temperatures during heating operations. When heating patterns are used,
make regular verifications of the temperatures throughout the pattern. Remove the heating flame
from the material before taking measurements.
i. Cooling
Before using any artificial cooling, the Fabricator shall allow steel to cool naturally below 316° C. Use
only dry compressed air. Do not quench with water or a water and air mixture.
j. Reheating
The Fabricator shall reheat only after the material has cooled below 121° C.
k. Over Heating
The Engineer shall reject a product, if any portion of the material is exposed to heating higher than
the allowable temperature.
23.5.4.2 Heat-curving Bridge Members

This section outlines specifications for heat-curving bridge members, which is also known as weak
axis shaping.
Page 23-26
a. General Requirements for Heat-curving

Rolled beams and girders may be heat curved at the job site, provided that the heating is performed
in accordance with the Engineer’s approval.
Flanges of curved, welded girders may be cut to the radii specified in the Contract documents or
curved by applying heat as specified in the succeeding articles providing the radii is not less than
allowed by Article 10.15.2, “Minimum Radius of Curvature,” of the AASHTO Standard Specifications
for Highway Bridges, Latest Edition, Design Specifications.
b. Materials for Rolled Beams and Welded Girders

Structural steels conforming to AASHTO M 270M/M 270-12 (ASTM A709 / A709M - 11), Grade 36,
50, 50S, 50W, HPS 50W, HPS 70W, or HPS 100W (Grade 250, 345, 345S, 345W, HPS 345W, HPS
485W, or HPS 690W) may be heat-curved.
c. Type of Heating for Rolled Beams and Welded Girders

Beams and girders may be curved by either continuous or V-type heating as approved by the
Engineer. For the continuous method, a strip or intermittent strips along the edge of the top and
bottom flange shall be heated approximately simultaneously depending on flange widths and
thicknesses; the strip shall be of sufficient width and temperature to obtain the required curvature.
For the V-type heating, the top and bottom flanges shall be heated in truncated triangular or wedge-
shaped areas having their base along the flange edge and spaced at regular intervals along each
flange; the spacing and temperature shall be as required to obtain the required curvature and heating
shall progress along the top and bottom flange at approximately the same rate.
For the V-type heating, the apex of the truncated triangular area applied to the inside flange surface
shall terminate just before the juncture of the web and the flange is reached. To avoid unnecessary
web distortion, special care shall be taken when heating the inside flange surfaces (the surfaces that
intersect the web) so that heat is not applied directly to the web. When the radius of curvature is 305
metres or more, the apex of the truncated triangular heating pattern applied to the outside flange
surface shall extend to the juncture of the flange and web. When the radius of curvature is less than
305 metres, the apex of the truncated triangular heating pattern applied to the outside flange surface
shall extend past the web for a distance equal to one-eighth of the flange width or 75mm, whichever
is less. The truncated triangular pattern shall have an included angle of approximately 15 to 30
degrees but the base of the triangle shall not exceed 250mm. Variations in the patterns prescribed
above may be made with the approval of the Engineer.
For both types of heating, the flange edges to be heated are those that will be on the inside of the
horizontal curve after cooling. Heating both inside and outside flange surfaces is only mandatory
when the flange thickness is 31mm or greater, in which case, the two surfaces shall be heated
concurrently. The maximum temperature shall be prescribed as per Article 23.5.4.1.
d. Sequence of Heat-curving Operations

The Fabricator shall heat curve girders before they are painted. The heat-curving operation may be
conducted either before or after all the required welding of transverse intermediate stiffeners is
completed. However, unless provisions are made for girder shrinkage, connection plates and bearing
stiffeners shall be located and attached after heat-curving. If longitudinal stiffeners are required, they
shall be heat-curved or oxygen-cut separately and then welded to the curved girder. When cover
plates are to be attached to rolled beams, they may be attached before heat-curving if the total
thickness of one flange and cover plate is less than 63.5mm and the radius of curvature is greater
than 305 metres. For other rolled beams with cover plates, the beams shall be heat-curved before
the cover plates are attached; cover plates shall be either heat-curved or oxygen-cut separately and
then welded to the curved beam.
Page 23-27
e. Web Position for Heat-curving

When the radius is less than 305 metres, the Fabricator shall heat curve members with the web in
the horizontal position or preloaded to induce stress before heating. Otherwise, members may be
heat curved with the web in either the vertical or horizontal position.
When heat-curving with the web in the horizontal position, provide intermediate safety catch blocks
between supports of the member and not more than 50 mm below the flanges to catch the member
in case of a sudden sag.
When heat-curving with the web in the vertical position, the member shall be braced or supported in
such a manner that the tendency of the member to deflect laterally during the heat-curving process
will not cause the member to overturn.
f. Subsequent Heat-curving Applications

If multiple locations are to be heated, the Fabricator shall not reheat the same location until after at
least three heats at other locations.
g. Locating Heating Patterns

The Fabricator shall space the heating patterns along the full length of each flange to produce a
circular (not parabolic) curvature. Adjust the heating patterns to produce the necessary curvature.
Compensate for differences in flange thickness and width as necessary. Use enough heating
patterns in each piece to eliminate chording effects.
h. Minimum Radius for Heat-curving

Heat-curving of beams and girders is allowed when the horizontal radius of curvature measured to
the centreline of the member web is greater than both values calculated in Equation 23-4 and
Equation 23-5, and greater than 45.7 metres at any and all cross sections throughout the length of
the member. Do not heat curve steels manufactured to a yield strength greater than 345 MPa, other
than ASTM A709 / A709M - 11, Grade HPS 485W.
(7.3 bD)
R=
√Fy Ψ t
Equation 23-4: Radius calculation 1
(51720 b)
R=
Fy Ψ
Equation 23-5: Radius calculation 2
Where:
Fy = Specified minimum yield
point of member web, MPa
Ψ= Ratio of the total cross
section area to the cross-sectional area of both flanges
b= Width of the widest flange,
mm
D= Clear distance between
flanges, mm
t= Web thickness, mm
R= Radius, mm
Page 23-28
In addition to the above requirements, the Fabricator shall not heat curve if the radius is less than
305 metres when a flange’s thickness exceeds 75 mm or its width exceeds 762 mm.
23.5.4.3 Heat-cambering Steel

This section outlines specifications for heat-cambering steel, which is also known as strong axis
shaping.
a. General Requirements For Heat-cambering

Girders shall be cambered before heat-curving. Camber for rolled beams may be obtained by heat-
cambering methods approved by the Engineer. For plate girders, the web shall be cut to the
prescribed camber with suitable allowance for shrinkage due to cutting, welding, and heat-curving.
However, subject to the approval of the Engineer, moderate deviations from specified camber may
be corrected by a carefully supervised application of heat.
Procedures for cambering of built-up plate girders shall be submitted as a part of the Quality Control
Plan. In the procedures, address any proposed preloading and heat application and control. Minor
heat adjustments in camber at the finishing stage of the girder do not require approval if the patterns
and temperatures are followed in accordance with the approved procedures. The Fabricator shall
not use heat-cambering as the primary source of vertical camber in horizontally curved main load-
carrying members; cut the web plate to the required position. Only use heat-cambering on
horizontally curved main members to adjust cut cambering with the approval of the Engineer.
b. Web Position for Heat-cambering

The Fabricator shall support members to be heat-cambered with the web vertical. Space supports
to take maximum advantage of dead load in the member before the application of heat.
c. Subsequent Heat-cambering Applications

If multiple locations are to be heated, the Fabricator shall not reheat the same location until after at
least three heats at other locations.
d. Heat-cambering Rolled Beams

Rolled beams may be heat-cambered to provide the required curvature at the producing mill. The
Fabricator shall attach all detail material, such as connection plates, bearing stiffeners and gusset
plates, after the beam has been heat-cambered.
e. Measurement of Curvature and Camber

Horizontal curvature and vertical camber shall be measured for final acceptance after all welding
and heating operations are completed and the flanges have cooled to a uniform temperature.
Horizontal curvature shall be checked with the girder in the vertical position.
23.5.4.4 Heat-straightening Damaged Structural Steel

The Fabricator shall submit procedures for heat-straightening for the Engineer to review before
beginning work. Such procedures shall describe, in detail, the distortion to be corrected and all
details for preloading, heating, cooling, verifying final dimensions, and non-destructive testing.
a. Heat-straightening Cracked Steel

As a minimum, the Fabricator shall visually inspect all heat-straightened areas. The Fabricator shall
notify the Engineer after finding any suspected areas of cracking. In accordance with direction from
the Engineer, the Fabricator shall inspect these areas by one or more of the following methods:
1. Visual inspection
2. Liquid penetrant examination as described in ASTM E165 / E165M - 12
3. Magnetic particle examination as described in ASTM E709 - 08
Page 23-29
4. Ultrasonic examination as described in Section 6, Part C of the AASHTO/AWS

D1.5M/D1.5:2010, Bridge Welding Code
5. Radiographic examination as described in Section 6, Part B of the AASHTO/AWS
D1.5M/D1.5:2010, Bridge Welding Code
b. Restraining Forces for Heat-straightening Damaged Steel

Restraining forces (usually jacks) shall be set to restrain the steel during heating, but allow free
Contraction during cooling. In addition, the Fabricator shall apply the restraining forces in a direction
tending to restore the member and limit the magnitude so that the material is not overstressed during
heating.
c. Heating Damaged Structural Steel

The Fabricator shall heat the steel in a single pass following the specified pattern and allow it to cool
to below 121° C before reheating. The Fabricator shall select heating patterns and sequences that
are appropriate for the type of damage and shape of the cross section. Simultaneous vee heats may
be used if the clear spacing between vees is greater than the width of the plate element.
d. Subsequent Repairs after Heat-straightening Steel

The Fabricator may repair any members that are damaged after heat cambering. However, they
shall not repair previously heat-straightened members in the same region of damage without the
approval of the Engineer.
23.5.4.5 Hot Bending Steel Plates

Where a smaller radius than that allowed in Section 23.5.2 is required, non-primary load carrying
components may be bent using heating together with mechanical force in accordance with the
guidelines provided in Article 23.5.4.1. The Fabricator shall apply heat uniformly through the
thickness of the plate. They shall provide the hot bending procedures to the Engineer for review.
23.5.4.6 Heat Treatment for Structural Steel

When any special form of heat treatment is required, it shall be described in the Contract documents.
The Fabricator shall perform heat treatments following any boring, machining and/or straightening
operations.
a. Normalizing and Annealing Structural Steel

Structural members that are indicated in the Contract documents to be annealed or normalized shall
have finished machining, boring, and straightening done subsequent to heat treatment. Normalizing
and annealing (full annealing) shall be as specified in ASTM A941 - 10a. Temperatures shall be
maintained uniformly throughout the furnace during the heating and cooling so that the temperature
at no two points on the member will differ by more than 55° C at any one time.
Members of AASHTO M 270M/M 270-12 (ASTM A709 / A709M - 11) Grades 690/690W or Grade
485W steels shall not be annealed or normalized and shall be stress relieved only with the approval
of the Engineer.
b. Relieving Stress during Heat Treatment for Structural Steel

Where required, the Fabricator shall perform thermal stress relief in accordance with the procedure
outlined in the AASHTO/AWS D1.5M/D1.5:2010, Bridge Welding Code. Welding materials shall be
consistent with the stress relieving process used.
A record of each furnace charge shall identify the pieces in the charge and show the temperatures
and the actually used schedule. Proper instruments, including recording pyrometres, shall be
provided for determining at any time the temperatures of members in the furnace. Records of
treatment operations shall be available to and meet the approval of the Engineer. Holding
Page 23-30
temperature for stress relieving shall be in accordance with Section 4.4 of the current AASHTO/A
WS D1.5M/D1.5 Bridge Welding Code.
Members, such as bridge shoes, pedestals, or other parts that are built up by welding sections of
plate together shall be stress relieved in accordance with the procedure of Section 4.4 of the current
AASHTO/ A WS D 1.5M/D 1.5 Bridge Welding Code, when required by the Contract documents.
23.5.5 Bolt Holes for Steel Structures

23.5.5.1 Holes for High-strength Bolts and Unfinished Bolts
All holes for bolts shall be either punched or drilled, except as noted herein. The width of each
standard hole shall be the nominal diameter of the bolt plus 1.6mm. The standard hole diameter for
metric bolts M24 and smaller shall be the nominal diameter of the bolt plus 2 mm. For metric bolts
M27 and larger, the standard hole diameter shall be the nominal diameter of the bolt plus 3 mm.
Except as noted in the sub-articles below, material forming parts of a member composed of not more
than five thicknesses of metal may be punched full-size.
When more than five thicknesses of material are joined or, as required by Article 23.5.5.5, material
shall be subdrilled or subpunched and then reamed full-size, or drilled full-size while in assembly.
When required, all holes shall be either subpunched or subdrilled 4.8mm smaller and, after
assembling, reamed or drilled to full size.
Holes in cross frames, lateral bracing components, and the corresponding holes in connection plates
between girders and cross frames or lateral components may be punched full size. Holes in
longitudinal main load-carrying members, transverse floor beams, and any components designated
as fracture critical (FCMs) shall not be punched full-size.
When shown in the Contract documents, enlarged or slotted holes are allowed with high-strength
bolts.
With the Owner’s approval, round or slotted holes for non-main members in thin plate may be
thermally cut by plasma, laser, or oxygen-acetylene methods subject to the requirements herein.
a. Punched Holes
If any holes must be enlarged to admit the bolts, such holes shall be reamed. Holes must be clean-
cut without torn or ragged edges. The slightly conical hole that naturally results from punching
operations shall be considered acceptable.
b. Reamed or Drilled Holes

Reamed or drilled holes shall be cylindrical, perpendicular to the member, and shall comply with the
requirements of Article 23.5.5.1 as to size. Where practical, reamers shall be directed by mechanical
means. Burrs on the outside surfaces shall be removed. Reaming and drilling shall be done with
twist drills, twist reamers, or rotobroach cutters. Connecting parts requiring reamed or drilled holes
shall be assembled and securely held while being reamed or drilled and shall be match-marked
before disassembling.
c. Accuracy of Holes
Holes not more than 0.8mm larger in diameter than the true decimal equivalent of the nominal
diameter that may result from a drill or reamer of the nominal diameter shall be considered
acceptable. The width of slotted holes which are produced by thermal cutting or a combination of
drilling or punching and thermal cutting should be not more than 0.8mm greater than the nominal
width. The thermally-cut surface shall be ground smooth to obtain a maximum surface roughness of
ANSI 25 μm (RMS).
Page 23-31
23.5.5.2 Accuracy of Hole Group

a. Accuracy before Reaming
All holes punched full-size, subpunched, or subdrilled shall be so accurately punched that after
assembling (before any reaming is done) a cylindrical pin 3.2mm smaller in diameter than the
nominal size of the punched hole may be entered perpendicular to the face of the member, without
drifting, in at least 75 percent of the contiguous holes in the same plane. If the requirement is not
fulfilled, the badly punched pieces shall be rejected. If any hole will not pass a pin 4.8mm smaller in
diameter than the nominal size of the punched hole, this shall be cause for rejection.
b. Accuracy after Reaming

When holes are reamed or drilled, 85 percent of the holes in any contiguous group shall, after
reaming or drilling, show no offset greater than 0.8mm between adjacent thicknesses of metal.
All steel templates shall have hardened steel bushings in holes accurately dimensioned from the
centerlines of the connection as inscribed on the template. The centrelines shall be used in locating
accurately the template from the milled or scribed ends of the members.
23.5.5.3 Numerically-controlled Drilled Field Connections

In lieu of subsized holes and reaming while assembled, or drilling holes full-size while assembled,
the Contractor shall have the option to drill or punch bolt holes full-size in unassembled pieces and/or
connections including templates for use with matching subsized and reamed holes, by means of
suitable numerically-controlled (N/C) drilling or punching equipment. Full-size punched holes shall
meet the requirements of Article 23.5.5.1.
If N/C drilling or punching equipment is used, the Contractor shall be required to demonstrate the
accuracy of this drilling or punching procedure in accordance with the provisions of Article 23.6.1.4
by means of check assemblies.
Holes drilled or punched by N/C equipment shall be drilled or punched to appropriate size either
through individual pieces or drilled through any combination of pieces held tightly together.
23.5.5.4 Holes for Ribbed Bolts, Turned Bolts, or Other Approved

Bearing-type Bolts
All holes for ribbed bolts, turned bolts, or other approved bearing-type bolts shall be subpunched or
subdrilled 4.8mm smaller than the nominal diameter of the bolt and reamed when assembled, or
drilled to a steel template or, after assembling, drilled from the solid at the option of the Fabricator.
In any case, the finished holes shall provide a driving fit as specified in the Contract documents.
23.5.5.5 Preparation of Field Connections

Holes in all field connections and field splices of main member of trusses, arches, continuous-beam
spans, bents, towers (each face), plate girders, and rigid frames shall be subpunched or subdrilled
and subsequently reamed while assembled or drilled full-size through a steel template while
assembled. Holes in cross frames, lateral bracing components, and the corresponding holes in
connection plates between girders and cross frames or lateral components may be punched full size.
Holes in longitudinal main load-carrying members, transverse floor beams, and any components
designated as fracture critical (FCMs) shall not be punched full-size. Holes for field splices of rolled
beam stringers continuous over floor beams or cross frames may be drilled full-size unassembled to
a steel template. All holes for floor beams or cross frames may be drilled full-size unassembled to a
steel template, except that all holes for floor beam and stringer field end connections shall be
subpunched and reamed while assembled or drilled full-size to a steel template. Reaming or drilling
full-size of field-connection holes through a steel template shall be done after the template has been
located with utmost care as to position and angle and firmly bolted in place. Templates used for
reaming matching members or the opposite faces of a single member shall be exact duplicates.
Page 23-32
Templates used for connections on like parts or members shall be so accurately located that the
parts or members are duplicates and require no match-marking.
For any connection, in lieu of subpunching and reaming or subdrilling and reaming, the Fabricator
may, at the Fabricator’s option, drill holes full-size with all thicknesses or material assembled in
proper position.
23.5.5.6 Slotted Bolt Holes

Slots may be made by a single punch, or by joining two adjacent drilled or punched holes when
punching is permitted. When joining holes, thermal cutting is to follow the common tangent to the
two holes, and this cut is to be ground. The Fabricator shall not make slotted holes more than 0.8
mm in width nor 1.6 mm greater in length than specified. The Fabricator shall grind smooth any flame
cut portions of the slot to ANSI 25 μm (RMS).
Unless shown otherwise in the Contract documents, the bolt (and anchor rod) slotted hole geometry
shall comply with the measurements shown in Table 23-6.
Table 23-6: Bolt hole geometry
Bolt Standard Oversize Short-slotted (width Long-slotted (width

Diametre (d) diametre diametre x length) x length)
12.7 mm 14.3 mm 15.9 mm 14.3 mm x 17.5 mm 14.3 mm x 31.7 mm
(d + 1.6 mm) X (d + 1.6 mm) X (2.5 x

28.6+ mm d + 1.6 mm d + 7.9 mm
(d + 9.5 mm) d)
a. Bolt Hole Tolerances and Quality

The Fabricator shall make bolt (and anchor rod) holes using any method suitable to him and as
specified in this section. With the Engineer’s approval, the Fabricator may thermally cut holes for
high strength fasteners in main or primary load-carrying members that are not to be punched full
size. Such cutting shall comply with the specifications in this section. The Fabricator shall grind
thermally cut holes to make them smooth.
Holes in a bolt group relative to the same holes in the component or components it is joined to in a
connection shall not be misaligned more than 0.8mm for 85% of the bolt holes in that group. Bolt
holes are to be normal to the work and have no tears, cracks, fins, dirt, loose rust, burrs, or other
anomalies. Surfaces shall be flat within a slope of 1/20. Bolt holes shall be round within ± 0.8mm
and within ± 0.8mm of the specified size. For subsize holes, a pin 3.2 mm smaller than the subsize
holes must be able to pass through all assembled plies in at least 75% of the locations before
reaming. Holes inclined more than 3 degrees to a surface in any direction must have a hardened
beveled washer provided at that face. Unless the Contract documents specify otherwise, coating the
insides of bolt holes is not required.
23.5.5.7 Bolt Holes in Plates Not Subjected to Tensile Stress

The Fabricator may thermally cut large diametre holes in heavy plates, such as bearing plates, that
are not subjected to tensile stress and may thermally cut slotted holes in materials that are not
subject to tensile stress. The Fabricator shall follow such cutting with appropriate grinding to smooth
Page 23-33
the periphery. The Fabricator shall stop the practice if gouges or other defects occur or if the
Engineer so directs.
The Contractor shall not thermally cut holes in grade 690 or 690W steel, as defined in ASTM A709
/ A709M - 11. Provide hole centrelines aligned within ± 1.6mm of theoretical. The inside (cut) faces
of the hole are to be perpendicular to the plane of the plate. Eighty-five percent of the (open) hole
diametre is not to exceed that specified in the Contract documents, ± 1.6mm. Local notches, gouges
or the maximum diametre shall not exceed that specified in the Contract documents ± 2.4mm.
23.5.5.8 Bolts Configuration

a. Distances of Bolt Holes to the Edge of the Steel Structure
The Contractor shall ensure that the centre of each bolt hole is at least as far from the edge of the
steel structure as the measurement indicated in Table 23-7.
Table 23-7: Distances of bolt holes from edge of steel structure
Fastener size Sheared edge Rolled edges of plates or shapes or gas cut edges
15.9 mm 28.6 mm 22.2 mm
19.0 mm 31.7 mm 25.4 mm
22.2 mm 38.1 mm 31.7 mm
25.4 mm 44.4 mm 31.7 mm
b. Bolted Splice Gaps

Unless the Contract documents show otherwise, the tolerance for bolted splice gaps (open distance
face-of-web/flange to face-of-web/flange) shall be from zero (no gap between faces) to a maximum
of 3.2 mm greater than the gap shown on the Contract plans. If no gap is shown in the Contract
plans, assume that a nominal gap of 9.5 mm is required. In addition, meet the edge distance
requirements, provided above.
c. Maximum Distances between Edges to Hole Centres

Unless otherwise specified in the Contract documents, the maximum fabricated distance from any
edge to the centre of the hole shall be 8 times the thickness of the thinnest outside plate, not to
exceed 127 mm with no additional tolerance allowed.
d. Spaces between Bolt Holes

The Fabricator shall space bolt holes within ± 3.2mm of that shown in the Contract documents.
23.5.6 Contact and Bearing Surfaces for Steel Structures

Surface finishes of bearings, base plates, and other contact surfaces shall comply with the ANSI
surface roughness requirements as defined in ANSI/ASME B46.1-2009, Surface Texture, Surface
Roughness, Waviness and Lay, given in Table 23-8, ANSI Surface Roughness Requirements.
Table 23-8: ANSI surface roughness requirements
Surface Roughness
Steel slabs ANSI 50 μm (RMS)
Heavy plates in contact in shoes to be welded ANSI 25 μm (RMS)
Page 23-34
Surface Roughness
Milled ends of compression members, milled or ground ends of stiffeners ANSI 12.5 μm
and fillers (RMS)
Bridge rollers and rockers ANSI 6.3 μm (RMS)
Pins and pin holes ANSI 3.2 μm (RMS)
Sliding bearings ANSI 3.2 μm (RMS)
23.5.7 Cleaning and Coating Steel Structures

The Contractor shall comply with the specifications outlined in Sections 24.3 and 24.4 of Chapter
24, Painting, when cleaning, coating, and galvanising steel structures.
In addition, the Contractor shall remove lubricants from the exposed surfaces of installed fastener
assemblies and other surfaces in accordance with the approved quality control plan or the paint
Manufacturer’s recommendations before painting. The Contractor shall demonstrate the lubricant
removal procedures to the Engineer before preparing for painting. The Contractor shall bring to the
Engineer’s attention any Manufacturer’s process or procedure that conflicts with those specified in
the Contract documents.
23.5.8 Geometry for Members of Steel Structures

This section outlines geometrical requirements for members of steel structures.
23.5.8.1 General Geometrical Requirements

This section outlines general geometrical requirements for members of steel structures.
a. Tolerances for Members of Steel Structures

The Contractor shall ensure that members of a steel structure comply with the following dimensional
tolerances:
• Rolled shapes, plates, bars, wide flange sections and miscellaneous steel in accordance with
(ASTM A6 / A6M – 12).
• Fabricate girders in accordance with the AASHTO/AWS D1.5M/D1.5:2010, Bridge Welding
Code and as described later in this section.
• For built-up members not specifically covered by AASHTO/AWS D1.5M/D1.5:2010, apply
AASHTO/AWS D1.5M/D1.5:2010, Bridge Welding Code, except as noted below or as
b. Camber and Sweep for Members of Steel Structures

Tolerances for camber and sweep of continuous and simply supported girders of any shape shall be
as described in the AASHTO/AWS D1.5M/D1.5:2010, Bridge Welding Code. Camber and sweep
tolerances for steel pier caps shall be the same as those specified for girders. Measure sweep for
horizontally curved members from the theoretical centreline for comparison to the aforementioned
requirements.
c. Alternate Sections for Members of Steel Structures

Rolled sections or fabricated sections of equal or slightly greater dimensions than the section
specified may be proposed for the Engineer’s approval. Changes that reduce fatigue resistance or
significantly affect splice design or deflection will require complete design calculations.
Page 23-35
d. Web Flatness for Members of Steel Structures

Maximum deviation from flatness for webs of curved or cambered sections shall be the same as for
straight built up girders. Measure curved girder web flatness using a straightedge oriented
perpendicular to the flanges (‘vertical’, flange to flange).
e. Girder Lengths for Steel Structures

If measuring girder length with a device that is free of thermal effects, appropriately adjust the
measurements to the reference temperature shown in the Contract documents. Measure the length
of horizontally curved girders along the arc.
23.5.8.2 Special Members of Steel Structures

This section outlines specifications for special members in steel structures.
a. Box Members as Bent Caps

Box members that function as bent caps must meet the requirements outlined in this section.
Tolerances: Unless otherwise shown in the Contract documents, submit tolerances for bearing
planes and box twist to the Engineer for review and approval. Before submitting these tolerance
values for approval, coordinate between the erector and the Fabricator.
Bearings: Unless otherwise specified in the Contract documents, each bearing is to be true to a
tolerance of 0.8 mm across its entire width in either direction.
Beam Trueness: Unless otherwise specified in the Contract documents, the plane of beam supports
on the box girder (the bearing area specifically attached to the box girder) is to be true to the box
girder bearing within 1.6 mm in the short direction and true to the vertical axis of the nesting girders
(those girders attached to or resting on the box girder) within 1.6mm.
b. Trapezoidal Bridge Members

As a minimum, trapezoidal bridge members (tub or box girders) shall meet AASHTO/AWS
D1.5M/D1.5:2010, Bridge Welding Code dimensional tolerances. Camber may be verified with the
girder in its upright position, supported to avoid dead load deflections.
c. Pinholes
Unless shown elsewhere in the Contract documents, bore pinholes must meet the following
specifications:
• True to the specified diametre
• Smooth to ANSI 3 (3.2 μm)
• At right angles with the axis of the member
• Parallel with each other
• With a diametre of the pinhole not exceeding that of the pin by more than 0.4 mm for pins
127 mm or less in diametre, or 0.8 mm for larger pins.
d. Truss Chord Joints

Abutting joints in truss chords not specified to be mill-to-bear, shall have openings of 6.3 mm ± 3.2
mm.
Abutting joints in truss chords specified to be mill-to-bear, shall be faced and brought into bearing.
When assembling truss chord joints, the Contractor shall provide 85% or more of the abutting
surfaces in full contact. Allowable visible gaps shall not exceed 0.4 mm.
Page 23-36
e. Horizontally Curved Beams and/or Skewed Steel Girders

Account for torsion induced deflections for horizontally curved beams and/or skewed steel girders.
Unless otherwise defined in the Contract documents, a horizontally curved beam or girder is a
longitudinal or transverse bridge component with a radius less than 3,048 metre anywhere along its
continuous length.
23.5.8.3 Dimensions and Tolerances as per BS & BS EN Standards

As an alternative, dimensions and tolerances may comply with the appropriate standard shown in
Table 23-9:
Table 23-9: Material and Dimension as per BS & BS EN Standards
Dimension
Form Material Quality Dimensions
Tolerances
U.B. and U.C. BS 4-1:2005 BS EN 10034:1993
Joists BS 4-1:2005 BS 4-1:2005
BS EN 10025-
Channels BS 4-1:2005 BS 4-1:2005
2:20041
BS EN 10056- BS EN 10056-
Angles
1:1999 1:1999
BS EN
Plate and Flats Not Applicable
10029:20103
Structural Hollow Sections Hot BS EN 10210- BS EN 10210- BS EN 10210-

Finished 1:20062 2:2006 2:2006
BS EN 10219- BS EN 10219- BS EN 10219-

Hollow Sections Cold Formed
2:2006 2:2006 2:2006
Galvanised Open Sections and

BS EN 10346:2009 Not Applicable BS EN 10143:2006
Strip
Notes:
1. Material quality requirements for Fine Grain Steels and Weather resistant grades are given
in EN 10025-3:2004.
2. BS EN 10210-1 contains material quality requirements for Non-alloy and Fine Grain Steels.
3. Tolerances for plates cut from wide strip produced on continuous mills are given in BS EN
10051:2010.
23.5.9 Surface Condition

a. Steel surfaces when used shall not be more heavily pitted or rusted than Grade C of BS
7079:2009 Part A1.
b. Surface defects in hot rolled sections, plates and wide flats revealed during surface
preparation which are not in accordance with the requirements of BS EN 10163-1:2004 shall
be rectified accordingly.
c. Surface defects in hot rolled hollow sections revealed during surface preparation which are
not in accordance with the requirements of BS EN 10210-1:2006 shall be rectified
accordingly.
Page 23-37
23.5.10 Pins and rollers for Steel Structures

Pins and rollers shall be accurately turned to the dimensions shown on the Contract plans and shall
be straight, smooth, and free from flaws. Pins and rollers more than 225 mm in diameter shall be
forged and annealed. Pins and rollers 225 mm or less in diameter may be either forged and annealed
or cold- finished carbon-steel shafting.
In pins larger than 225 mm in diameter, a hole not less than 50 mm in diameter shall be bored full-
length along the axis after the forging has been allowed to cool to a temperature below the critical
range, under suitable conditions to prevent damage by rapid cooling, and before being annealed.
23.5.10.1 Boring Holes for Pins

Pin holes shall be bored true to the specified diameter, smooth and straight, at right angles with the
axis of the member and parallel with each other unless otherwise required. The final surface shall
be produced by a finishing cut.
Pin hole diameters shall not exceed that of the pin by more than 0.5 mm for pins 125 mm or less in
diameter, or by 0.8 mm for larger pins.
Distance outside to outside of end holes in tension members and inside to inside of end holes in
compression members shall not vary from that specified more than 0.8 mm. Boring of pin holes in
built-up members shall be done after the member has been assembled.
23.5.10.2 Threads for Bolts and Pins

Threads for all bolts and pins for structural steel construction shall conform to the Specifications of
International Thread Standards, UNC Thread ANSI B 1.1, Class 2A for external threads and Class
2B for internal threads, except that pin ends having a diameter of 35 mm or more shall be threaded
six threads to the inch (metric screw threads-M Profile ANSI B 1.13M with a tolerance Class 6g for
external threads and 6H for internal threads).
23.5.11 Eye Bars for Steel Structures

Pin holes may be flame-cut at least 50 mm smaller in diameter than the finished pin diameter. All
eye bars that are to be placed side by side in the structure shall be securely fastened together in the
order that they will be placed on and bored at both ends while so clamped. Eye bars shall be packed
and match-marked for shipment and erection. All identifying marks shall be stamped with steel
stencils on the edge of one head of each member after fabrication is completed so as to be visible
when the bars are nested in place on the structure. Steel die stamps shall be low stress-type. No
welding is allowed on eye bars or to secure adjacent eye bars.
The eye bars shall be straight and free from twists and the pin holes shall be accurately located on
the centreline of the bar. The inclination of any bar to the plane of the truss shall not exceed a slope
of five-tenth percent (0.5%). The edges of eye bars that lie between the transverse centreline of their
pin holes shall be cut simultaneously with two mechanically operated torches abreast of each other,
guided by a substantial template, in such a manner as to prevent distortion of the plates.
23.5.12 Stiffeners for Steel Structures

End bearing stiffeners for girders and stiffeners intended as supports for concentrated loads shall
have full bearing (either milled, ground, or on weldable steel in compression areas of flanges, welded
as specified in the Contract documents) on the flanges to which they transmit load or from which
they receive load. Intermediate stiffeners not intended to support concentrated loads, unless
specified in the Contract documents, shall have a tight fit against the compression flange.
Page 23-38
23.5.13 Abutting Joints for Steel Structures

Abutting ends in compression members of trusses and columns shall be milled or saw-cut to give a
square joint and uniform bearing. At other joints, not required to be faced, the opening shall not
exceed 10 mm.
23.5.14 Fabrication of Stainless Steel

Insofar as practicable, fabrication, fitting and assembly of stainless steel work shall be done in the
shop. Work that cannot be permanently shop-assembled shall be completely assembled, marked
and disassembled before shipment to ensure proper assembly in the field. Unless otherwise
specified, methods of fabrication, assembly and erection shall be at the discretion of the Contractor
and as approved by the Engineer. All exposed work shall be carefully matched to produce continuity
of line and design in accordance with the Contract plans. All joints in exposed work shall be
accurately fitted and firmly secured with hairline contacts.
All welding of stainless steel shall comply with AWS D 1.6/D1.6M: 2007, Structural Welding Code -
Stainless Steel. Type 308 weld rods shall be used in welding.
Type, size and spacing of welds shall be as shown on approved shop drawings. Welds behind
finished surfaces shall be done so as to minimize distortion and/or discoloration of the finished side.
All discoloration of finished surfaces due to welding shall be removed by mechanical or electrical
cleaning. All weld spatter and welding oxides on finished surface shall be removed by blasting,
grinding or an electrochemical process.
All stainless steel surfaces in contact with other dissimilar metals shall be provided with a 2 mm thick
neoprene gasket between contact faces.
23.5.15 Orthotropic-deck Superstructures

Dimensional tolerance limits for orthotropic-deck bridge members shall be applied to each completed
but unloaded member and shall be as specified in paragraph 3.5 of the current AASHTO/ A WS D
1.5M/D 1.5 Bridge Welding Code, except as follows:
a. Deviations from detailed flatness, straightness, or curvature at any point shall be the
perpendicular distance from that point to a template edge which has the detailed straightness
or curvature and which is in contact with the element at two other points.
b. Template edge may have any length not exceeding the greatest dimension of the element
being examined and, for any panel, not exceeding 1.5 times the least dimension of the panel;
it may be placed anywhere within the boundaries of the element.
c. Deviations shall be measured between adjacent points of contact of the template edge with
the element; the distance between these adjacent points of contact shall be used in the
formulas to establish the tolerance limits for the segment being measured whenever this
distance is less than the applicable dimension of the element specified for the formula.
23.5.15.1 Flatness of Panels for Orthotropic-deck Superstructures

Maximum deviation, δ, from detailed flatness or curvature of a panel shall not exceed the greater of
5 mm or the result of Equation 23-6.
D
δ ≤
726 √T
Equation 23-6: Maximum deviation from detailed flatness
Where:
δ= Maximum deviation in mm.
D= Least dimension along the
boundary of the panel in mm.
Page 23-39
T= Minimum thickness of the

plate comprising the panel in mm.
23.5.15.2 Straightness of Longitudinal Stiffeners Subject to Calculated

Compressive Stress, Including Orthotropic-Deck Ribs
A maximum deviation, δ, from detailed straightness or curvature in any direction perpendicular to its
length of a longitudinal web stiffener or other stiffener subject to calculated compressive stress shall
not exceed the result of Equation 23-7.
L
δ ≤
480
Equation 23-7: Maximum deviation from detailed straightness (longitudinal)
Where:
L = Length of the stiffener or rib between cross members, webs, or flanges, in mm.
23.5.15.3 Straightness of Transverse Web Stiffeners and Other

Stiffeners Not Subject to Calculated Compressive Stress
A maximum deviation, δ, from detailed straightness or curvature in any direction perpendicular to its
length of a transverse web stiffener or other stiffener not subject to calculated compressive stress
shall not exceed the result of Equation 23-8.
L
δ ≤
240
Equation 23-8: Maximum deviation from detailed straightness (transverse)
Where:
L = Length of the stiffener or rib between cross members, webs, or flanges, in mm.
23.5.16 Full-size Tests for Steel Structures

When full-size tests of fabricated structural members or eye bars are required in the Contract
documents, the Contractor shall provide suitable facilities, material, supervision, and labour
necessary for making and recording the required tests. The Contractor shall provide the Engineer
with detailed testing plan that include the loading pattern and the testing setup, the number of cycles
per loading, the frequency of the loading, and the layout of the instrumentation gauges.
23.6 Assembly of Steel Structures

This section outlines standards and specifications for the assembly of steel structures.
23.6.1 Shop Assembly for Steel Structures

The Contractor shall ensure the fit of all connections and the geometry of all components. Unless
specified elsewhere in the Contract documents, the Contractor shall check the fit of all longitudinal
girder and beam lines in accordance the specifications outlined in this section. The Contractor shall
perform this before transporting pieces in question to the site for erection.
23.6.1.1 Progressive Girder or Truss Assembly

The Contractor shall assemble the structure for a minimum of three spans, panels, field sections,
segments or longitudinal chords of the structure. Successive assemblies shall consist of at least one
longitudinal segment of the previous assembly, repositioned as necessary for accurate alignment,
plus two or more longitudinal segments added at the advancing end. For entire structures less than
45.7 metres long or less than three segments, the entire longitudinal line shall be assembled. The
Page 23-40
Contractor shall meet the requirements outlined in Article 23.6.1.4 when using computer-numerically-
controlled drilling equipment.
When a transverse structural steel member or members is required for the continuation of the
uninterrupted girder or beam line, truss, arch rib, bent tower face or rigid frame, and is designated
elsewhere in the Contract documents to be shop assembled, the Fabricator may include this member
or component in a separate subassembly and not the three segment longitudinal assembly
(discussed above). If a member or component is combined in a different subassembly, the Fabricator
shall include the longitudinal member or component, as designated elsewhere in the Contract
documents to be shop assembled, directly into the transverse structural member. The Fabricator
shall not include transverse members in a longitudinal assembly unless the Contract documents or
the Engineer direct otherwise. The Fabricator shall account for end rotations and deflections, as
necessary, and submit the procedure to the Engineer for review.
23.6.1.2 Progressive Chord Assembly

When the Contract documents so specify, the Fabricator shall assemble truss chords for a minimum
of three panels or longitudinal segments of the structure. Successive assemblies shall consist of at
least one longitudinal segment of the previous assembly, repositioned as necessary for accurate
alignment, plus two or more longitudinal segments added at the advancing end. For entire structures
less than 45.7 metres long or less than three segments, the Fabricator shall assemble the entire
longitudinal line. The Fabricator shall meet the requirements outlined in Article 23.6.1.4 when using
computer-numerically-controlled drilling equipment.
The Fabricator shall account for transverse members that are indicted elsewhere in the Contract
documents to be included in the shop assembly, as outlined in Article 23.6.1.1.
When assembled in accordance with this subsection, the holes of connections shall be so located
that they shall be drilled to the final geometric angles. This shall require that the truss members,
when erected under the no load (or practically no load or stress) condition, must be bent and forced
to fit the end conditions. This condition introduces an initial reverse secondary stress that will
theoretically wane when the structure assumes the loading for which it is cambered. The Fabricator
shall submit the procedure to the Engineer for review.
23.6.1.3 Special Complete Structure Assembly

When the Contract documents specify otherwise, a special complete shop assembly shall include
assembling the entire structure, including the diaphragms, cross frames, integral steel substructure,
and floor components. Miscellaneous components are not included unless the Contract documents
direct otherwise. Procedures for each structure or structure type shall include incremental erection,
temporary field support locations, stage construction, and final tightening of field connections. The
Contractor shall submit the procedures to the Engineer for review.
23.6.1.4 Computer-numerically-controlled (CNC) Drilling Associated

with Progressive Girder, Truss or Chord Assembly
If the Fabricator chooses to drill the holes in all plies of all connections of the continuous main girder
or beam line, truss, arch rib, bent, tower face or rigid frame and any intersecting (transverse)
members using computer-controlled numerical drilling procedures, piece-wise assembly of the entire
continuous girder or beam line, truss, arch rib, bent, tower face or rigid frame is not required if the
requirements outlined in this section are met.
Before transporting to a site, the Fabricator shall perform a check fit of the first three spans, panels,
field sections, segments or longitudinal chords; or entire first bent, tower face or rigid frame of the
structure to ensure the accuracy of the CNC procedures and equipment.
As selected by and at the discretion of the Engineer and before transporting to the site, the Fabricator
shall perform another check fit of a different assembly of three spans, panels, field sections,
segments or longitudinal chords; or another entire bent, tower face or rigid frame of the structure to
Page 23-41
ensure that the accuracy of the CNC procedures and equipment is maintained. If either of the above
fails to meet the Contract requirements, the Fabricator shall assemble the entire girder or beam line,
truss, arch rib, bent, tower face or rigid frame as originally prescribed in Article 23.6.1.1 or Article
23.6.1.2 as prescribed elsewhere in the Contract documents. Account for transverse members
indicated elsewhere in the Contract documents to be included in the shop assembly as in Article
23.6.1.1.
23.6.2 Evaluation of Steel Structure Assemblies

The Engineer shall evaluate and accept materials and work conforming to the Contract documents.
These evaluations may take place before or following delivery of the materials to the site of the
structure. Materials or work that fails to meet the Contract requirements shall be rejected.
The Engineer may, at their discretion, permit further inspections and testing of materials or work that
fail to meet the Contract requirements for acceptance. The Contractor shall bear the cost of such
inspections and tests.
The Contractor shall bring to the attention of the Engineer all nonconforming work and or materials
that cannot be brought into conformance with the Contract documents using pre-established
procedures, as outlined in the quality control plan that has been approved by the Owner. The
Contractor shall submit the following information to the Engineer:
a. A cover letter prepared on the Contractor’s letterhead and addressed to the Engineer briefly
describing the nonconforming work and the proposed credit to the Contract proportionate to
the nonconformance. For each fabricating facility and for each project within that fabrication
facility, submittals must be numbered consecutively beginning with the number 1, at the start
of each project. Erectors will start with one for each individual project.
b. A completed Owner Nonconforming Structural Steel and Miscellaneous Metal Component
Data Sheet, prepared by the Contractor and countersigned by the Engineer’s designated
representative to indicate agreement between the Contractor and the Owner regarding the
nonconformance, not any solution, resolution, or credit. If the Contractor and the Engineer’s
designated representative are not in agreement regarding the nonconformance, the
Engineer’s designated representative will either reject the submittal, indicating their reasons
for the rejection, or modify the submittal and forward to the Engineer. In the event of
modification, the Contractor shall initial the submittal before it is forwarded to the Engineer,
thereby indicating the Contractor’s concurrence with the modification.
c. A list of supporting information, such as sketches, documentation, calculations, and pictures,
must be included in the appropriate space on the Nonconforming Component Data Sheet.
Supporting information regarding the Contract noncompliance in the form of separate
documents is only necessary when space on the Owner Nonconforming Structural Steel and
Miscellaneous Metal Component Data Sheet is inadequate for the required data. All of the
supporting information required for the form must be prepared by or under the supervision of
the Professional Engineer who will sign and seal one complete copy of the supporting
information.
If the Engineer so requests, the Contractor shall submit a structural and durability evaluation of the
proposed repair or remediation. This evaluation must be conducted under the supervision of a
Professional Engineer and the submittal shall bear the Professional Engineer’s signature and seal.
23.6.3 Certification of Members or Components of Steel Structures

The Contractor shall coordinate with the Engineer to schedule final inspection of the completed work
within two weeks before shipment or erection to verify that all the Contract document requirements
have been met. After verification that all the Contract document requirements have been met and all
necessary repairs have been satisfactorily completed, the Quality Control Manager shall certify, by
initials or signature, such materials, components or members. The record shall include certification
for the following items:
Page 23-42
a. Items being shipped or stored before final assembly. The Contractor shall affix a certification
in the form of a stamp or tag in accordance with 23.2.5 and as indicated in the Quality Control
Plan, and with a copy of the certification placed in the Contractor’s permanent project records,
b. Work being placed into its final position. Such documentation shall comply with the approved
Quality Control Plan and shall reside in the Contractor’s permanent project records.
The Contractor shall submit a summary certification at the least once a month or with each payment
request that includes the following or similar wording.
“The undersigned, being a responsible official of (insert the Contractor identification) certifies that
the materials, components or members listed herein have been produced under strict quality control
and meet the requirements of the Contract documents.”
Include a positive identification in the certification such that the applicable materials, components or
members can be uniquely identified using just the summary certification document. A Quality Control
Manager shall sign this summary certification.
23.6.4 Bolting Steel Structures

Surfaces of metal in contact shall be cleaned before assembling. Parts of a member shall be
assembled, well pinned, and firmly drawn together before drilling, reaming, or bolting is commenced.
Assembled pieces shall be taken apart, if necessary, for the removal of burrs and shavings produced
by the operation. Members shall be free from twists, bends, and other deformations.
Drifting done during assembly shall be only such as to bring the parts into position and shall not be
sufficient to enlarge holes or distort metal.
23.6.5 Welded Connections for Steel Structures

Surfaces and edges to be welded shall be smooth, uniform, clean, and free of defects which would
adversely affect the quality of the weld. Edge preparation shall be done in accordance with the
current AASHTO/AWS D1.5M/D1.5:2010, Bridge Welding Code.
23.6.6 Preassembly of Field Connections for Steel Structures

Field connections of main members of trusses, arches, continuous beams, plate girders, bents,
towers, and rigid frames shall be preassembled before erection as necessary to verify the geometry
of the completed structure or unit and to verify or prepare field splices. Attaining accurate geometry
is the responsibility of the Contractor, who shall propose an appropriate method of preassembly for
approval by the Engineer. Methods and details of preassembly shall be consistent with the erection
procedure shown on the erection plans and camber diagrams prepared by the Contractor and
approved by the Engineer. As a minimum, a preassembly procedure shall consist of assembling
three contiguous panels accurately adjusted for line and camber. Successive assemblies shall
consist of at least one section or panel of the previous assembly (repositioned if necessary and
adequately pinned to assure accurate alignment) plus two or more sections or panels added at the
advancing end. In the case of structures longer than 46 m, each assembly shall be not less than
45.7 m long regardless of the length of individual continuous panels or sections. At the option of the
Fabricator, the sequence of assembly may start from any location in the structure and proceed in
one or both directions as long as the preceding requirements are satisfied.
At the discretion of the Engineer, if the pre-assembly procedure causes any damage to connections
or any of the structural attachments, the affected part shall be replaced at the Contractor's expense.
23.6.6.1 Bolted Connections for Steel Structures

For bolted connections, holes shall be prepared as outlined in Section 23.5.5. Where applicable,
major components shall be assembled with milled ends of compression members in full bearing and
then shall have their subsized holes reamed to the specified size while the connections are
assembled.
Page 23-43
a. Ordinary Bolted Assemblies

The combination of bolts and nuts for ordinary bolted assemblies shall comply with BS 4190:2001
and BS 3692:2001. Any bolt assemblies which seize when being tightened shall be replaced.
Different bolt grades of the same diameter shall not be used in the same structure unless otherwise
agreed by the Engineer.
The bolt length shall be chosen such that, after tightening, at least one thread plus the thread run-
out will be clear between the nut and the unthreaded shank of the bolt and at least one clear thread
shall show above the nut.
When the members being connected have a finished surface protective treatment which may be
damaged by the nut or bolt head being rotated, a washer shall be placed under the rotating part.
A suitable plate, or heavy duty, washer shall be used under the head and nut when bolts are used
to assemble components with oversize or slotted holes.
When the bolt head or nut is in contact with a surface which is inclined at more than 30o a
plane at right angles to the bolt axis, a taper washer shall be placed to achieve satisfactory bearing.
Nuts shall be checked after being galvanized for free running on the bolt and retapped if necessary
to ensure a satisfactory tightening performance.
Bolts may be assembled using power tools or shall be fully tightened by hand using appropriate
spanners in accordance with BS 2583:1955.
Precision bolts to BS 3692:2001 may be used as fitted bolts when holes are drilled or reamed after
assembly so that the clearance in the hole is not more than 0.3 mm.
Where parts cannot be brought together by drifting without distorting the steelwork, rectification may
be made by reaming with the approval of the Engineer, provided the design of the connection will
allow the use of larger diameter holes and bolts.
b. High Strength Friction Grip Assemblies

The combination of bolts, nuts, and washers for high strength friction grip bolts shall comply with BS
EN 14399:2005 parts 1 to 8 as appropriate.
The use of friction grip bolts shall comply with BS EN 1993-1-8:2005. Tightening which complies with
BS EN 1993-1-8:2005 may be by the torque control method, part-turn method, or with load indicating
devices used in accordance with the Manufacturer's recommendations.
When considering the coefficient of friction to use in the design of high strength friction grip bolted
connections, the following values shall be used:
1. Unless the Engineer advises otherwise, untreated surfaces which are in accordance with BS
EN 1993-1-8:2005 may be considered as having a slip factor of 0.45; masking shall be used
to keep the surfaces free of protective treatments.
2. Surfaces which have been machined, or given any type of treatment, shall have the slip factor
determined by tests carried out in accordance with BS EN 1993-1-8:2005.
If, after complete tightening, a bolt or nut has to be slackened off, the whole bolt assembly is to be
disposed of.
Where parts cannot be brought together by drifting without distorting the steelwork, rectification can
be made with the Engineer approval by reaming, provided that the design of the connection will allow
the use of larger diameter bolts. Calculations shall be made to demonstrate that the connection
remains adequate for the forces in the connection.
23.6.6.2 Checking Assembly for Numerically-controlled Drilling

When the Contractor elects to use numerically-controlled drilling, a check of assembly shall be
required for each major structural type of each project, unless otherwise designated in the Contract
documents, and shall consist of at least three contiguous shop sections or, in a truss, all members
Page 23-44
in at least three contiguous panels but not less than the number of panels associated with three
contiguous chord lengths (that is, length between field splices).
Check assemblies should be based on the proposed order of erection, joints in bearings, special
complex points, and similar considerations.
If the check assembly fails in some specific manner to demonstrate that the required accuracy is
being obtained, further check assemblies may be required by the Engineer for which there shall be
no additional cost to the Owner.
Each assembly, including camber, alignment, accuracy of holes, and fit of milled joints, shall be
approved by the Engineer before reaming is commenced or before an N/C drilled check assembly
is dismantled.
23.6.6.3 Field-welded Connections for Steel Structures

For field-welded connections the fit of members including the proper space between abutting flanges
shall be prepared or verified with the segment preassembled in accordance with Section 23.6.6.
23.6.7 Match-marking Connecting Parts for Steel Structures

Connecting parts preassembled in the shop to assure proper fit in the field shall be match-marked,
and a diagram showing such marks shall be furnished to the Engineer.
23.6.8 Steel Structure Connections Using Unfinished, Turned, or

Ribbed Bolts
When unfinished bolts are specified, the bolts shall be unfinished, turned, or ribbed bolts conforming
to the requirements for Grade A bolts of Standard Specification for Carbon Steel Bolts and Studs,
60 000 PSI Tensile Strength, ASTM A307 - 10, and Standard Specification for Carbon and Alloy
Steel Externally Threaded Metric Fasteners, ASTM F568M-07 (Property Class 4.6, 400-MPa tensile
strength). Bolts shall have single self-locking nuts or double nuts unless otherwise specified in the
Contract documents. Beveled washers shall be used where bearing faces have a slope of more than
1:20 with respect to a plane normal to the bolt axis. The specifications of this section do not pertain
to the use of high-strength bolts. Bolted connections fabricated with high-strength bolts shall conform
to Section 23.6.9.
23.6.8.1 Turned Bolts for Steel Structures

The surface of the body of turned bolts shall meet the ANSI/ASME B46.1-2009 roughness rating
value of 3.2 μm. Heads and nuts shall be hexagonal with standard dimensions for bolts of the nominal
size specified or the next larger nominal size. Diameter of threads shall be equal to the body of the
bolt or the nominal diameter of the bolt specified. Holes for turned bolts shall be carefully reamed
with bolts furnished to provide for a light driving fit. Threads shall be entirely outside of the holes. A
washer shall be provided under the nut. Shop assemblies other than the check assemblies will not
be required.
23.6.8.2 Ribbed Bolts for Steel Structures

The body of ribbed bolts shall be of an approved form with continuous longitudinal ribs. A diameter
of the body measured on a circle through the points of the ribs shall be 2 mm greater than the nominal
diameter specified for the bolts.
Ribbed bolts shall be furnished with round heads conforming to ASME/ANSI B 18.5-2008, Round
head short square neck bolts, (ANSI B 18.5.2.2 M or B 18.5.2.3 M) as specified. Nuts shall be
hexagonal, either recessed or with a washer of suitable thickness. Ribbed bolts shall make a driving
fit with the holes. The hardness of the ribs shall be such that the ribs do not distort to permit the bolts
to turn in the holes during tightening. If for any reason the bolt twists before drawing tight, the hole
shall be carefully reamed and an oversized bolt used as a replacement.
Page 23-45
23.6.9 Steel Structure Connections Using High-strength Bolts

This section covers the assembly of structural joints using AASHTO M 164-05 (ASTM A325 - 10) or
AASHTO M 253-05 (ASTM A490 – 12) high-strength bolts or equivalent fasteners, installed so as to
develop the minimum required bolt tension specified in Table 23-10. The bolts are used in holes
conforming to the requirements of Section 23.5.5.
The Contractor shall tighten (ASTM A325 – 10) bolts in accordance with the procedures specified
herein for turn-of-nut or direct-tension-indicator (DTI) tightening.
When the Engineer approves (ASTM A307 – 10) bolts for use in miscellaneous components, tighten
them such that the plies of the joint are in firm contact. Use three to five impacts of an impact wrench
or the full effort of a person using an ordinary spud wrench to obtain a snug connection.
Lubricate and maintain consistency in lubrication of fastener assembly during Rotational Capacity
(RC) testing and installation. Assemblies that exhibit a loss of lubrication, as determined by the
Engineer, may be relubricated and retested before installation.
Fasten aluminum, other materials or assemblies of dissimilar materials in accordance with the
Contract documents.
Install ordinary rough or machine bolts and nuts in accordance with the Contract documents.
23.6.9.1 Bolted Parts of Steel Structures

All material within the grip of the bolt shall be steel; there shall be no compressible material such as
gaskets or insulation within the grip. Bolted steel parts shall fit solidly together after the bolts are
snugged and may be coated or uncoated. The slope of the surfaces of parts in contact with the bolt
head or nut shall not exceed 1:20 with respect to a plane normal to the bolt axis.
23.6.9.2 Surface Conditions for High-strength Bolts

At the time of assembly, all joint surfaces, including surfaces adjacent to the bolt head and nut, shall
be free of scale, except tight mill scale, and shall be free of dirt or other foreign material. Burrs that
would prevent solid seating of the connected parts in the snug condition shall be removed.
Paint is permitted on the faying surface including slip critical joints when designed in accordance
with Article 6.13.2, "Bolted Connections," of the AASHTO LRFD Bridge Design Specifications.
Contacting surfaces of slip-critical connections shall meet the requirements of the following
paragraphs, as applicable:
a. In non-coated joints, paint, including any inadvertent overspray, shall be excluded from areas
closer than one bolt diameter but not less than 25 mm from the edge of any hole and all areas
within the bolt pattern.
b. Joints specified to have painted faying surfaces shall be blast cleaned and coated with a
paint which has been qualified in accordance with requirements of Article 6.13.2.8, "Slip
Resistance," of the AASHTO LRFD Bridge Design Specifications.
c. Coated joints shall not be assembled before the coating has cured for the minimum time used
in the qualifying test.
Faying surfaces specified to be galvanized shall be hot-dip galvanized in accordance with AASHTO
M 111M/M 111-11 (ASTM A123 / A123M - 12). The Contractor shall provide certification to the
Engineer that galvanized faying surfaces meet or exceed a Class C slip critical classification, unless
a different classification is required elsewhere in the Contract documents. The Contractor shall
mechanically roughen the galvanized faying surfaces by means of hand wire brushing. Power wire
brushing is not permitted.
"Surface conditions" refers to Article 6.13.2, "Bolted Connections," and Article 6.13.2.8, "Slip
Resistance," of the AASHTO LRFD Bridge Design Specifications.
Page 23-46
23.6.9.3 Reaming for High-strength Bolts

The Contractor shall not over size bolt holes by reaming (or any other method) without the approval
of the Engineer.
23.6.9.4 Drifting for High-strength Bolts

The Contractor shall not over size, stretch, or otherwise damage bolt holes by improper and
excessive drifting.
23.6.9.5 Filler Material for Splice Plate

Unless otherwise specified in the Contract documents, the Contractor shall provide filler material
edges within 3 mm of the adjacent splice material edge.
23.6.9.6 Installing High-strength Fasteners

Fastener components shall be assigned lot numbers, including rotational-capacity lot numbers,
before shipping and components shall be assembled when installed. Such components shall be
protected from dirt and moisture at the job site. Only the number of anticipated components to be
installed and tensioned during a work shift shall be removed from protective storage. Components
not used shall be returned to protective storage at the end of the shift. Assemblies for slip-critical
connections which accumulate rust or dirt resulting from job site conditions shall be cleaned,
relubricated, and tested for rotational capacity before installation. All galvanized nuts shall be
lubricated with a lubricant containing a visible dye. Plain bolts must be oily to touch when delivered
and installed. Lubricant on exposed surfaces shall be removed before painting.
A bolt-tension measuring device (a Skidmore-Wilhelm Calibrator or other equivalent bolt-tension
indicating device) shall be at all job sites wherever final connections are being made. The Contractor
shall confirm the accuracy of the tension measuring device by having it calibrated by an approved
testing agency once a year. The tension-measuring device shall be used to perform the rotational-
capacity test and to confirm:
a. The suitability to satisfy the requirements of Table 23-10 of the complete fastener assembly,
including lubrication if required to be used in the work
b. calibration of the wrenches, and
c. the understanding and proper use by the bolting crew of the installation method.
To perform the calibrated wrench verification test for short grip bolts, direct tension indicators (DTI)
with solid plates may be used in lieu of a tension-measuring device. The DTI lot shall be first verified
with a longer grip bolt in the Skidmore-Wilhelm Calibrator or an acceptable equivalent device. The
frequency of confirmation testing, the number of tests to be performed, and the test procedure shall
be as specified in this section, as applicable. The accuracy of the tension measuring device shall be
confirmed by an approved testing agency at least annually.
Bolts and nuts together with washers of size and quality specified in the Contract documents, located
as required below, shall be installed in properly aligned holes and tensioned and inspected by any
of the installation methods described in this section to at least the minimum tension specified in Table
23-10. Tensioning may be done by turning the bolt while the nut is prevented from rotating. When it
is impractical to turn the nut, impact wrenches, if used, shall be of adequate capacity and sufficiently
supplied with air to apply the proper tension to each bolt in approximately ten seconds.
Bolts shall be installed in all holes of the connection and the connection brought to a snug condition.
Unless shown otherwise in the Erection Plan, the Contractor shall install the bolts of the connection
by progressing systematically from the most rigid part of the connection to the free edges. Install
bolts in all holes of the connection and bring them to a ‘snug tight’ condition. Following the sequence
indicated in the Erection Plan, further tighten all the bolts in the connection until the full connection
is in a snug condition.
Page 23-47
For connections (such as large main load-carrying members or truss joints) in which previously
tightened high strength bolts become loose and require retightening upon the tensioning of others,
install into a minimum of ten percent of the holes fully tensioned bolts before final tensioning of the
permanent bolts. Distribute these first bolts randomly throughout the connection. If directed by the
Engineer, remove the initial bolts and install permanent bolts at each location, otherwise retighten in
accordance with this section.
Table 23-10: Minimum required bolt tension
AASHTO M 164-05 AASHTO M 253-05

Bolt size
ASTM A325 - 10 ASTM A490 – 12
13 mm 53.5 kN 66.7 kN
16 mm 84.5 Kn 106.8 kN
19 mm 124.6 kN 155.7 kN
22 mm 173.5 kN 218.0 kN
25 mm 227.0 kN 284.7 kN
29 mm 249.0 kN 356.0 kN
32 mm 316.0 kN 453.7 kN
35 mm 378.0 kN 538.2 kN
38 mm 458.0 kN 658.3 kN
Minimum bolt tension shall be taken as seventy percent (70%) of specified minimum tensile strength
of bolts (as specified in ASTM Specifications for tests of full-size A325 and A490 bolts with UNC
threads (Metric Screw Threads: M Profile, ANSI ASME B1.13M-2005), loaded in axial tension)
rounded to the nearest 1000 N. Table 23-11 shows necessary rotations.
Table 23-11: Nut rotation from snug condition
Geometry of outer faces of bolted parts
Both faces One face normal to bolt axis Both faces sloped not more
Bolt length (from
normal to and other face sloped not than 1:20 from normal to
underside of head to
bolt axis more than 1:20 (Bevel bolt axis (Bevel washers not
end of bolt)
washer not used) used)
Up to and including
1/3 turn 1/2 turn 2/3 turn
4 diametres
Over 4 diametres,
but not exceeding 8 1/2 turn 2/3 turn 5/6 turn
diametres
Over 8 diametres,
but not exceeding 2/3 turn 5/6 turn 1 turn
12 diametres
Page 23-48
Rotation, as used in Table 23-11, shall be taken as relative to the bolt, regardless of the element
(nut or bolt) being turned. The tolerances are minus 0, plus 30 degrees for bolts installed by a 1/2
turn or less; for bolts installed by 2/3 turn or more, the tolerance are minus 0, plus 45 degrees.
Values given in Table 23-11 shall be applicable only to connections in which all material within grip
of the bolt is steel.
For situations in which the bolt length measured from the underside of the head to the end of the
bolt exceeds 12 diameters, the required rotation shall be determined by actual tests in a suitable
tension device simulating the actual conditions. Submit procedures to the Engineer for review.
a. Rotational Capacity Tests

At the location of and before installation of permanent high-strength fasteners in main or primary
load carrying member connections, the Contractor shall perform rotational capacity (RC) tests to
ensure that the fasteners are capable of developing the specified strength and that the fasteners are
properly lubricated. As a minimum, the Contractor shall test two assemblies per LOT designation.
The bolt, nut and washer shall come from the same LOT and be packed in the same container (or
group of containers assigned the same LOT), except in special cases where nuts and washers have
only one production LOT number for each size.
Assemblies specified as galvanized shall be tested after galvanising. Washers are required for RC
tests even though they may not be required for jobsite installation. Where washers are not required
for jobsite installation, LOT identification is not required. The washer coating shall be the same as
that for the bolt and nut. The following shall apply:
1. Except as modified herein, the rotational-capacity test shall be performed in accordance with
the requirements of AASHTO M 164-05 (ASTM A325 - 10).
2. Perform the RC test in a manner that replicates the anticipated fastener installation technique
(that is, if a spud wrench is to be used as a part of the installation process, use the wrench
similarly for the RC test).
3. If any of the required tests fails, the entire LOT will be rejected.
4. Each combination of bolt production lot, nut lot, and washer lot shall be tested as an
assembly.
5. A rotational-capacity lot number shall have been assigned to each combination of lots tested.
6. Minimum frequency of testing shall be two assemblies per rotational-capacity lot.
7. For bolts that are long enough to fit in a Skidmore-Wilhelm Calibrator, the bolt, nut, and
washer assembly shall be assembled in a Skidmore- Wilhelm Calibrator or an acceptable
equivalent device.
8. Bolts that are too short to test in a Skidmore-Wilhelm Calibrator may be tested in a steel joint.
The tension requirement, in the section below, need not apply. The maximum torque
requirement, torque ≤ 0.250PD, shall be computed using a value of P equal to the turn test
tension taken as 1.15 times the bolt tension in Table 23-7.
9. Tension reached at the rotation below, i.e., the turn-test tension, shall be equal to or greater
than 1.15 times the required fastener tension, i.e., installation tension, shown in Table 23-10.
10. In a tension-measuring device, the minimum rotation from an initial tension of ten percent of
the minimum required tension shall be two times the required number of turns indicated in
Table 23-11 without stripping or failure.
After the required installation tension listed above has been exceeded, one reading of tension and
torque shall be taken and recorded. The torque value shall conform to Equation 23-9.
Page 23-49
Torque ≤ 0.250 P D
Equation 23-9: Torque for rotational capacity testing
Where:
Torque measured torque, N.mm.
P= measured bolt tension,
N.
D= bolt diametre, mm.
b. Requirement for Washers for Installation with High-strength Fasteners

The Contractor shall provide ASTM F436 - 11 hardened steel washers as follows:
1. For connections (and all associated testing) using (ASTM A490 – 12) bolts, use a hardened
washer under each element.
2. For connections using (ASTM A325 – 10) bolts, use hardened washers under the turned
element.
3. Use hardened steel washers as part of the Rotational Capacity tests.
4. Where the outer face of the bolted parts has a slope of greater than 1:20 with respect to a
plane normal to the bolt axis, use a hardened, beveled washer to compensate for the lack of
parallelism.
5. Where bolts are to be installed in a oversized or slotted hole in an outer ply, provide a single
washer satisfying ASTM F436 - 11, or continuous bar satisfying ASTM A709 / A709M – 11.
For (ASTM A325 – 10) bolts, provide a thickness of at least 8mm; and for (ASTM A490 – 12)
bolts, provide a thickness of 10mm. Provide these washers or bars to completely cover the
slot after installation. Provide a finish consistent with the bolt specified.
6. In non-Direct-Tension-Indicator (DTI) applications, clip washers on one side to a point not
closer than 22mm of the bolt diametre from the center of the washer, if necessary.
7. Hardened bevelled washers for American Standard Beams and Channels shall be required
and shall be square or rectangular, shall conform to the requirements of AASHTO M 293-10
(ASTM F436 - 11), and shall taper in thickness.
8. Where necessary, washers may be clipped on one side to a point not closer than 0.875 times
the bolt diametre from the center of the washer.
c. Use of Washers with Direct-tension-indicators (DTIs) Devices

When DTIs are used; the Contractor shall use ASTM F436 - 11 hardened washers as follows:
1. When the nut is turned and the DTI is located under the bolt head, a hardened washer is to
be located under the nut.
2. When the nut is turned and the DTI is located under the nut, a hardened washer is to be
located between the nut and the DTI.
3. When the bolt head is turned and the DTI is located under the nut, a hardened washer is to
be located under the bolt head.
4. When the bolt head is turned and the DTI is located under the bolt head, a hardened washer
is to be located between the bolt head and the DTI.
d. Hardened Washers for Installation with High-strength Fasteners

Hardened washers are not required for connections using AASHTO M 164-05 (ASTM A325 - 10)
and AASHTO M 253-05 (ASTM A490 – 12) bolts, except as follows:
1. Hardened washers shall be used under the turned element when tensioning is to be
performed by calibrated wrench method.
2. Irrespective of the tensioning method, hardened washers shall be used under both the head
and the nut when AASHTO M 253-05 (ASTM A490 – 12) bolts are to be installed in material
Page 23-50
having a specified yield point less than 275 MPa. When DTIs are used, they may replace a
hardened washer provided a standard sized hole is used.
3. Where AASHTO M 164-05 (ASTM A325 - 10) bolts of any diametre or AASHTO M 253-05
(ASTM A490 – 12) bolts equal to or less than 24 mm in diametre are to be installed in oversize
or short-slotted holes in an outer ply, a hardened washer conforming to AASHTO M 293-10
(ASTM F436 - 11) shall be used.
4. Where AASHTO M 253-05 (ASTM A490 – 12) bolts over 24 mm in diametre are to be
installed in an oversize or short-slotted hole in an outer ply, hardened washers conforming to
AASHTO M 293-10 (ASTM F436 - 11), except with 8 mm minimum thickness, shall be used
under both the head and the nut in lieu of standard thickness hardened washers. Multiple
hardened washers with combined thickness equal to or greater than 8 mm shall not be
considered as satisfying this requirement.
5. Where AASHTO M 164-05 (ASTM A325 - 10) bolts of any diametre or AASHTO M 253-05
(ASTM A490 – 12) bolts equal to or less than 24 mm in diametre are to be installed in a long
slotted hole in an outer ply, a plate washer or continuous bar of at least 8 mm thickness with
standard holes shall be provided. These washers or bars shall have a size sufficient to
completely cover the slot after installation and shall be of structural grade material, but need
not be hardened, except as follows.
6. Where AASHTO M 253-05 (ASTM A490 – 12) bolts over 24 mm in diametre are to be used
in long slotted holes in external plies, a single hardened washer conforming to AASHTO M
293-10 (ASTM F436 - 11), but with 8 mm minimum thickness shall be used in lieu of washers
or bars of structural grade material. Multiple hardened washers with combined thickness
equal to or greater than 8 mm shall not be considered as satisfying this requirement.
e. Alternate High-strength Fasteners

As an alternative, the Contractor may use high-strength fasteners that comply with the requirements
outlined in Article 23.4.2.5. Such fasteners shall have a geometry that provides a bearing circle on
the head or nut with a diametre equal to or greater than the diametre of hardened washers that meet
the requirements of AASHTO M 293-10 (ASTM F436 - 11) and satisfy the requirements for washers
outlined in this chapter. The Contractor may use such fasteners without washers.
f. Turn-of Nut Installation Method for High-strength Fasteners

When the turn-of-nut installation method is used, hardened washers are not required, except as may
be specified in Article 23.6.9.6.
For each work shift, the Contractor shall perform tests utilizing a representative sample of five
fastener assemblies, from each LOT to be installed that shift. Perform the tests using the tension
measuring device, following the same procedure to be used for actual installation of the fastener
assemblies, to a snug-tight tension and corresponding torque, which, when the additional turns
required in Table 23-11, Nut Rotation from the Snug Condition are added, will result in at least 1.05
times the minimum required fastener installation tension as shown in Table 23-10. Place a washer
under the part turned in the tightening of the bolt. Consider the job inspection snug-tight torque as
the average of three test values determined after rejecting the high and low-test values. Periodic
retesting shall be performed when ordered by the Engineer.
After snugging, the applicable amount of rotation specified in Table 23-11 shall be achieved. During
the tensioning operation there shall be no rotation of the part not turned by the wrench. Tensioning
shall progress systematically from the most rigid part of the joint to its free edges.
Snug-tight Condition: In the turn-of-nut method, first bring all the fastener assemblies of the
connection to a ‘snug-tight’ condition to ensure that all parts of the connection are in firm contact with
each other. For the purposes of this specification, “firm contact” shall mean the condition that exists
on a faying surface when the plies are solidly seated against each other, but not necessarily in
continuous contact. Regard snug-tight as the tightness required to produce the bolt tension, which
following the final applied rotation, produces at least 1.05 times the minimum required bolt tension
Page 23-51
in accordance with Table 20.8. In the presence of the Engineer, and on a daily basis, determine the
job inspection snug-tight torque as specified herein.
Final Tightening: After verification of the snug-tight condition in accordance with Article 23.6.9.6 by
the Engineer, the Contractor shall tighten all fastener assemblies in the joint by applying the
applicable amount of nut rotation specified in Table 23-11. Once snug-tight, bring all fasteners to the
required tension within the same work shift.
g. Calibrated Wrench Installation Method for High-strength Fasteners

A calibrated wrench method may be used only when wrenches are calibrated on a daily basis and
when a hardened washer is used under the turned element. Standard torques determined from
tables or from formulas which are assumed to relate torque to tension shall not be acceptable.
When calibrated wrenches are used for installation, they shall be set to deliver a torque which has
been calibrated to produce a tension not less than five percent in excess of the minimum tension
specified in Table 23-10. The installation procedures shall be calibrated by verification testing at least
once each working day for each fastener assembly that is being installed in the work that day. This
verification testing shall be accomplished in a tension-measuring device capable of indicating actual
bolt tension by testing three typical fastener assemblies from each lot. Bolts, nuts, and washers
under the turned element shall be sampled from production lots. Wrenches shall be recalibrated
when a significant difference is noted in the surface condition of the bolts, threads, nuts, or washers.
It shall be verified during actual installation in the assembled steel work that the wrench adjustment
selected by the calibration does not produce a nut or bolt head rotation from snug condition greater
than that permitted in Table 23-11. If manual torque wrenches are used, nuts shall be torqued in the
tensioning direction when torque is measured.
When calibrated wrenches are used to install and tension bolts in a connection, bolts shall be
installed with hardened washers under the turned element. Following snugging, the connection shall
be tensioned using the calibrated wrench. Tensioning shall progress systematically from the most
rigid part of the joint to its free edges. The wrench shall be returned to "touch up" previously tensioned
bolts which may have been relaxed as a result of the subsequent tensioning of adjacent bolts until
all bolts are tensioned to the prescribed amount.
h. Alternative Design Bolt Installation Method for High-strength Fasteners

When fasteners which incorporate a design feature intended to indirectly indicate that the applied
torque develops the required bolt tension or to automatically develop the tension required by Table
23-10 and that have been qualified under Article 23.4.2.4 are to be installed, verification testing using
a representative sample of not less than three fastener assemblies of each diametre, length and
grade to be used in the work shall be performed at the job site in a device capable of indicating bolt
tension. The test assembly shall include flat-hardened washers, if required in the actual connection,
arranged as in the actual connections to be tensioned. The verification test shall demonstrate that
each bolt develops a tension not less than five percent greater than the tension required by Table
23-10. The Manufacturer's installation procedure shall be followed for installation of bolts in the
calibration device and in all connections. Periodic retesting shall be performed when ordered by the
Engineer.
When alternative design fasteners, which are intended to control or indicate bolt tension of the
fasteners are used, bolts shall be installed in all holes of the connection and initially snugged
sufficiently to bring all plies of the joint into firm contact, but without yielding or fracturing the control
or indicator element of the fasteners. All fasteners shall then be further tensioned, progressing
systematically from the most rigid part of the connection to the free edges in a manner that will
minimize relaxation of previously tensioned bolts. In some cases, proper tensioning of the bolts may
require more than a single cycle of systematic partial tensioning before final yielding or fracturing of
the control or indicator element of individual fasteners. If yielding or fracture occurs before the final
tensioning cycle, the individual fastener assembly shall be replaced with a new one.
Page 23-52
i. Direct Tension Indicator Installation Method for High-strength Fasteners

Every day, when installing direct tension indicator (DTI) devices that meet the requirements of Article
23.4.2.5 in accordance with the method specified below, the Contractor shall perform the DTI
verification tests described below at the location of installation.
Unless otherwise approved by the Engineer, the DTIs shall be installed under the head of the bolt
and the nut turned to tension the bolt. The Manufacturer's recommendations shall be followed for
the proper orientation of the DTI and additional washers, if any, required for the correct use of the
DTI. Installation of a DTI under the turned element may be permitted if a washer is used to separate
the turned element from the DTI.
The Contractor shall perform DTI verification test on a minimum of two high-strength fastener
assemblies from each fastener assembly LOT and position of the DTI before production installation.
If either assembly fails, test additional fastener assembly LOT/DTI combinations as requested by the
Engineer to verify that the Requirements of the Contract documents have been satisfied. These two
tests are in addition to the RC tests required in Article 23.6.9.6. If, after additional testing, the DTI
fails to meet the requirements of these specifications, the LOT will be rejected by the Engineer.
j. Verification of Direct Tension Indicator Installation

Verification testing shall be performed in a calibrated bolt-tension measuring device. A special flat
insert shall be used in place of the normal bolt head holding insert. Three verification tests shall be
required for each combination of fastener assembly rotational-capacity lot, DTI lot, and DTI position
relative to the turned element (bolt head or nut) to be used on the project. The fastener assembly
shall be installed in the tension-measuring device with the DTI located in the same position as in the
work. The element intended to be stationary (bolt or nut) shall be restrained from rotation.
The verification tests shall be conducted in two stages. The bolt nut and DTI assembly shall be
installed in a manner so that at least three and preferably not more than five threads are located
between the bearing face of the nut and the bolt head. The bolt shall be tensioned first to the load
equal to that listed in Table 23-10 under Verification Tension for the grade and diameter of the bolt.
If an impact wrench is used, the tension developed using the impact wrench shall be no more than
two- thirds of the required tension. Subsequently, a manual wrench shall be used to attain the
required tension. The number of refusals of the 0.125 mm tapered feeler gage in the spaces between
the protrusions shall be recorded. The number of refusals for uncoated DTIs under the stationary or
turned element, or coated DTIs under the stationary element, shall not exceed the number listed
under Maximum Verification Refusals in Table 23-12 for the grade and diameter of bolt used. The
maximum number of verification refusals for coated DTIs (galvanized, painted, or epoxy-coated),
when used under the turned element, shall be no more than the number of spaces on the DTI less
one. The DTI lot shall be rejected if the number of refusals exceeds the values in the table or, for
coated DTIs if the gage is refused in all spaces.
After the number of refusals is recorded at the verification load, the bolt shall be further tensioned
until the 0.125 mm feeler gage is refused at all the spaces and a visible gap exists in at least one
space. The load at this condition shall be recorded and the bolt removed from the tension-measuring
device. The nut shall be able to be run down by hand for the complete thread length of the bolt
excluding thread run-out. If the nut cannot be run down for this thread length, the DTI lot shall be
rejected unless the load recorded is less than 95 percent of the average load measured in the
rotational capacity test of the fastener lot as specified in Article 23.6.9.6, "Rotational-Capacity Tests".
If the bolt is too short to be tested in the calibration device, the DTI lot shall be verified on a long bolt
in a calibrator to determine the number of refusals at the verification tension listed in Table 23-12. A
number of refusals shall not exceed the values listed under maximum verification refusals in Table
23-12. Another DTI from the same lot shall then be verified with the short bolt in a convenient hole
in the work. A bolt shall be tensioned until the 0.125 mm feeler gage is refused in all spaces and a
visible gap exists in at least one space. A bolt shall then be removed from the tension-measuring
device and the nut shall be able to be run down by hand for the complete thread length of the bolt
excluding thread run-out. A DTI lot shall be rejected if the nut cannot be run down this thread length.
Page 23-53
Table 23-12: Direct tension indicator requirements
Bolt Verification Maximum verification DTI spaces Minimum installation

size tension refusals refusals
A325 A490 A325 A490 A325 A490 A325 A490
13 mm 57.8 kN 71.2 kN 1 2 4 5 2 3
111.2
16 mm 89.0 kN 1 2 4 5 2 3
kN
129.0 164.6
19 mm 2 2 5 6 3 3
kN kN
182.4 227.0
22 mm 2 2 5 6 3 3
kN kN
240.2 298.0
25 mm 2 3 6 7 3 4
kN kN
262.4 373.7
29 mm 2 3 6 7 3 4
kN kN
333.6 476.0
32 mm 3 3 7 8 4 4
kN kN
396.0 564.0
35 mm 3 3 7 8 4 4
kN kN
480.4 689.5
38 mm 3 4 8 9 4 5
kN kN
k. Installation of Fastener Assemblies with Direct Tension Indicator Devices

Installation of fastener assemblies using DTI devices shall be performed in two stages. A stationary
element shall be held against rotation during each stage of the installation. A connection shall be
first snugged with bolts installed in all the holes of the connection and tensioned sufficiently to bring
all the plies of the connection into firm contact. A number of spaces in which a 0.125 mm feeler gage
is refused in the DTI after snugging shall not exceed those listed under Maximum Verification
Refusals in Table 23-12. If the number exceeds the values in the table, the fastener assembly shall
be removed and another DTI installed and snugged.
For uncoated DTIs used under a stationary or turned element and for coated DTIs used under
stationary element, the bolts shall be further tensioned until the number of refusals of the 0.125 mm
feeler gage shall be equal to or greater than the number listed under Minimum Installation Refusals
in Table 23-12. If the bolt is tensioned so that no visible gap in any space remains, the bolt and DTI
shall be removed and replaced by a new properly tensioned bolt and DTI.
When coated DTIs (galvanized, painted, or epoxy coated) are used under a turned element, the
0.125 mm feeler gage shall be refused in all spaces.
l. Reusing and Retightening High-strength Fasteners

The Contractor shall not reuse (ASTM A490 – 12) bolts or galvanized (ASTM A325 – 10) bolts. Black
(ASTM A325 – 10) bolts with free spinning nuts may be reused one time with the Engineer’s
approval. Previously tightened bolts that may have been loosened by the tightening of adjacent bolts
Page 23-54
can be further tightened from the original position. The Contractor shall ensure proper lubrication
before retightening, discard and replace fractured or damaged bolts.
m. Installing Lock-pin and Collar Fasteners

Installation of lock-pin and collar fasteners shall be by methods and procedures approved by the
Engineer.
n. Inspecting Installation of High-strength Fasteners

The Engineer shall determine that the following requirements of this Sub-article are met in the work.
Before the installation of fasteners in the work, the Engineer shall:
1. check the marking, surface condition, and storage of bolts, nuts, washers, and DTIs, if used,
and the faying surfaces of joints for compliance with the requirements of Sections 23.4.2 and
23.6.9, and Article 23.6.9.6 and
2. observe calibration and/or testing procedures required in Article 23.6.9.6, as applicable, to
confirm that the selected procedure is properly used and that, when so used with the fastener
assemblies supplied, the tensions specified in Table 23-10 are developed.
The Engineer shall monitor the installation of fasteners in the work to assure that the selected
installation method, as demonstrated in the initial testing to develop the specified tension, is routinely
followed.
o. Procedures to Inspect Installation of High-strength Fasteners

Either the Engineer or the Contractor, in the presence of the Engineer at the Engineer's option, shall
inspect the tensioned bolts using an inspection torque wrench, unless alternate fasteners or direct
tension indicator devices are used, allowing verification by other methods. Inspection tests should
be conducted before possible loss of lubrication or corrosion influence on tightening torque.
Three fastener assembly lots in the same condition as those under inspection shall be placed
individually in a device calibrated to measure bolt tension. This calibration operation shall be done
at least once each inspection day.
There shall be a washer under the turned element in tensioning each bolt if washers are used on the
structure. If washers are not used on the structure, the material used in the tension-measuring device
which abuts the part turned shall be of the same specification as that used on the structure. In the
calibrated device, each bolt shall be tensioning by any convenient means to the specified tension.
The inspecting wrench shall then be applied to the tensioned bolt to determine the torque required
to turn the nut or head five degrees (25 mm at a 300 mm radius) in the tensioning direction. The
average of the torque required for all three bolts shall be taken as the job-inspection torque.
p. Turn-of-nut Tightening for High-strength Fasteners

Turn-of-nut tightening for high-strength fasteners shall meet the following requirements.
1. Once the snug-tight condition is achieved for all of the fastener assemblies of the connection,
within 24 hours of snugging the first bolt in the connection and in the presence of the
Engineer, the Contractor shall verify for a minimum of three (3) bolts [two (2) for two bolt
connections] or 10% of the fastener assemblies, that the job inspection snug-tight torque has
been attained. These fasteners are to have a snug-tight torque equal to or exceeding that
specified in 23.6.9.6. Perform this check using the same torque wrench used in 23.6.9.6.
2. If the tested fasteners do not obtain the job inspection snug-tight torque, test all remaining
untested fastener assemblies using the torque wrench in the connection in question.
Following testing of all assemblies, bring to snug-tight all assemblies and retest as stated
above. Resnug and retest as necessary using the calibrated torque wrench until the minimum
testing stated above is performed favorably.
3. Following confirmation of the snug-tight condition as performed by the Contractor, and in the
presence of the Engineer, match mark the fastener assemblies on the end of the bolt thread
Page 23-55
and on the nut, and then tighten the nut the amount of rotation specified in Table 23-11. The
Engineer will accept the connection as fully tightened when all of the following conditions are
met:
• Rotation specified in Table 23-11 has been achieved
• There are no loose assemblies in the connection
• All plies of the connection are in firm contact
• There are no indications that excessive stretching or yielding has occurred in the
fastener assembly
• Bolt stick-through is consistent per lot
q. Direct Tension Indicator Tightening for High-strength Fasteners

Before bringing the connection to a snug-tight condition, the Contractor shall verify in the presence
of the Engineer that the ‘dimples’ of the DTI are not deformed or damaged. Bring the connection to
a snug-tight condition and tighten in accordance with the requirements of Article 23.6.9.6. The
Engineer will accept the connection as fully tightened when all of the following conditions are met:
1. the requirements of Article 23.6.9.6 have been achieved
2. there are no loose assemblies in the connection
3. all plies of the connection are in firm contact
4. there are no indications that excessive stretching or yielding has occurred in the fastener
assembly
5. Bolt stick-through is consistent per lot
23.6.10 Welding for Steel Structures

Except as noted in the Contract documents, shop and field welding, welder qualifications,
prequalification of weld details, and inspection of welds shall conform to the requirements of the
current AASHTO/AWS D1.5M/D1.5:2010, Bridge Welding Code.
Brackets, clips, shipping devices, or other material not required by the Contract documents shall not
be welded or tacked to any member unless specified in the Contract documents and approved by
the Engineer.
Additional or alternate requirements for hollow steel structural sections and non-dynamically loaded
members or components are listed below.
Welding shall be a metal arc process in accordance with BS EN 1011-2:2001 and BS EN 1011-
8:2004, as appropriate, together with other clauses contained in this section, unless otherwise
specifically permitted by the Engineer.
Welding consumables used shall be chosen to ensure that the mechanical properties of the weld
metal are not less than those required for the parent metal.
Joints shall be prepared in accordance with BS EN 1011-2:2001. Precautions shall be taken to
ensure cleanliness of the connection prior to welding.
23.6.10.1 Welding on Non-dynamically Loaded Elements

The Contractor shall perform welding on miscellaneous components and other statically (non-
dynamically, noncyclically, etc.) loaded structural elements in accordance with the AWS D1.1,
Structural Welding Code, or the AASHTO/AWS D1.5M/D1.5:2010, Bridge Welding Code. Unless
otherwise specified in the Contract documents or as approved by the Engineer, follow the Bridge
Welding Code for weld inspection and welder certifications.
23.6.10.2 Electroslag Welding

The Contractor shall use Narrow-Gap Improved Electroslag Welding (NGI-ESW) for joining non-
fracture critical members or components up to 75mm thick. These members or components may be
subjected to tension, compression or stress reversal. Inspect 100% of all NGI-ESW welds subject to
Page 23-56
tension stresses or reversal of stress by both UT (ultrasonic examination as described in Section 6,

Part C of the AASHTO/AWS D1.5M/D1.5:2010, Bridge Welding Code) and RT (radiographic
examination as described in Section 6, Part B of the AASHTO/AWS D1.5M/D1.5:2010, Bridge
Welding Code).
Perform NGI-ESW welding in accordance with the AASHTO/AWS D1.5M/D1.5:2010, Bridge
Welding Code. Supplemented by the recommendations from the following references:
• Report No. FHWA-SA-96-053, “Technical Information Guide for Narrow.Gap Improved
Electroslag Welding”.
• Report No. FHWA-SA-96-052, “Process Operational Guide for Narrow-Gap Improved
Electroslag Welding”.
23.6.10.3 Welding of Hollow Structural Steel Sections (Pipes and Tubes)

Except as noted in the Contract documents, the Contractor shall perform all shop and field welding
of Hollow Structural Shapes in accordance with the ANSI/AWS D1.1/D1.1M:2010, Structural Welding
Code – Steel, as amended herein.
a. Welding Highway Signs, Luminaires and Traffic Signals

For structural steel sign structures, lighting poles, and traffic signal poles, the Contractor shall comply
with the additional requirements of AASHTO Standard Specification for Structural Steel Supports for
Highway Signs, Luminaires and Traffic Signals, 5th Edition, Section 1.4.2, Welding of Steel
Structures.
b. Welding Bridge Structures

For tubular bridge structures including pedestrian bridges, the Contractor shall comply with the
requirements of the ANSI/AWS D1.1/D1.1M:2010, Structural Welding Code – Steel, as amended by
the following:
1. Qualify all welding processes in accordance with the AASHTO/AWS D1.5M/D1.5:2010,
Bridge Welding Code. Comply with all qualification criteria including production thickness and
position limitations. Use ASTM A709 / A709M - 11 Grade 50 for this test.
2. UT NDE technicians performing inspection of TKY welds are to be qualified to the
requirements and recommendations for operator qualification specified in API RP 2X:2004,
Recommended practice for ultrasonic and magnetic examination of offshore structural
fabrication and guidelines for qualification of technicians, 4th Edition, including a practical
test with mockup tubular welds containing built-in flaws.
3. Perform nondestructive testing of all tubular complete joint penetration groove welds in main
members using Ultrasonic Testing in accordance with the ANSI/AWS D1.1/D1.1M:2010,
Structural Welding Code – Steel.
Perform ultrasonic testing at the following frequency:
• One hundred percent of each joint subject to tension or reversal of stress.
• Twenty-five percent of each joint subject to compression or shear.
If unacceptable discontinuities are found in the joint, the remainder of the joint shall be tested.
Perform Magnetic Particle Testing on 300mm in every 3.0 metre on each fillet and partial penetration
groove welds in main members but no less than 300mm on welds less than 3.0 metre.
23.6.10.4 Non-destructive Testing of Welds

a. Record of Testing
The test results shall be recorded and be available for inspection by the Engineer.
Page 23-57
b. Visual Inspection of Welds

Visual inspection shall be made in accordance with guidance given in BS EN ISO 17637:2011 over
the full length of the weld and before NDT inspection is performed. Any welds which will be rendered
inaccessible by subsequent work shall be examined in prior to the loss of access.
A suitably qualified person for visual inspection of welds may be a welding inspector or a welder who
can provide evidence of having been trained and assessed for competence in visual inspection of
the relevant types of welds.
c. Surface Flaw Detection

Where a closer examination of a weld surface is required, magnetic particle inspection (MPI) shall
be used in accordance with the recommendations given in BS EN ISO 9934-1:2001.
If magnetic particle inspection equipment is not available, dye penetrant inspection (DPI) may be
used in accordance with the recommendations given in BS EN ISO 3452-1:2013.
Final surface flaw detection of a welded joint shall be carried out not less than 16 hours from the
time of completion of the weld to be inspected, or not less than 40 hours in the case of welds to
Design Grade 55 material. The Contractor shall note that where a welding procedure requires an
inspection after initial weld runs before further welding is performed, such inspections may be carried
out when the weld metal has cooled to ambient temperature.
A suitably qualified person for surface flaw detection of welds may be a welding inspector or a welder
who holds a current certificate of competence in surface flaw detection of the relevant types of work,
from a recognised authority.
d. Ultrasonic Examination
Where ultrasonic examination is required, it shall be made in accordance with BS EN ISO
17640:2010, Level 2B. Examination shall be carried out not less than 16 hours from the time of
completion of the weld to be inspected, or not less than 40 hours in the case of butt welds thicker
than 40 mm or any welds to Design Grade 55 material.
Operators carrying out final ultrasonic examination of the weld shall hold a current certificate of
competence from a recognised authority.
23.6.10.5 Field Welding

The Contractor shall field weld only with the approval of the Engineer. Provide any additional field
welding procedures as requested by the Engineer for review.
23.6.10.6 Tack Welding

The Contractor shall not weld or tack any fill plates, brackets, clips, shipping devices, or other
materials not required by the Contract documents or allowed by the AASHTO/AWS
1. Tack welds shall be made using the same procedures as for the root runs of main welds. The
length of the tack shall be the lesser of 4 times the thickness of the thicker part or 50 mm,
unless demonstrated by a weld procedure qualification.
2. Tack welds which are not defective may be incorporated into main welds provided that the
welder is qualified as in Article 23.4.11.3 of this chapter. However, where joints are welded
using an automatic or mechanised process, the suitability of the tack weld used for
incorporation into automatic processes shall be demonstrated in the weld procedure
qualification.
3. Where tack welds are made in circumstances other than those identified above, they must
be removed.
Page 23-58
23.7 Erecting Steel Structures

The Contractor shall provide all tools, machinery, and equipment necessary to erect the structure.
Falsework and forms shall be in accordance with the requirements of Section 1.20.8 of Chapter 1,
General Requirements.
23.7.1 Pre-erection Requirements

The Contractor shall complete all of the requirements outlined in this section before erecting the steel
structure for the Project.
23.7.1.1 Quality Control Plan for Erecting Steel Structures

Develop an Erection Quality Control Plan for review and approval of the Engineer.
23.7.1.2 Submittals for Erecting Steel Structures

The Contractor shall provide submittals to the Engineer for review in accordance with the Contract
documents.
23.7.1.3 Plan for Erecting Steel Structures

The Contractor shall submit, for the Engineer’s review, an Erection Plan locating all primary
members, lifting equipment and temporary supports or braces, and bolting pattern tightening
procedures not considered routine. Ensure that the plan are signed and stamped by Professional
Engineer. Include supporting calculations indicating that the design unit stresses indicated in the
Contract documents have not been exceeded. Provide this Plan or Plans to the Engineer three
weeks before erecting the piece or pieces.
The following information shall be included in the Erection Plan:
a. A plan of the work area showing all substructure units and foundations; surface roads and
railroads; all streams, creeks and rivers; and all overhead and underground utilities.
b. The erection sequence for all primary load-carrying members and all primary load-carrying
member bracing. Note any and all permanent or temporary support and/or bracing locations,
including crane-holding positions.
c. The center of gravity locations, pick weight and delivery orientation for all primary load-
carrying members and pick weight.
d. Identify any bolting requirements not considered routine.
e. Locate all pick crane work points.
f. Identify all temporary works and staging areas such as barges, mats and temporary
excavation support.
g. Provide capacity charts on the drawings for each crane configuration and boom extension
utilized.
h. Details of all temporary bracing, falsework, towers and shoring.
i. Provide any procedures requested by the Engineer and not contained in the Quality Control
Plan.
23.7.2 Special Requirements to Resist Steel Weathering

The Contractor shall not use marking materials (grease sticks, crayons) that leave behind a residual
film that may affect the weathering process of the steel. Store the girders as required for non-
weathering steels.
23.7.2.1 Preparing Steel Against Weathering

Before erection, the Contractor shall perform the following as appropriate:
Page 23-59
Blast clean the exposed fascia of the exterior girders (both I and box) to meet criteria of SSPC-SP
10/NACE No. 2, Near-White Blast Cleaning; blast clean the remaining exposed surfaces of steel
trapezoidal girders, not required to be prepared otherwise, to meet criteria of SSPC-SP 6/NACE No.
3, Commercial Blast Cleaning; for steel I-girders, if a non-uniform mill scale finish has developed, as
determined by the Engineer, blast clean all remaining exposed surfaces, not required to be prepared
otherwise, to an SSPC-SP 6/NACE No. 3 criteria; coat the inside of box members including, but not
limited to, all bracing members, cross frames and diaphragms with only the prime coat. For the
bottom or walking surface, certify that the applicable OSHA requirements on slip resistance will be
obtained after applying the coating. Reapply the coating as necessary to satisfy the OSHA
requirements. Submit the composition of coating to the Engineer for review.
23.7.2.2 Preparing a Concrete Substructure Against Weathering

Before erection of the girders, the Contractor shall wrap all exposed substructure concrete surfaces
with polyethylene sheeting, or equal, as approved by the Engineer, to protect them against staining
from the weathering steel components. Leave the sheeting in place and keep it free of tears or
separations until just before the preparation for and application of the Class 5 Finish. In any case,
do not remove the sheeting before placement of the concrete deck. As directed by the Engineer,
clean all visible stains on concrete in areas not receiving a Class 5 Finish by sandblasting and follow-
on cleaning using a stain remover or commercial cleaner after completion of the structure in
accordance with Chapter 4, Concrete Works, of these standard specifications, and Chapter 21,
23.7.2.3 Structure and Site Clean Up after Weather Protection

Upon the completion of construction, the Contractor shall remove all oil, dirt, grease or other foreign
material, including excessive or uneven mill scale from the steel. Remove lubricants from the
exposed surfaces of installed fastener assemblies and other surfaces in accordance with the
Manufacturer’s recommendations. Final surface finish is to be an even mill scale as approved by the
Engineer.
23.7.3 Aligning Steel Structure with Substructure

Before the erection of primary load-carrying members, the Contractor shall conduct a survey to
document the vertical, longitudinal and transverse position of all substructure units and anchor rod
locations. Appropriately account for ambient temperature in the survey.
Should a discrepancy be identified with the Contract documents, the Contractor shall submit the
necessary details to the Engineer for resolution.
23.7.4 Placing Anchor Rods for Erection of Steel Structure

The Contractor shall locate and place anchor rods within the tolerance shown in the Contract
documents or within 6mm of the theoretical location shown. If anchor rods cannot be located to the
specified tolerance, place only with the approval of the Engineer. Unless shown otherwise in the
Contract documents, provide galvanized anchor rods, nuts and washers as follows:
1. Set the anchor rods in preformed holes vertical to the plane of the bridge seat.
2. Provide 100mm diametre holes.
3. Provide non-shrink grout/mortar of a strength greater than or equal to that of the substructure
concrete strength, or as shown elsewhere in the Contract documents.
4. Install the rods in accordance with the grout/mortar Manufacturer’s recommendations.
5. Clean the threads of the anchor rods as necessary without damaging the coating.
Page 23-60
23.7.5 Preparing Bearing Areas and Setting Bearings for Erection of

Steel Structure
Before placing superstructure bearing units (including but not limited to neoprene pads and masonry
plates), the Contractor shall prepare the top of concrete pad (bearing area) in accordance with
Section 21.10.4 of Chapters 21, Concrete Structures, and Chapter 25, Bearing Devices. If a
discrepancy is identified, report it to the Engineer for resolution.
For expansion bearings with slotted holes for anchor rods, which allow movement of the
superstructure with respect to the substructure, the Contractor shall vary the location of the slotted
plate in relation to the anchor rods, in accordance with the prevailing temperature at the time of
setting. For fixed bearings at multiple adjacent piers, if necessary, horizontally jack the substructure
units to correctly set the centerline of bearing. Adequately account for temperature.
Unless specified elsewhere in the Contract documents, the Contractor shall locate the theoretical
centerline of bearings to within 1.5mm transverse to longitudinal girder lines; and in the direction
parallel to the longitudinal girder line locate the theoretical centerline of bearing within 6mm of the
theoretical centerline of bearing.
After setting the bearings and installing anchor rod nuts, washers and any other associated hardware
specified in the Contract documents, the Contractor shall clean the protruding/ exposed surfaces of
the assembly of all deleterious material.
23.7.6 Tightening Anchor Rod Nuts for Erection of Steel Structure

when tightening anchor rod nuts during the erection of a steel structure, the Contractor shall comply
with the specifications outlined in this section.
23.7.6.1 Tightening Fixed Bearings

The Contractor shall tighten anchor nuts to a ‘snug tight’ condition such that the different mating
surfaces (such as the top of concrete, neoprene and steel) are in firm contact. The nut is to be tight
enough to develop friction between surfaces to prevent sliding, but not over tightened that bulging
or damage occurs in any of the mating materials.
23.7.6.2 Tightening Expansion Bearings

The Contractor shall draw down the nut such that a total gap of 1.5 mm exists between the washer
and nut and washer and bearing surface. Tighten a second nut of the same specification to a snug
tight condition against the first nut maintaining the required gap.
23.7.7 Bearings for Erection of Steel Structures

Bridge bearings shall be furnished and installed in conformance with Chapter 25, Bearing Devices.
If the steel superstructure is to be placed on a substructure that was built under a separate Contract,
the Contractor shall verify that the masonry has been constructed in the right location and to the
correct lines and elevations before ordering materials.
23.7.8 Procedure to Erect a Steel Structure

When erecting the steel structure for the Project, the Contractor shall comply with the requirements
and specifications outlined in this section.
23.7.8.1 Conformance to Project Drawings during Erection

The erection procedure shall conform to the erection drawings submitted in accordance with Section
23.3.2. Any modifications to or deviations from this erection procedure shall require revised drawings
and verification of stresses and geometry.
Page 23-61
23.7.8.2 Accounting for stresses during erection of Steel Structure

Any erection stresses induced in the structure as a result of using a method of erection which differs
from the Contract documents shall be accounted for by the Contractor. Erection design calculations
for such changed methods shall be prepared at the Contractor's expense and submitted to the
Engineer. The calculations shall indicate any change in stresses or change in behavior for the
temporary and final structures. Additional material required to keep both the temporary and final
stresses within the allowable limits used in design shall be provided at the Contractor's expense.
The Contractor shall be responsible for providing temporary bracing or stiffening devices to
accommodate handling stresses in individual members or segments of the structure during erection.
When the partial structure is deemed prone to suitability concerns, the Contractor shall provide the
requisite calculations showing that the partial structure will remain stable until the complete continuity
of the structure is reached.
23.7.8.3 Maintaining an Erected Steel Structures Alignment and

Camber
During erection, the Contractor shall be responsible for supporting segments of the structure in a
manner that will produce the proper alignment and camber in the completed structure. Cross frames
and diagonal bracing shall be installed as necessary during the erection process to provide stability
and assure correct geometry. Temporary bracing, if necessary at any stage of erection, shall be
provided by the Contractor.
23.7.8.4 Final Position of Girder Webs for a Steel Structure

Unless shown elsewhere in the Contract documents, the Contractor shall detail the girders and cross
frames as directed by the Engineer. The final condition is to be defined as with the deck and parapets
cast, but without any future wearing surface. A web will be considered plumb if it is within a tolerance
horizontally between the top and bottom of the web of 7.8mm per metre of web depth compared
against the theoretical position as required in the Contract documents. Measure the out-of-plumb
perpendicular to the face of the web. Erect trapezoidal girders to the geometry shown in the Contract
documents to the same 7.8mm per metre of web depth tolerance.
23.7.9 Field Assembly for Erection of a Steel Structure

Parts shall be accurately assembled as specified in the Contract documents or erection drawings
and any match-marks shall be followed. Material shall be carefully handled so that no parts will be
bent, broken, or otherwise damaged. Hammering which will injure or distort the members shall not
be done. Bearing surfaces and surfaces to be in permanent contact shall be cleaned before the
members are assembled. Splices and field connections shall have one-half of the holes filled with
bolts and cylindrical erection pins (half bolts and half pins) before installing and tightening the
balance of high-strength bolts. Splices and connections carrying traffic during erection shall have
three-fourths of the holes so filled.
Fitting-up bolts may be the same high-strength bolts used in the installation. If other fitting-up bolts
are used, they shall be of the same nominal diameter as the high strength bolts and cylindrical
erection pins shall be 0.8 mm larger.
23.7.10 Connection of Pins for an Erected Steel Structure

Pilot and driving nuts shall be used in driving pins. They shall be furnished by the Contractor without
charge. Pins shall be so driven that the members will take full bearing on them. Pin nuts shall be
screwed up tight and the threads burred at the face of the nut with a pointed tool.
Page 23-62
23.7.11 Correcting Misfits in an Erected Steel Structure

Correction of minor misfits involving minor amounts of reaming, cutting, grinding, and chipping shall
be considered a legitimate part of the erection. However, any error in the shop fabrication or
deformation resulting from handling and transporting shall be cause for rejection.
The Contractor shall be responsible for all misfits, errors, and damage and shall make the necessary
corrections and replacements.
23.8 Expansion Joints for Steel Structures

Expansion joints shall be fabricated and installed in accordance with the requirements of this section
and the requirements of Chapter 26, Bridge Deck Joint Systems.
Complete working drawings for fabrication and installation of expansion joints shall be submitted.
The Contractor shall include the joint Manufacturer‘s instructions for proper installation of the joint
on the drawings. Joint opening dimension for an ambient temperature of thirty degree Celsius (30°C)
and adjustments to that dimension due to temperature variations shall be shown.
The Contractor shall fabricate expansion joints accurately to conform to the specified concrete floor
section, matching cross slopes and break points. Expansion joints shall be assembled and checked
for fit in the shop, then it shall be match marked for shipment.
For sealed expansion joints, the steel receptors shall be fabricated to be continuous the full length
of joint including 150 mm extensions. The number of splices in the steel receptor shall be minimized.
To splice, a partial penetration weld, ground smooth shall be used. Welding shall not be done in
areas in contact with the neoprene.
The Contractor shall provide and install a neoprene gland continuous the full length of joint including
150 mm extensions. At locations where joints are shown to be for skew of thirty-five degree (35°)
and greater, the neoprene shall be spliced by vulcanizing or other approved method that provides
strength and durability equal to unspliced neoprene. Splices shall be permanently watertight.
23.9 Inspection and Final Acceptance for Steel Structures

The Contractor shall perform Quality Control inspections of all phases of the work. The inspection
frequency and depth shall be sufficient to ensure that all materials and workmanship incorporated
into the work meet the requirements of the Contract documents and that the processes are controlled
to ensure that the final finished product(s) conform to the physical characteristics and dimensions
required by the Contract documents. A Quality Control Manager shall be responsible for all
inspection operations. An adequate number of Quality Control Inspectors shall be available to ensure
review of all materials and fabrication processes are preformed in accordance with the Quality
Control Plan. Weekly meetings shall be held with the Engineer to review inspection findings. The
review of this information is to identify any refinements and/or improvements in the process being
utilized in the work. The Engineer may alter the frequency of meetings.
Material (except bearing devices and painting) for steel structures will be evaluated under this
section. Production certifications shall be furnished for each shipment of structural steel, steel
forgings, and high-strength bolts, nuts, and washers.
Construction of steel structures shall be evaluated under this section. Bearing devices shall be
evaluated under Chapter 25, Bearing Devices. Painting shall be evaluated under Chapter 24,
Painting.
The Contractor shall ensure the final alignment, profile and fastening of the erected steel is in
accordance with the Contract documents.
Page 23-63
23.10 Additional Provisions for Curved Steel Girders

Provisions of this section apply to horizontally curved girders and shall be considered in addition to
other provisions of these Specifications. However, when there is a conflict between these provisions
for curved girders and other provisions of these Specifications, these provisions shall prevail.
These provisions shall be used by the Contractor to create a construction plan as required herein.
These provisions shall apply to the superstructure including fabrication, shipping, erection of the
girders, cross-frames and other structural steel elements, and placement of the concrete deck.
23.10.1 Contractor’s Construction Plan for Curved Girder Bridge

The Engineer’s construction plan, if shown in the Contract documents, shall not be taken as
supplanting or implying any supplantation of the Contractor’s responsibility for the fabrication,
erection, or construction of any part of the bridge.
The Contractor shall provide a construction plan which details fabrication, procedures for erection,
and deck placement, and which shall be referred to herein as the Contractor’s construction plan.
This plan may be based on the plan shown in the Contract documents, if one is provided, or may be
developed entirely by the Contractor. In either event, it shall demonstrate the general stability of the
structure and individual components during each stage of construction, including while supported on
any temporary jacks. The Contractor’s construction plan shall be stamped by a Professional
Engineer and be accepted by the Owner or the Engineer. Where the Contractor’s construction plan
causes a difference in camber of the girders for dead load from that presented on the Contract
documents, acceptance by the Owner or the Engineer shall be obtained before commencement of
fabrication. The Contractor’s construction plan shall include:
a. Fabrication procedures, including method of curving the girders
b. Shipping weights, lengths, widths, and heights, and means of shipping
c. Erection plan, including sequence of erection; crane capacities; and the location, capacity
and elevation of any temporary supports
d. Deck placement sequence, including the time between placements; and the magnitude and
position of any temporary load required to prevent girder lift-off at bearings
Computations which show that the factored construction stresses satisfy the requirements of Articles
6.10.3 or 6.11.3, “Constructability,” of the AASHTO LRFD Bridge Design Specifications, as
applicable, shall be provided.
23.10.2 Fabricating Materials for Curved Girder Bridges

The Fabricator shall ensure that the steel can be fit up in the no-load condition unless specified
otherwise in the construction plan.
23.10.2.1 Handling Materials for Curved Girder Bridges

Rolled shapes and plates composing the flanges and webs shall be handled in such a manner as to
prevent visible deformations or other incidental damage.
23.10.2.2 Fabricating Curved Girders

Fabrication of curved girders for the Owner bridges shall comply with the requirements and
a. Fabricating Rolled I-beams

Horizontal curvature may be obtained by heat-curving. Heat-curving of beams shall be performed in
accordance with the provisions of Article 6.7.7, “Heat-Curved Rolled Beams and Welded Plate
Girders,” of the AASHTO LRFD Bridge Design Specifications and Section 23.5.4 of these
Page 23-64
Specifications. The Engineer shall determine the necessity of providing the additional camber
specified in Article 6.7.7, “Camber,” of the AASHTO LRFD Bridge Design Specifications.
b. Fabricating Welded I-girders

In addition to heat-curving as specified in this section, welded girders may be fabricated from cut-
curved flanges.
Vertical camber shall be obtained by cutting the web plate to the necessary contour.
c. Fabricating Welded Box and Tub Girders

Box flanges shall be cut-curved. Top flanges of tub girders may be curved according to the provisions
of this section.
23.10.2.3 Fabricating Web Attachments for Curved Girder Bridges

Fabrication of web attachments for curved girder bridges shall comply with the requirements and
a. Fabricating Transverse Stiffeners

Transverse stiffeners shall be bolted to the web or welded to the web with continuous fillet welds on
both sides of the stiffener. These welds shall be terminated between 4tw and the lesser of 6tw and
100mm from the near edge of the adjacent flange or longitudinal web stiffener welds. If transverse
stiffeners or transverse web elements serving as stiffeners are interrupted by a longitudinal stiffener,
the transverse stiffeners shall be attached to the longitudinal stiffener to develop the flexural and
axial resistance of the transverse stiffener. If single-sided transverse stiffeners are used, the end of
the stiffener should be attached to both flanges. Fillet welds on both sides of the stiffener may be
used.
When pairs of transverse stiffeners are used, they shall be fitted tightly to both flanges.
b. Fabricating Connection Plates

Connection plates, otherwise identified as transverse stiffeners at cross-frames and diaphragms,
shall be attached to both flanges by either welding or bolting. If a bolted connection is shown on the
Contract documents, a welded connection may not be substituted without permission from the
Engineer.
c. Fabricating Longitudinal Stiffeners

Wherever practical, longitudinal stiffeners shall extend uninterrupted over their specified length
unless otherwise permitted in the Contract documents. Longitudinal stiffeners shall be bolted to the
web or welded to the web with continuous fillet welds on both sides of the stiffener.
Where longitudinal stiffeners are interrupted, they should be fitted to, and attached to, the continuous
element sufficiently to develop the required strength and stiffness of the longitudinal stiffener.
d. Fabricating Cross-frames and Diaphragms

Cross-frames and diaphragms shall be detailed to fit under the no-load condition unless otherwise
specified.
23.10.2.4 Fabricating Bolt Holes for Curved Girder Bridges

Unless permitted otherwise in the Contract documents, bolt holes in girder splices and primary load-
carrying members shall be standard size. Exceptions shall be approved by the Engineer.
Page 23-65
23.10.2.5 Tolerances in Curved Girder Bridges

Materials for curved girder bridges shall comply with the requirements and specifications outlined in
this section.
a. Tolerance for Welded Web Flatness in Curved Girder Bridges

Webs shall meet dimensional tolerances specified in the AASHTO/AWS D1.5M/D1.5:2010, Bridge
Welding Code. Flatness shall be measured with respect to a straightedge oriented perpendicular to
the flanges.
b. Tolerance for Camber in Curved Girder Bridges

Cambers provided on the Contract documents shall be adhered to unless steel erection or deck
placement is to be performed in a manner that will lead to deflections different from those used to
determine the camber specified. If the Contractor or the Contractor’s Fabricator/Detailer or Erector
intends other procedures or outcomes, the approach shall be confirmed with the Engineer, and any
documentation required for approval shall be provided at no cost to the Owner. Any required
submissions should be made and approved before the submission of the shop drawings for approval.
c. Tolerance for Sweep in Curved Girder Bridges

Sweep tolerance shall meet the requirements of the AASHTO/AWS D1.5M/D1.5:2010, Bridge
Welding Code. Sweep tolerance shall be measured radially from the theoretical curve of the girder.
d. Tolerance for Lengths of Curved Girders

Girder lengths shall be determined based on an ambient temperature of 30o C. Girder length shall
be measured along the arc.
23.10.2.6 Fabricating Fit-up for Curved Girder Bridges

Fit-up of girder sections shall meet the provisions of Section 23.6.6, “Preassembly of Field
Connections for Steel Structures,” of these Specifications. Unless otherwise specified in the
Contractor’s construction plan, fit-up shall be assumed to be performed under the no-load condition.
When numerically controlled drilling is employed, trial fit-up of cross-frames or diaphragms between
properly positioned girder sections shall be performed as specified in Article 23.6.1.4 of these
specifications.
Shop fit-up of bolted connections in load-carrying connections of cross-frames and diaphragms to
the girders may be required for structures with complex geometry or stiff elements.
Girder Section Field Splices may be fit up in either the vertical or horizontal position. Girder splices
may be fit up before heat-curving.
23.10.3 Transportation Plan for Curved Girders

A Transportation Plan may be required by the Owner or the Engineer for complex or large structures.
The type of girder supports required and their locations shall be identified. The types, size, and
locations of tie-downs shall be shown. A sufficient number of tie-downs shall be specified to provide
adequate redundancy.
Girder stresses due to selfweight while being shipped shall be computed with a dynamic load
allowance of 100 percent.
The computed girder stresses shall satisfy the provisions of Article 6.10.3.2 or Article 6.11.3.2 of the
AASHTO LRFD Bridge Design Specifications, as applicable.
Fatigue stresses shall not exceed the constant amplitude fatigue threshold for the appropriate
categories in Table 6.6.1.2.5-3 of the AASHTO LRFD Bridge Design Specifications.
Page 23-66
Wherever practical, girder sections should be shipped in the same orientation as in the completed
structure. Girders shall be supported in such a manner that their cross-section shape is maintained
and through-thickness stresses are minimized.
Supports should be such to ensure that dynamic lateral bending stresses are controlled.
Temporary stiffening trusses or beams, if required to meet the requirements of this section, shall be
specified in the Transportation Plan.
23.10.4 Erecting Steel for Curved Girder Bridges

Erection shall be performed in accordance with the Contractor’s construction plan as approved by
the Engineer.
Factored stresses due to selfweight of the steel and wind at each stage of erection shall not exceed
those computed according to the provisions of Article 6.10.3 or Article 6.11.3, as applicable, of the
AASHTO LRFD Bridge Design Specifications and Article 23.7.8.2, “Accounting for stresses during
erection of steel structures”, of these Specifications.
Reaming of bolt holes during erection shall be permitted only with the approval of the Engineer.
Bolted girder splices shall be field assembled according to the provisions of Section 23.6.1 of these
Specifications.
23.10.4.1 Erecting Falsework for Curved Girder Bridges

Falsework shall be designed to carry vertical and lateral loads that are specified in the construction
plan. The elevation of falsework shall be such as to support the girders at the cambered no-load
elevation. Jacks used in conjunction with the falsework shall have a stroke adequate to permit full
unloading. Unloading of temporary supports should be performed such that all temporary supports
at each cross-section are unloaded uniformly.
Where appropriate, cranes may be substituted for falsework.
23.10.4.2 Erecting Bearings for Curved Girder Bridges

Computed bearing rotation during construction shall not exceed the rotational capacity of the
bearing. Bearings shall be installed such that, after dead load has been applied, sufficient rotation
capacity shall be available to accommodate rotations due to environmental loads and live load.
Expansion bearings shall be installed so that they will be in the center of the permitted travel at the
ambient temperature of 30° C unless otherwise specified by the Engineer.
23.10.4.3 Erecting I-girders for Curved Girder Bridges

The Contractor shall ensure that girders are stable throughout the erection process. The stage of
completeness of the bolted connections shall be considered when evaluating the strength and
stability of the steel during erection.
23.10.4.4 Erecting Closed Box and Tub Girders for Curved Girder
Bridges
The Contractor shall ensure that the cross-section shape of each box is maintained during erection.
Top lateral bracing should be installed in tub girders before shipping and erection of the field pieces.
23.10.5 Erecting Decks for Curved Girder Bridges

When erecting decks for the curved girder bridge for the Project, the Contractor shall comply with
the requirements and specifications outlined in this section.
Page 23-67
23.10.5.1 Erecting Forms for Decks on Curved Girder Bridges

Plywood, permanent metal forms, or concrete panels may be used as deck forms as approved by
the Engineer. Proprietary forms shall be placed in accordance with the Manufacturer’s specifications
incorporating any modifications to those Specifications approved by the Engineer. Form work shall
be supported by the superstructure.
a. Erecting Overhangs for Decks on Curved Girder Bridges

Overhang forms shall be removed after the deck has cured. Wherever practical, overhang brackets
should bear near the bottom flange and be attached to the top flange. If overhang brackets bear
against the web, the Contractor shall ensure that precautions have been taken to prevent permanent
deformation of the web and excessive deflection of the wet slab and forms. The lateral force on the
top flange due to overhang brackets shall be investigated to ensure that the flange is adequate as
specified in Article 6.10.3.4, “Deck Placement,” of the AASHTO LRFD Bridge Design Specifications.
Loads applied on the overhang brackets shall be considered in determining lateral flange bending
stresses, cross-frame forces, and associated web and top flange deformations. If the loads or their
application are to be different than those provided for in the Contract documents, an additional
analysis shall be made by the Contractor and approved by the Engineer.
b. Erecting Tub Girders for Decks on Curved Girder Bridges

Deck forms shall not be supported at locations other than girder flanges unless specifically
considered in the design.
23.10.5.2 Placing Concrete for Decks on Curved Girder Bridges

Concrete placements shall be made in the sequence specified in the approved construction plan.
Time between placements shall be such that the concrete in prior pours has reached an age or
strength specified in the construction plan. Any accelerating or retarding agents to be used in the
concrete mix shall be specified.
Duration of each placement shall be specified in the construction plan. Placements that include both
negative and positive dead load moment regions should be placed such that the positive moment
region is poured first.
23.10.6 Reporting Modification to Construction Plan for Curved Girder

Bridge
Any modifications to the construction plan in the field from the original plan shall be documented with
appropriate approvals noted.
23.11 Post-weld Treatment for Steel Structures

Post-weld treatments for steel structures shall comply with the requirements and specifications
Typical post-weld treatment includes ultrasonic impact treatment, heat treatment, grinding, weld toe
remelting (GTAW dressing or plasma arc dressing), hammer peening, and shot peening.
23.11.1 Ultrasonic Impact Treatment for Steel Structures

If required, the objective of ultrasonic impact treatment (UIT) is to improve the fatigue strength of
welded connections by plastically deforming the material at the weld toes and introducing residual
compressive stresses substantially greater than the largest anticipated tensile stresses to a depth of
no less than 0.5mm. This treatment is necessary only at the weld toe which is defined as the interface
of the weld metal and base metal. Due to the finite size of the UIT needles and the recommended
treatment procedure, some base metal adjacent to the weld toe will get treated.
Page 23-68
23.11.1.1 Procedure for Ultrasonic Impact Treatment for Steel

Structures
UIT shall be accomplished in accordance with the equipment Manufacturer’s recommendations,
except as specifically described in the Contract documents.
The use of UIT shall be limited to base metal with a specified minimum yield strength of 690 MPa or
less.
Before UIT, the weld toe to receive UIT shall be visually inspected and magnetic particle-tested for
conformance to the quality standards specified in the Contract documents. The instrument shall be
calibrated against the maximum flaw size allowed. Discontinuities greater than 0.8mm shall be
repaired satisfactorily before initiating the work.
UIT shall be done along the toe of the weld in a manner that will cause the center of the resultant
treatment groove to be at the weld toe, with equal treatment and smooth transition to the adjacent
weld and base metal.
UIT shall be performed so as to result in a uniform groove with a distinct and uniform bright metallic
surface, as verified by visual inspection immediately after completion. When viewed under a 10x
magnifying glass, the groove shall be free from any visible indications of the untreated base metal
or weld metal. If such untreated indications exist within the treated area, such area shall be retreated
to obtain a uniform, bright metallic surface across the entire surface of the UIT groove.
23.11.1.2 Other Weld Metal and Base Metal Treatments

Because the benefits of UIT are primarily derived from the introduction of compressive residual
stresses, the Contractor shall avoid other processes, such as heat treatment, hot dipped galvanising,
or overloading, that might relieve these stresses after performing the toe treatment.
23.11.1.3 Dead Load Consideration

If the structure is going to be subjected to a significant dead load when in use, it is advisable that
this be taken into consideration and the structure be loaded before treatment. An enhancement
corresponding to the lower stress ratio may be obtained in that case, depending on the live load
stress ratio of the nominal stress cycles applied after the treatment.
23.12 Additional Requirements for Steel Structures

In addition to the requirements of these specifications, the fabrication, transport and erection of steel
structures shall also conform to the following additional requirements.
a. Steel with Enhanced Through Thickness Properties

Where the Contract plans indicate a requirement for steel with enhanced through thickness
properties, these shall be in accordance with BS EN 10164:2004, Steel products with improved
deformation properties perpendicular to the surface of the product - Technical delivery conditions, or
an equivalent specification approved by the Engineer.
b. Laminar Defects in Plate Material

The areas of plates presented in
Table 23-13, shall not have laminations exceeding the limits specified in BS EN 10160:1999,
Ultrasonic testing of steel flat product of thickness equal or greater than 6 mm (reflection method).
Table 23-13 presents acceptance levels for internal imperfections in steel plate, strip and wide flats,
based on Ultrasonic Testing.
Table 23-13: Acceptance Levels for internal imperfections in steel plates
Page 23-69
Acceptance
Level
For a band of flange or web plate of width 25 times the plate thickness on each
B4
side of a bearing diaphragm where attached by welding:
For a band of web plate of width 25 times the plate thickness on each side of a
B4
single sided bearing stiffener where attached by welding :
For edges of plates where corner welds will be made on to the surface of such
E
plates:
For welded cruciform joints transmitting primary tensile stresses through the plate
thickness, on a band of width four times the thickness of the plate each side of B4
the proposed attachment:
c. Dimensions of Cope Holes

The radius of cope holes and of re-entrant corners in plate material shall be the greater of 30mm or
2 times the plate thickness unless specified otherwise in the Contract plans.
d. Reference Temperature
Dimensions of steel structures shown on the Contract plans shall be correct at the specified mean
temperature.
Page 23-70
INDEX
abutment, 23-4 field connections, 23-34, 23-43, 23-64, 23-67
allowable temperature, 23-28, 23-29 field-welded connections, 23-47
arc process, 23-58 flame-cut, 23-40
artificial cooling, 23-29 fracture critical, 23-14, 23-18, 23-33, 23-35,
bearing, 23-4, 23-21, 23-30, 23-31, 23-34, 23- 23-58
36, 23-38, 23-40, 23-45, 23-46, 23-47, 23- friction grip bolts, 23-46
53, 23-55, 23-62, 23-63, 23-64, 23-65, 23- full-size tests, 23-42
68, 23-71 galvanising, 23-20, 23-21, 23-24, 23-37, 23-
Bracing members, 23-4 51, 23-70
Bridge bearings, 23-63 girders, 23-4, 23-14, 23-16, 23-17, 23-18, 23-
bridge structures, 23-59 29, 23-30, 23-31, 23-33, 23-34, 23-37, 23-
bulk materials, 23-14 38, 23-39, 23-40, 23-45, 23-61, 23-63, 23-
calibrated wrench, 23-49, 23-52, 23-53, 23-54 65, 23-66, 23-67, 23-68
camber, 23-15, 23-16, 23-17, 23-31, 23-37, harmful materials, 23-14
23-45, 23-47, 23-63, 23-65, 23-66, 23-67 Head markings, 23-20
Camber, 23-17, 23-31, 23-37, 23-38, 23-63, heat-curving bridge members, 23-29
23-66, 23-67 heating patterns, 23-28, 23-30, 23-32
cold bending, 23-26 higher standards, 23-4
collar fasteners, 23-21, 23-22, 23-56 horizontal radius, 23-30
connection plates, 23-4, 23-30, 23-31, 23-33, inspection frequency, 23-64
23-35 jacks, 23-28, 23-32, 23-65
container, 23-14, 23-15, 23-51 large diametre holes, 23-36
Cross frames, 23-4, 23-14, 23-63 lateral bracing components, 23-33, 23-34
Cup and countersunk bolts, 23-22 lighting poles, 23-58
curvature, 23-27, 23-29, 23-30, 23-31, 23-41, load carrying capacity, 23-16
23-42, 23-66 Load-indicating devices, 23-22
curved beams, 23-4, 23-39 Lock nuts, 23-22
dead load, 23-16, 23-17, 23-31, 23-38, 23-65, lubricants, 23-37, 23-61
23-68, 23-69, 23-70 Magnetic particle examination, 23-32
Deck forms, 23-69 Maximum deviation, 23-38, 23-41, 23-42
Department of Transport, 23-4 moisture, 23-14, 23-15, 23-49
diaphragms, 23-4, 23-18, 23-43, 23-61, 23-66, non-destructive testing, 23-4, 23-32
23-67 Non-Redundant Members, 23-18
dimensional tolerances, 23-37, 23-38, 23-67 orthotropic-deck bridge, 23-41
direct tension indicator (DTI) devices, 23-54 Overhang forms, 23-69
drilled holes, 23-33 permanent metal forms, 23-69
Electroslag Welding, 23-58 pier, 23-4, 23-37
equipment, 23-27, 23-34, 23-42, 23-43, 23-59, pinholes, 23-38
23-60, 23-70 Post-weld treatments, 23-69
erection, 23-4, 23-14, 23-15, 23-16, 23-17, 23- preheat, 23-25
40, 23-41, 23-42, 23-43, 23-44, 23-45, 23- Preload compressive stresses, 23-28
46, 23-60, 23-61, 23-62, 23-63, 23-64, 23- primary load, 23-4, 23-14, 23-18, 23-32, 23-
65, 23-67, 23-68, 23-70 35, 23-51, 23-61, 23-62, 23-67
Erection design calculations, 23-63 Radiographic examination, 23-32
Erection Quality Control, 23-60 reaming, 23-34, 23-35, 23-36, 23-45, 23-46,
Expansion joints, 23-64 23-47, 23-48, 23-64
fabricated girders, 23-4 Rib members, 23-4
Fabricator, 23-12, 23-13, 23-14, 23-15, 23-17, rolled beams, 23-4, 23-14, 23-18, 23-30, 23-
23-18, 23-26, 23-27, 23-28, 23-29, 23-30, 31
23-31, 23-32, 23-33, 23-34, 23-35, 23-36, shear studs, 23-14
23-38, 23-43, 23-45, 23-65, 23-67 sign structures, 23-58
Falsework, 23-4, 23-15, 23-16, 23-60, 23-68 slip-critical connections, 23-48, 23-49
Page 23-71
slotted hole geometry, 23-35

splice plates, 23-14, 23-18, 23-26
stainless steel, 23-19, 23-41
standard hole, 23-33
steel arches, 23-4
Steel castings, 23-23
Steel forgings, 23-23
Steel surfaces, 23-39
structural members, 23-14, 23-42
Stud shear connectors, 23-22
supplier, 23-14, 23-20
Surface finishes, 23-36
Tack welds, 23-60
Tensile properties, 23-22, 23-23
Threads, 23-5, 23-40, 23-47, 23-50
torches, 23-28, 23-40
traffic signal poles, 23-58
truss chords, 23-38, 23-43
truss members, 23-4, 23-43
turn-of-nut, 23-47, 23-53
Ultrasonic, 23-10, 23-11, 23-32, 23-59, 23-60,
23-69, 23-70
ultrasonic examination, 23-26, 23-58, 23-60
Visual inspection, 23-26, 23-32, 23-59
V-type heating, 23-29
Washers, 23-7, 23-15, 23-20, 23-21, 23-22,
23-51, 23-52
Welder qualification, 23-25
welder qualifications, 23-58
welding, 23-9, 23-11, 23-16, 23-18, 23-19, 23-
22, 23-24, 23-25, 23-26, 23-30, 23-31, 23-
33, 23-40, 23-41, 23-58, 23-59, 23-60, 23-
66, 23-71
Page 23-72
PART 2
ROAD STRUCTURES
CHAPTER 24 - PAINTING
DOCUMENT NO: TR-

FIRST EDITION
JANUARY 2018
Chapter 24: Painting

TABLE OF CONTENTS
24 Painting ........................................................................................................................... 24-1
24.1 General ........................................................................................................................ 24-1
24.1.1 Protection of Public, Property, and Workers .......................................................... 24-1
24.1.2 Existing Paint Removal ......................................................................................... 24-1
24.1.3 Protection of Work ................................................................................................ 24-2
24.1.4 Qualification Samples and Tests ........................................................................... 24-2
24.1.5 General Requirements for Surface Preparation .................................................... 24-3
24.1.6 General Requirements for Paint Application ......................................................... 24-3
24.3 Painting Structural Iron and Steel Surfaces.................................................................. 24-9
24.3.1 General................................................................................................................. 24-9
24.3.1.1 Compatibility ................................................................................................ 24-10
24.3.1.2 Toxicity ........................................................................................................ 24-10
24.3.1.3 Volatile Organics.......................................................................................... 24-10
24.3.1.4 Color ............................................................................................................ 24-10
24.3.1.5 Performance Requirements ......................................................................... 24-10
24.3.2 Paint Systems for New External Visible Surfaces or Surfaces with All Existing Paint
Removed .......................................................................................................................... 24-12
24.3.2.1 Paint System No. 1 - Inorganic Zinc Silicate System.................................... 24-13
24.3.2.2 Paint System No. 2 – Zinc Rich Epoxy System ............................................ 24-14
24.3.2.3 Paint System No. 3 – Moisture Cured Polyurethane System ....................... 24-14
24.3.2.4 Paint System No. 4 – Acrylic Latex System ................................................. 24-16
24.3.2.5 Paint System No. 5 – Low VOC Alkyd System............................................. 24-16
24.3.3 Paint Systems for Surfaces with Existing Sound Paint ........................................ 24-17
24.3.3.1 Paint System No. 6 – Moisture Cured Polyurethane System ....................... 24-18
24.3.3.2 Paint System No. 7 – Low VOC Alkyd System............................................. 24-18
24.3.3.3 Paint System No. 8 – Low Viscosity Epoxy System ..................................... 24-18
24.3.4 Paint System No. 9 for New Internal Invisible Surfaces....................................... 24-18
24.3.5 Surface Preparation of Iron and Steel Surfaces .................................................. 24-18
24.3.5.1 New surfaces or Surfaces with all Existing Paint Removed .......................... 24-18
24.3.5.2 Surfaces with Existing Sound Paint.............................................................. 24-19
24.3.5.3 Cleaning Methods of Iron and Steel Surfaces .............................................. 24-19
24.3.6 Sampling and Testing ......................................................................................... 24-22
24.3.7 Time of Application ............................................................................................. 24-22
24.3.8 Storage of Paint and Thinner .............................................................................. 24-23
24.3.9 Mixing and Thinning ............................................................................................ 24-23
24.3.10 Application of Paint ............................................................................................. 24-24
24.3.10.1 General........................................................................................................ 24-24
24.3.10.2 Brush Application ......................................................................................... 24-25
24.3.10.3 Spray Application of Paint ............................................................................ 24-25
24.3.10.4 Shop Painting .............................................................................................. 24-26
24.3.10.5 Field Painting ............................................................................................... 24-26
24.3.10.6 Drying of Painted Iron and Steel .................................................................. 24-27
24.3.10.7 Handling of Painted Iron and Steel .............................................................. 24-27
24.3.10.8 Measurement of Dry Film Thickness (DFT) of Paints ................................... 24-27
24.4 Painting Galvanized Surfaces .................................................................................... 24-29
24.4.1 Paint System No. 10 – Polyamide Cured Rust Inhibitive Epoxy System ............. 24-30
24.4.2 Paint System No. 11 – Vinyl Wash System ......................................................... 24-30
24.5 Painting Steel Sheet, H, Pipe Pilings, and other Surfaces .......................................... 24-31
24.5.1 Surface Preparation ............................................................................................ 24-31
24.5.2 Application Requirements ................................................................................... 24-31
Page i
CHAPTER 24: PAINTING First Edition -January 2018
24.6 Painting Aluminium Surfaces ..................................................................................... 24-32

24.6.1 Surface Preparation ............................................................................................ 24-32
24.6.2 Paint Systems for Aluminium Surfaces ............................................................... 24-32
24.6.2.1 Paint System No. 11 - Polyvinylidene Difluoride Coating ............................. 24-33
24.6.2.2 Paint System No. 12 - Epoxy ....................................................................... 24-33
24.6.3 Aluminium in Contact with Dissimilar Metals ....................................................... 24-33
24.7 Painting Exposed Surfaces of Concrete Structures .................................................... 24-33
24.7.1 General Requirements for Concrete Painting ...................................................... 24-34
24.7.2 Paint Test Areas for the Engineer’s Approval ...................................................... 24-35
24.7.3 Project and Weather Conditions ......................................................................... 24-35
24.7.4 Surface Preparation and Application ................................................................... 24-36
24.7.5 Paint Materials .................................................................................................... 24-37
24.7.5.1 Exposed Concrete Surfaces ........................................................................ 24-37
24.7.5.2 Concrete Surfaces in Splash Zones ............................................................. 24-39
Index ...................................................................................................................................... 24-40
Page ii
LIST OF TABLES
Table 24-1: Designations and titles for AASHTO and ASTM standards that apply to painting works
.................................................................................................................................................. 24-6
Table 24-2: Designations and titles for BS, and BS EN, and DIN standards that apply to painting
works ......................................................................................................................................... 24-9
Table 24-3: Performance requirements of coatings .................................................................. 24-11
Table 24-4: Structural iron and steel coating systems for new surfaces and surfaces with all existing
paint removed .......................................................................................................................... 24-12
Table 24-5: Acceptance levels for salt fog ................................................................................ 24-16
Table 24-6: Acceptance levels for cyclic exposure ................................................................... 24-16
Table 24-7: Structural iron and steel coating systems for surfaces with existing sound paint ... 24-17
Table 24-8: Methods of testing Paint properties ....................................................................... 24-22
Table 24-9: Galvanized surface coating systems ..................................................................... 24-30
Table 24-10: Characteristics of coal tar epoxy coating ............................................................. 24-31
Table 24-11: Polyvinylidene difluoride (PVDF) requirements.................................................... 24-33
Table 24-12: Pigmented elastomeric aliphatic acrylic coating for exposed concrete surfaces .. 24-37
Table 24-13: Silane/Siloxane primer for exposed concrete surfaces ....................................... 24-38
Page iii
24 PAINTING
24.1 General
This specification sets out the minimum requirements and the standards for surface treatment and
painting of structural iron and steel, galvanized, aluminium, and concrete surfaces to control
corrosion and deterioration.
The Contractor shall comply with the specifications in this chapter and the Contract documents when
performing painting services for the Project. Painting services shall include at least the following
activities:
• Preparing surfaces
• Applying paint (painting surfaces)
• Curing paint
• Protecting works under construction, existing facilities, vehicles, and the public from damage
caused by painting
• Furnishing of all labour, equipment, and materials needed to perform painting services
• The applicator/painter shall demonstrate to the Engineer his proficiency in applying the
manufacturer’s recommendations
24.1.1 Protection of Public, Property, and Workers

The Contractor shall comply with the Steel Structures Painting Council's (SSPC) Guide to Safety
and Health Requirements (SSPC-PA Guide 10), and OSHA requirements. All applicable
environmental protection and occupational safety and health standards, rules, regulations, and
orders shall be observed by the Contractor. Failure to comply with these standards, rules,
regulations, and orders shall be sufficient cause for suspension or disqualification.
All reasonable precautions shall be taken to contain waste materials, including used blasting material
and old paint, classified as hazardous. Disposal of hazardous waste material shall be performed in
accordance with all applicable laws.
Protective devices, such as tarps, screens, or covers, shall be provided by the Contractor, as
necessary, to prevent damage to the work and to other properties, or persons from all cleaning and
painting operations. All damage caused by the painting works to vehicles, persons, or property shall
be the responsibility of the Contractor.
Paint or paint stains that result in an unsightly appearance on surfaces not designated to be painted
shall be removed or obliterated by the Contractor at its expense.
24.1.2 Existing Paint Removal

If the paint being removed is a hazardous material containing lead or chromium, the Contractor shall
comply with all the following:
• SSPC Guide 6I(CON) - Guide for Containing Debris Generated During Paint Removal
Operations;
• SSPC Guide 7I(DIS) - Guide for the Disposal of Lead-Contaminated Surface Preparation
Debris;
• 40 CFR Parts 260 - 268 - Code of Federal Regulations;
• 29 CFR 1926.62 - OSHA Construction Industry Standards for Lead;
• 40 CFR 50.6 - EPA National Primary and Secondary Ambient Air Quality Standards for
Particulate Matter; and
• 40 CFR 50.12 - EPA National Primary and Secondary Ambient Air Quality Standards for
Lead.
Page 24-1
At least 28 days before beginning surface preparation, the Contractor shall submit a written plan for
acceptance that details the measures to be used for protecting the environment, public, adjacent
property, and workers. The Contactor shall include in the plan the following:
a. Manufacturer's material safety data sheets and product data sheets for all cleaning and
painting products.
b. A detailed containment plan for removed material, cleaning products, and paint debris. The
Contractor shall include details of attachment that do not require welding or drilling holes in
the existing structure. Connections with clamps or other approved devices shall be made.
c. A detailed disposal plan for removed material, cleaning products, and paint debris.
d. The Contractor shall include specific safety measures to protect workers from site hazards
including falls, fumes, fires, or explosions.
e. If paint being removed is a hazardous material, the Contractor shall include specific safety
measures to comply with 29 CFR 1926.62, 40 CFR 50.6, 40 CFR 50.12, and other 40 CFR
Parts 260-268.
f. Emergency spill procedures.
g. To perform quality control functions, the Contractor shall provide a competent person as
defined in SSPC-QP 2 with the following:
1. An SSPC Competent Person Certificate or equivalent subject to the Engineer’s
approval;
2. A certificate of completion of 29 CFR 1926.62 Lead in Construction training or
equivalent subject to the Engineer’s approval;
3. Minimum of 2 years industrial field painting experience;
4. Minimum of 90 days of field supervisory or management experience in paint removal
projects; and
5. Documentation of the individual’s qualifications including records of training and
experience.
The Contractor shall perform work according to the accepted plan. If the measures fail to perform as
intended, the Contractor shall immediately stop work and take corrective action. The Contractor shall
collect and properly dispose of all material including waste water that is used in preparing, cleaning,
or painting.
24.1.3 Protection of Work

Adjacent surfaces that are not to be painted shall be protected by using tarps, screens, paper, cloth,
or other suitable means. The Contractor shall prevent contamination of freshly-painted surfaces by
dust, oil, grease, or other harmful or deleterious material. Additionally, the Contractor shall protect
all parts of work under construction against disfigurement by splatters, splashes, and smirches of
paint materials.
Surfaces that are marred or damaged as a result painting operations shall be repaired by the
Contractor, at its expense, with materials and to a condition equal to that of the coating specified
herein.
If traffic causes an objectionable amount of dust to collect where the Contractor is conducting
painting operations, the Engineer may require the Contractor to sprinkle the adjacent roadbed and
shoulders with water or a dust palliative.
Upon completion of all painting operations, and of any other work that deposits dust, grease, or other
foreign materials on painted surfaces, the Contractor shall thoroughly clean the painted surfaces.
When structures are opened to public traffic, the Contractor shall have completed all painting and
surfaces shall be undamaged and clean.
24.1.4 Qualification Samples and Tests

The manufacturer shall supply, to an independent test laboratory and to the Owner, samples of the
paint system for evaluation. Prior to approval and use, the manufacturer shall submit a certification
Page 24-2
of the independent laboratory, together with results of all tests, stating that these materials meet the
requirements as set forth herein. The certified test report shall state lots tested, manufacturer’s
name, product names, and dates of manufacture. New certified test results and samples for testing
by the Owner shall be submitted any time the manufacturing process or paint formulation is changed.
All costs of testing, other than tests conducted by the Owner, shall be borne by the manufacturer.
24.1.5 General Requirements for Surface Preparation

The surface preparation and application procedures shall be in accordance with instructions by the
paint manufacturer. The Contractor shall submit complete instructions by the paint manufacturer for
the preparation of all surfaces and the application of all final paint materials to the Engineer. The
Contractor shall also submit materials content data for each paint and performance data indicating
expected durability in the Abu Dhabi climate.
The Contractor shall notify the Engineer in writing at least 7 days before beginning operations.
Immediately before painting, the Contractor shall prepare the surface according to the following:
a. Clean the surface to the specified cleanliness level.
b. Remove dirt, dust, and other contaminants from the surface using methods recommended
by the paint manufacturer.
c. Thoroughly dry the surface.
d. Determine that the surface temperature is between 10oC and 32oC.
e. Determine that the humidity is 85 percent or less, unless specified otherwise on the
manufacturer's product data sheet.
Suitable engineering controls such as enclosures and dehumidification may be used to provide the
conditions required above. Subject to the approval of the Engineer, the Contractor may provide a
suitable enclosure to permit painting during inclement weather. Such provisions shall artificially
control atmospheric conditions inside an enclosure within limits suitable for painting throughout the
painting operation.
Surfaces painted under cover in damp or cold weather shall remain under cover at no additional cost
until the paint dries or weather conditions permit open exposure.
All blast cleaning, except that performed within enclosed structures, and all painting shall be
performed during daylight hours unless the Contract documents specify otherwise.
24.1.6 General Requirements for Paint Application

The Contractor shall use safe handling practices that conform to the manufacturer's safety data
sheet and instructions. Paint shall be mixed and applied according to the product instructions. Paint
shall be mixed with mechanical mixers for a sufficient length of time to thoroughly blend the pigment
and vehicle together. Mixing shall be continued during application. The Contractor shall not thin paint
that is formulated ready for application.
The Contractor shall paint in a neat and workmanlike manner that does not produce excessive paint
build-up, runs, sags, skips, holidays, or thin areas in the paint film. The wet film thickness shall be
measured during application and the application rate shall be adjusted such that, after curing, the
desired dry film thickness (DFT) is obtained. Paint shall be applied by brush, spray, roller, or any
combination thereof if permitted by the manufacturer's product data sheet.
The Contractor shall use brushes that have sufficient bristle body and length to spread the paint in
a uniform film.
Airless or conventional spray equipment shall be used with suitable traps, filters, or separators to
exclude oil and water from the compressed air. The Contractor shall use compressed air that does
not show black or wet spots when tested according to ASTM D4285 - 83(2012). Spray gun tip sizes
and pressures recommended by the manufacturer shall be used.
Page 24-3
The Contractor shall use rollers only on flat, even surfaces. Rollers that leave a stippled texture in
the paint film shall not be used.
The Contractor shall use sheepskin daubers, bottle brushes, or other acceptable methods to paint
surfaces that are inaccessible for painting by regular means.
Each coat of paint shall be cured by the contractor according to the manufacturer's
recommendations. The Contractor shall correct all thin areas, skips, holidays, and other deficiencies
before the next application of paint. Succeeding applications of paint shall be tinted to contrast with
the paint being covered. The Owner shall approve the color for the finish coat before application.
Surfaces that will be inaccessible after erection shall be coated with the full number of undercoats
required before erection. After erection, the Contractor shall thoroughly clean all areas where the
undercoating is damaged or deteriorated, and shall spot coat these with the specified undercoats to
the required thickness before applying the final coat.

All painting materials for which the Contract documents do not define specific requirements shall
comply with the requirements for applicable materials that are outlined in this section.
Standards and codes for painting shall be as specified in these specifications, in the Contract
Load and Resistance Factor Design, Bridge Construction
Specifications;
AAMA American Architectural Manufacturers Association;
AAMA 2605-05 Voluntary Specification, Performance Requirements and Test
Procedures for Superior Performing Organic Coatings on Aluminum
Extrusions and Panels;
AAMA 620-02 Voluntary Specifications for High Performance Organic Coatings on
Coil Coated Architectural Aluminum Substrates Specifications and test
methods used to evaluate coil coatings on aluminium;
AISC American Institute of Steel Construction;
AISC-420-10/ Certification Standard for Shop Application of Complex Protective
Coating
SPE-QP3 Systems;
APAS Australian Paint Approval Scheme;
FED-STD-595B Federal Standard 595B - Colors Used In Government Procurement;
FSS Federal Specifications and Standards;
MIL-DTL-53022D Detail Specification: Primer, Epoxy Coating, Corrosion Inhibiting Lead
and Chromate Free;
MIL-DTL-53039D Detail Specification: Coating, Aliphatic Polyurethane, Single
Component, Chemical Agent Resistant;
Page 24-4
MIL-P-24441/1B Military Specification Formula - Paint, Epoxy-Polyamide Green Primer,

Formula 150 Type 1;
NIST National Institute of Standards and Technology;
SSPC Steel Structures Painting Council;
SSPC-PA Guide to Safety and Health Requirements;
Guide 10
SSPC-PA 1 Shop, Field, and Maintenance Painting of Steel;
SSPC-PA 2 Procedure for Determining Conformance to Dry Coating Thickness
Requirements;
SSPC-PS 28.02 Three Coat Moisture Cured Polyurethane Coating System,
Performance Based;
SSPC-SP 1 Solvent Cleaning;
SSPC-SP 2 Hand Tool Cleaning;
SSPC-SP 3 Power Tool Cleaning;
SSPC-SP 5 White Metal Blast Cleaning;
SSPC-SP 6 Commercial Blast Cleaning;
SSPC-SP 10/ Near-White Blast Cleaning;
NACE No. 2
SSPC-Paint 16 Coal Tar Epoxy-Polyamide Black (or Dark Red);
SSPC-Paint 20 Zinc-Rich Primers (Type I, Inorganic, and Type II, Organic);
SSPC-Paint 21 White or Colored Silicone Alkyd Paint;
SSPC Paint 22 Epoxy Polyamide Paints (Primer, Intermediate, and Topcoat);
SSPC-Paint 23 Latex Primer for Steel Surfaces;
SSPC-Paint 24 Latex Semigloss Exterior Topcoat;
SSPC-Paint 27 Basic Zinc Chromate-Vinyl Butyral Wash Primer;
SSPC-Paint 31 Single-Package Waterborne Alkyd Primer for Steel Surfaces,
Performance-Based;
SSPC-Paint 36 Two-Component Weatherable Aliphatic Polyurethane Topcoat,
Performance-Based;
SSPC-Paint 38 Single-Component Moisture-Cure Weatherable, A;
SSPC-Paint 40 Zinc-Rich Moisture-Cure Polyurethane Primer, P;
SSPC-Paint 41 Moisture-Cured Polyurethane Primer;
SSPC-Paint 104 White or Tinted Alkyd Paint;
SSPC QP2 Certification Program (Field Removal of Hazardous Coatings);
SSPC-AB 3 Ferrous Metallic Abrasive;
TT-P-645B Federal Specification - Primer, Paint, Zinc-Molybdate, Alkyd Type;
NACE RP0178- Standard Recommended Practice - Fabrication Details, Surface Finish
Page 24-5
2003 (21002) Requirements and Proper Design Considerations for Tanks and
Vessels to be Lined for Immersion Service.
Table 24-1 and
American Society for Testing and Materials (ASTM), British (BS), European (BS EN), and German
(DIN) Standards that are related to materials for painting works. It also includes designations and
titles.
Table 24-1: Designations and titles for AASHTO and ASTM standards that apply to painting
works
AASHTO ASTM
Title
AASHTO T 277- ASTM C1202 - Standard Test Method for Electrical Indication of
07 (2011) 12 Concrete's Ability to Resist Chloride Ion Penetration
ASTM D4541 - Standard Test Method for Pull-Off Strength of Coatings

09e1 Using Portable Adhesion Testers
ASTM D4060 - Standard Test Method for Abrasion Resistance of Organic

10 Coatings by the Taber Abraser
ASTM D3960 - Standard Practice for Determining Volatile Organic

05 Compound (VOC) Content of Paints and Related Coatings
ASTM C642 - Standard Test Method for Density, Absorption, and Voids
06 in Hardened Concrete
ASTM D2697 - Standard Test Method for Volume Nonvolatile Matter in

03(2008) Clear or Pigmented Coatings
AASHTO M
Standard Specification for Inorganic Zinc-Rich Primer
300-03 (2012)
ASTM D520 -
Standard Specification for Zinc Dust Pigment
00(2011)
Standard Practice for Preparation of Cold-Rolled Steel

ASTM D609 -
Panels for Testing Paint, Varnish, Conversion Coatings,
00(2012)
and Related Coating Products
ASTM G7 / Standard Practice for Atmospheric Environmental

G7M - 13 Exposure Testing of Nonmetallic Materials
ASTM G152 - Standard Practice for Operating Open Flame Carbon Arc
13 Light Apparatus for Exposure of Nonmetallic Materials
ASTM G153 - Standard Practice for Operating Enclosed Carbon Arc Light
13 Apparatus for Exposure of Nonmetallic Materials
Page 24-6
AASHTO ASTM
Title
Standard Practice for Operating Fluorescent Ultraviolet

ASTM G154 -
(UV) Lamp Apparatus for Exposure of Nonmetallic
12a
Materials
ASTM B117 - Standard Practice for Operating Salt Spray (Fog)

11 Apparatus
ASTM D3359 - Standard Test Methods for Measuring Adhesion by Tape

09e2 Test
ASTM D4285 - Standard Test Method for Indicating Oil or Water in

83(2012) Compressed Air
ASTM D4417 - Standard Test Methods for Field Measurement of Surface

11 Profile of Blast Cleaned Steel
ASTM A36 /
A36M - 12
ASTM D1654 - Standard Test Method for Evaluation of Painted or Coated

08 Specimens Subjected to Corrosive Environments
ASTM A325M - Standard Specification for Structural Bolts, Steel, Heat

13 Treated 830 MPa Minimum Tensile Strength (Metric)
ASTM A490M - Standard Specification for High-Strength Steel Bolts,

12 Classes 10.9 and 10.9.3, for Structural Steel Joints (Metric)
Standard Practices for Producing Films of Uniform

ASTM D823 -
Thickness of Paint, Varnish, and Related Products on Test
95(2012)e1
Panels
ASTM D2805 - Standard Test Method for Hiding Power of Paints by

11 Reflectometry
ASTM D1730 - Standard Practices for Preparation of Aluminum and

09 Aluminum-Alloy Surfaces for Painting
AASHTO R 31- Standard Practice for Evaluation of Coating Systems for

09 Structural Steel
Standard Practice for Cyclic Salt Fog/UV Exposure of

ASTM D5894 -
Painted Metal, (Alternating Exposures in a Fog/Dry Cabinet
10
and a UV/Condensation Cabinet)

Standard Test Methods for Estimating Average Particle

ASTM B330-12 Size of Metal Powders and Related Compounds Using Air
Permeability
Page 24-7
AASHTO ASTM
Title
ASTM D2794 - Standard Test Method for Resistance of Organic Coatings

93(2010) to the Effects of Rapid Deformation (Impact)
ASTM D522 - Standard Test Methods for Mandrel Bend Test of Attached
93a(2008) Organic Coatings
ASTM D610 - Standard Practice for Evaluating Degree of Rusting on

08(2012) Painted Steel Surfaces
ASTM D714 - Standard Test Method for Evaluating Degree of Blistering

02(2009) of Paints
Standard Practice for Calculation of Color Tolerances and

ASTM D2244 -
Color Differences from Instrumentally Measured Color
11
Coordinates
ASTM D523 -
Standard Test Method for Specular Gloss
08
ASTM D543 - Standard Practices for Evaluating the Resistance of

06 Plastics to Chemical Reagents
ASTM D638 -
Standard Test Method for Tensile Properties of Plastics
10
ASTM D1894 - Standard Test Method for Static and Kinetic Coefficients of
11e1 Friction of Plastic Film and Sheeting
Standard Test Method for Dielectric Breakdown Voltage

ASTM D149 -
and Dielectric Strength of Solid Electrical Insulating
09(2013)
Materials at Commercial Power Frequencies
ASTM D2240 - Standard Test Method for Rubber Property—Durometer

05(2010) Hardness
Standard Test Method for Measurement of Dry Film

ASTM D5796 -
Thickness of Thin Film Coil-Coated Systems by Destructive
10
Means Using a Boring Device

ASTM C672 / Standard Test Method for Scaling Resistance of Concrete

C672M - 12 Surfaces Exposed to Deicing Chemicals
ASTM D412 - Standard Test Methods for Vulcanized Rubber and

06a(2013) Thermoplastic Elastomers—Tension
ASTM D4263 - Standard Test Method for Indicating Moisture in Concrete

83(2012) by the Plastic Sheet Method
Page 24-8
Table 24-2: Designations and titles for BS, and BS EN, and DIN standards that apply to
painting works
BS & BS EN DIN
Title
Testing concrete Method for determination of water

BS 1881-122:2011
absorption
Testing concrete Methods for analysis of hardened

BS 1881-124:1988
concrete
Method for determining the permeability to water vapour of

BS 3177:1959
flexible sheet materials used for packaging
BS EN 12390- Testing hardened concrete. Depth of penetration of water

8:2009 under pressure
Determination of the water vapour transmission rate of

DIN 53122-1
plastic film, rubber sheeting, paper, board and other sheet
(2001-08)
materials by gravimetry
BS EN ISO
2808:2007, BS Paints and varnishes. Determination of film thickness
3900-C5:2007
Paints and varnishes - Corrosion protection of steel

structures by protective paint systems - Measurement of,
ISO 19840:2012
and acceptance criteria for, the thickness of dry films on
rough surfaces
Products and systems for the protection and repair of

BS EN 1504- concrete structures. Definitions, requirements, quality
9:2008 control and evaluation of conformity - General principles for
use of products and systems
24.3 Painting Structural Iron and Steel Surfaces

24.3.1 General
All painting work shall consist of preparing the surfaces, furnishing and applying paint to all iron and
steel surfaces of structures or portions thereof that are designated to be painted unless otherwise
indicated on the Contract plans. The Contractor shall include the protection from paint spatter and
disfigurement of adjacent or nearby structures, and final cleanup, all in accordance with these
standard specifications and requirements of Contract documents.
All paint materials applied to structural iron and steel works shall comply with the following
requirements unless otherwise specified herein, indicated on the Contract plans, or specified in the
Particular Specifications.
Page 24-9
1. All coating systems shall be stored, thinned, handled, mixed and applied in accordance with
SSPC-PA 1, Shop, Field and Maintenance Painting of Steel, and the recommendations on
the Manufacturer’s product data sheets.
2. All paint furnished shall be shipped in strong, substantial containers, plainly marked with the
following:
• Trade name or trade mark;
• Paint type, color, formulation, lot number, and date of manufacture;
• Net mass;
• Volume including the percent of solids and the percent of volatile organic compound (VOC);
• Storage requirements;
• Mixing instructions and equipment cleanup instructions; and
• Name and address of the manufacturer.
3. The paint shall not show excessive settling in a freshly-opened full can, and shall easily be
re-dispersed with a paddle to a smooth, homogeneous state. The paint shall show no
curdling, livering, caking or color separation, and shall be free from lumps and skins.
4. The paint as received shall brush easily, possess good leveling properties, and show no
running or sagging tendencies when applied to smooth steel vertical surfaces.
5. The paint shall not skin within 48 hours in a three-quarters-filled closed container.
6. The paint shall dry to a smooth uniform finish, free from roughness, grit, unevenness, and
other surface imperfections. The paint shall show no streaking or separation when flowed on
clean glass.
7. The paint shall show no thickening, curdling, gelling, or hard caking after six months storage
in a full, tightly-covered container at a temperature of 21°C.
24.3.1.1 Compatibility
Each coating in the paint system shall be supplied by the same paint manufacturer.
24.3.1.2 Toxicity
Each coating shall contain less than 0.01 percent lead in the dry film and no more than trace amounts
of hexavalent chromium, cadmium, mercury or other toxic heavy metals.
24.3.1.3 Volatile Organics

The volatile organic compounds (VOC) content shall conform to the following VOC limits for both
shop and field painting:
a. Clear (unpigmented) coatings 1.68 kg per gallon max.
b. Other coatings 1.31 kg per gallon max.
More stringent limits shall be applied if required by SSPC-PA Guide 10, OSHA or local regulations.
24.3.1.4 Color
The Contractor shall furnish a contrasting color for each coat of paint. The finish coat color shall
conform to FED-STD-595B or Classic RAL System as approved by the Owner. The Contractor shall
provide color chips from the paint supplier.
24.3.1.5 Performance Requirements

Unless otherwise specified in this chapter, the Contractor shall prepare and submit to the Owner four
composite and four flat-scribed test panels in accordance with AASHTO R 31-09. In addition, the
Contractor shall submit 1 liter wet samples of each component of each coating incorporated in the
system being evaluated. Panels shall subject to outdoor exposure testing in accordance with ASTM
G7 / G7M - 13.
All coatings, regardless of color, shall meet the requirements below as shown in Table 24-3.
Page 24-10
Table 24-3: Performance requirements of coatings
Laboratory Testing
Property Test Method Requirement
Slip Coefficient AASHTO R 31-09 Min. Class B (primer only)
Blister Size = 10
Salt Fog
AASHTO R 31-09 Average Rust Creep at the
Resistance
Scribe ≤ 2.5 mm
Blister Size = 10
Average Rust Creep at the
Cyclic Weathering Scribe ≤ 5.0 mm
AASHTO R 31-09
Resistance
Color Retention ΔE ≤ 8,
Gloss loss less than 30 units
Abrasion
AASHTO R 31-09 Wear Index ≤ 2.7 mg/cycle
Resistance
Avg. system tensile strength ≥

Adhesion AASHTO R 31-09
5.52 MPa
Freeze Thaw
AASHTO R 31-09 Avg. tensile strength ≥ 5.52 MPa
Stability
IR scan (2.5 to 15 um) for each

Coatings Fourier Transform Infrared
base, catalyst, and mixed
Identification Spectroscopy
coating.
Greater than 1400 mm/kg, 1/2”

Impact Resistance ASTM D2794 - 93(2010)
impact, intrusion
AASHTO R 31-09, ASTM D522 -

Flexibility No cracking
93a(2008), 25 mm cylindrical mandrel
Outdoor Testing
ASTM D610 -08(2012) ≥ 9 after 5 years

Rusting ASTM D1654 - 08 (scribed) ≥ 9 after 5 years
ASTM D1654 - 08 (un-scribed) ≥ 9 after 5 years
Blistering ASTM D714 - 02(2009) 10 after 5 years
≥ 5.52 MPa (un-scribed area)

Adhesion ASTM D4541 - 09e1; annex A4
after 5 years
Color Retention ASTM D2244 - 11 ΔE ≤ 8 after 2 years
Page 24-11
Laboratory Testing
Gloss ASTM D523 - 08 ≤ 30 gloss units after 2 years
24.3.2 Paint Systems for New External Visible Surfaces or Surfaces

with All Existing Paint Removed
All structural iron and steel shall be painted with one of the following systems as shown in Table
24-4. The required system or choice of systems shall be shown on the Contract plans or in the
Particular Specifications.
If not indicated on the Contract plans or specified in the Particular Specifications, the paint system
applied to all structural iron and steel surfaces shall be System No. 2, Zinc Rich Epoxy System.
Table 24-4: Structural iron and steel coating systems for new surfaces and surfaces with all
existing paint removed
Paint System1
1 2 3 4 5
Coat
Aggressive Aggressive Aggressive Less Less
Aggressive Aggressive
Environments Environments Environments
Environments Environments
Aromatic
Inorganic zinc Zinc-rich Moisture- Low VOC
cured Acrylic latex
Primer Silicate epoxy alkyd
Polyurethane 2-3 mils DFT
4-5 mils DFT 4-5 mils DFT 3-4 mils DFT
3-4 mils DFT
Aromatic
Epoxy Epoxy Moisture- Low VOC
cured Acrylic latex
Intermediate Polyamide Polyamide alkyd
3-5 mils DFT
Aliphatic
Aliphatic Aliphatic Moisture- Low VOC
Polyurethane polyurethane cured Acrylic latex
Top Coat silicone-alkyd
Acrylic Acrylic
2-3 mils DFT
2-3 mils DFT 2-3 mils DFT
2-3 mils DFT
Total
9-13 mils DFT 9-13 mils DFT 8-12 mils DFT 6-9 mils DFT 8-11 mils DFT
Thickness2
Note 1: System 1, 2, or 3 is for the corrosion protection of iron and steel in aggressively corrosive
atmospheric environments such as marine, coastal, or industrial. System 4 or 5 is for use in those
environments with less humidity and free from high concentrations of salts or pollutants that cause
aggressive corrosion environments.
Page 24-12
Note 2: Dry Film Thickness (DFT).
24.3.2.1 Paint System No. 1 - Inorganic Zinc Silicate System

Paint System No. 1 shall consist of the following:
1. Primer coat on bare steel (not galvanized): Inorganic zinc silicate paint shall be a two-
component self-curing type conforming to SSPC-Paint 20, Type I, which, when mixed, cures
without the use of a separate curing solution, and shall have the properties described herein.
Pigment: The zinc pigment component shall comply with the requirements of ASTM D520 - 00(2011)
for Type II. The average particle size of the zinc powder shall not exceed 10 microns as determined
by the Fisher Sub-sieve Sizer and in accordance with ASTM B330-12.
Vehicle: The vehicle component shall consist primarily of an alkyd silicate in an appropriate alcohol
solvent. Total solids, by content shall be determined by drying the sample to a constant weight at
100°C.
Mixed paint shall comply with the following requirements:
i. The zinc portion shall be at least 75 percent by weight of the total solids of the dried
coating.
ii. The total solids, when heated at 100°C for 3 hours, shall be not less than 72 percent by
weight.
iii. The paint shall tolerate up to one percent water contamination without gellation.
iv. The usable pot life of the mixed paint shall be not less than 12 hours at 25°C. There shall
be no hard settling which cannot be easily re-dispersed during this period.
v. The inorganic zinc coating shall be so formulated as to produce a distinct contrast in color
with the blast cleaned iron and steel surfaces and with the topcoat.
Tests: Test panels of the iron and steel, meeting the requirements of ASTM D609 - 00(2012) having
dimensions of 5 cm x 13 cm x 3 mm, shall be prepared by thoroughly cleaning all surfaces. A 3-4
mils coating (DFT) shall then be applied to the test panels in accordance with the manufacturer's
current printed instruction. The coating shall be cured as recommended by the manufacturer. Each
of the following tests shall be performed on a minimum of three panels. The material will not be
accepted if any individual test panel fails any of the following tests:
i. Fresh Water Resistance: Panels shall be scribed down to base metal with an X of at least
5 cm legs and shall be immersed in fresh tap water at 24°C + 2°C. The panels shall show
no rusting, blistering, or softening when examined after 30 days.
ii. Salt Water Resistance: Panels shall be scribed down to base metal with an X of at least 5
cm legs and immersed in 5 percent sodium chloride at 24°C + 2°C at 7, 14 and 30 days.
The sodium chloride solution shall be replaced with fresh solution after each examination.
iii. Weathering Resistance: Panels shall be tested in accordance with ASTM G152 – 13 and
ASTM G153 - 13, Type D. The panels shall be placed on test at the beginning of the wet
cycle. After 1,000 hours continuous exposure, the coating shall show no rusting, loss of
adhesion to the steel test panel, or blistering.
iv. Weather and Salt Fog Resistance: Panels shall be tested in the weatherometer as
specified in (iii) for 300 hours. After this period the panels shall be removed and scribed
with an X of at least 5 cm legs down to base metal. The test panels shall then be tested in
accordance with ASTM B117 - 11. After 1,000 hours of continuous exposure, the coating
shall show no loss of bond, nor shall it show rusting or blistering beyond 2 mm from the
center of the scribe mark.
v. Resistance to Elevated Temperatures and Thermal Shock: Panels shall be exposed to a
temperature of 260°C for one hour, then quenched immediately in 18°C + 2°C water.
Panels subjected to this test shall show no blistering or flaking of the coating.
vi. Adhesion panels shall be tested in accordance with ASTM D3359 - 09e2 and shall attain
a rating of 3 or greater.
Page 24-13
vii. Mud Cracking Resistance: The coating when applied to test panels as above to a 5 to 6
mils DFT shall show no mud cracking when viewed under 10-X magnification.
The manufacturer and Brand Name Approval for Inorganic Zinc Primer: Prior to approval and use of
inorganic zinc, the Contractor shall submit in triplicate to the Engineer a certified test report from an
approved independent testing laboratory showing specific test results complying with all quantitative
and resistance test requirements specified. The certified test report shall also contain the exact ratio,
by weight, of the pigment component to the vehicle component of the paint used for the tests, the lot
tested, the manufacturer's name, brand name of paint, and date of manufacture.
New certified test results shall be submitted whenever the manufacturing process or the paint
formulation is changed, and may be required by the Engineer when sampling and testing of material
offered for use indicates noncompliance with any of the requirements herein specified.
2. Intermediate Coat: On surfaces prepared with primer as specified in Paragraph 1 of Article
24.3.2.1, an intermediate coat of high-build epoxy polyamide conforming to SSPC Paint 22
shall be applied as recommended by the manufacturer in a single application employing
multiple spray passes. The color of the intermediate coat shall contrast with both the primer
and top coat. The intermediate coat shall comply with MIL-P-24441/1B, Formula 150.
3. Top Coat: Top coat shall be an aliphatic polyurethane acrylic, conforming to SSPC-Paint 36,
applied as recommended by the manufacturer in a single application employing multiple
spray passes. The aliphatic polyurethane acrylic shall comply with the following minimum
requirements:
Solids 45.0% by volume
Pigment 19.7% by weight
Non-volatile vehicle 36.4% by weight
(Acrylic resin - 25.8% by weight)
(Polyurethane resin - 8.3% by weight)
(Additives - 2.3% by weight)
The Contractor shall submit top coat color chips for selection of color by the Engineer.
24.3.2.2 Paint System No. 2 – Zinc Rich Epoxy System

1. Primer coat on bare steel (not galvanized): Zinc-rich epoxy paint shall be a two-
component, high solid zinc-rich, (part A + part B) epoxy primer, conforming to composition
and performance requirements of SSPC-Paint 20 standard. It shall comply with the following
minimum requirements:
Solids 62+2% by volume
Gloss at 60ºC Matt.
Recommended thinner 4-100
All materials shall be applied in accordance with the manufacturer's directions. The
Contractor shall prepare the surface to achieve a 30-50 microns profile. The Contractor shall
stir well before application and while painting. Zinc-rich epoxy primer shall not be applied
when temperature falls below 10ºC.
2. Intermediate coat: an intermediate coat of high-build epoxy polyamide conforming to SSPC-
Paint 22 shall be applied as per Paragraph 2 of Article 24.3.2.1.
3. Top coat: a top coat of an aliphatic polyurethane acrylic conforming to SSPC-Paint 36 shall
be applied as per Paragraph 3 of Article 24.3.2.1.
24.3.2.3 Paint System No. 3 – Moisture Cured Polyurethane System

The moisture cured polyurethane paint system shall consist of an aromatic moisture cured
polyurethane primer, an aromatic moisture cured polyurethane intermediate coat, and aliphatic
moisture cured polyurethane top coats conforming to the performance requirements of SSPC-PS
28.02. It is intended for field painting blast-cleaned existing structures.
Page 24-14
1. Zinc - Rich moisture cured polyurethane Primer Requirements:

i. The material shall be a single component zinc-rich aromatic moisture cured
polyurethane primer conforming to the performance requirements of SSPC-Paint 40.
It shall be suitable for topcoating with polyurethanes.
ii. The zinc dust pigment shall be according to ASTM D520 - 00(2011), Type II.
iii. The organic zinc coating shall meet a Class B AASHTO LRFD Bridge Design
Specifications slip coefficient (0.50 or greater) for structural steel joints using ASTM
A325M – 13 or ASTM A490M - 12 bolts.
iv. The adhesion to an abrasively blasted steel substrate shall not be less than 6.2 MPa
when tested according to ASTM D4541 - 09e1 Annex A4.
2. Intermediate Coat Requirements:
i. The material shall be a single component aromatic moisture cured polyurethane
conforming to SSPC-Paint 41. It shall be suitable as an intermediate coat over the
primer and compatible with the top coat.
ii. The color of the intermediate coat shall provide a distinct contrast between the primer
and the finish coat.
3. Polyurethane Top Coat Requirements:
i. The material shall be a single component aliphatic moisture cured polyurethane
conforming to SSPC-Paint 38. It shall be suitable as a topcoat over the intermediate
coat.
ii. The top coat color shall be as specified in the Contract documents and as approved
by the Owner conforming to FED-STD-595B or Classic RAL System. The color
difference shall not exceed 3.0 Hunter Delta E Units. Color difference shall be
measured by instrumental comparison of the designated standard to a minimum DFT
of 3 mils (75 microns) of sample coating produced on a test panel according to ASTM
D823 - 95(2012)e1, Practice E, Hand–Held, Blade Film Application. Color
measurements shall be determined on a spectrophotometer with 45 degrees
circumferential/zero degrees geometry, illuminant C, and two degrees observer
angle. The spectrophotometer shall measure the visible spectrum from 380-720
nanometers with a wavelength interval and spectral bandpass of 10 nanometers.
The contrast ratio of the finish coat at 3 mils DFT shall not be less than 0.99 when tested
according to ASTM D2805 - 11.
iii. Test panels shall be aluminum alloy measuring 300 x 100 mm prepared according to
ASTM D1730 – 09 Type A, Method 1 Solvent Cleaning. A minimum dry film thickness
of 3 mils of top coat shall be applied to three test panels according to ASTM D823 -
95(2012)e1, Practice E, Hand Held Blade Film Application. The coated panels shall
be cured at least 30 days and not more than 45 days at 25 °C ± 2 °C and 65 ± 5
percent relative humidity. The panels shall be subjected to 300 hours of accelerated
weathering using the light and water exposure apparatus (fluorescent UV -
condensation type) as specified in ASTM G154 - 12a (equipped with UVB-313 lamps).
The cycle shall consist of eight hours UV exposure at 60 °C followed by four hours of
condensation at 40 °C. After exposure, the panel shall be rinsed with clean water and
allowed to dry at room temperature for one hour. The exposed panels shall not show
a color change of more than 3 Hunter Delta E Units.
4. Test Panel Preparation:
i. Test panels shall be ASTM A36 / A36M - 12, hot-rolled steel measuring 100 x 150
mm. Panels shall be blast-cleaned per SSPC–SP5 white metal condition using
recyclable metallic abrasive according to SSPC-AB3. The abrasive shall be a 60/40
mix of shot and grit. The shot shall be an SAE shot number S230 and the grit an SAE
number G40. Hardness of the shot and grit shall be Rockwell C45. The anchor profile
shall be 1.5-2.5 mils measured according to ASTM D4417 - 11, Method C.
ii. All coatings shall be spray applied at the manufacturer's recommended film thickness.
The coated panels shall be cured at least 30 days and not more than 45 days at 25
°C ± 2 °C and 65 ± 5 percent relative humidity.
Page 24-15
iii.The test panels shall be scribed according to ASTM D1654 – 08 with a single “X”
mark centered on the panel. The rectangular dimensions of the scribe shall have a
top width of 50 mm and a height of 100 mm. The scribe cut shall expose the steel
substrate as verified with a microscope.
iv. All testing shall be performed on triplicate panels as per the testing requirements of
Paragraph 5 of Article 24.3.2.3 .
5. Testing Requirements:
i. For testing purposes, the color of the top coat shall match FED-STD-595B, color chip
14062 (green), as approved by the Owner.
ii. Salt fog when tested according to ASTM B117 – 11 and evaluated according to
AASHTO R 31-09, the paint system shall exhibit no spontaneous delamination and
not exceed the following acceptance levels shown in Table 24-5 after 5,000 hours of
salt fog exposure.
Table 24-5: Acceptance levels for salt fog
Salt Fog Acceptance Criteria (max.)
Blister Conversion Value Rust Criteria
After 4000 Hours Maximum Creep Average Creep
10 6 mm 2 mm
iii. Cyclic exposure when tested according to ASTM D5894 – 10 and evaluated
according to AASHTO R 31-09, the paint system shall exhibit no spontaneous
delamination and not exceed the following acceptance levels shown in Table 24-6
after 5,040 hours of cyclic exposure.
Table 24-6: Acceptance levels for cyclic exposure
Cyclic Exposure Acceptance Criteria (max.)
Blister Conversion Value Rust Criteria
Maximum Creep Average Creep
10 13 mm 7 mm
iv. The adhesion to an abrasively blasted steel substrate shall not be less than 6.2 MPa
when tested according to ASTM D4541 - 09e1 Annex A4.
24.3.2.4 Paint System No. 4 – Acrylic Latex System

1. Primer coat on bare steel (not galvanized): Acrylic latex primer, conforming to composition
and performance requirements of SSPC-Paint 23 standard.
Intermediate coat: an intermediate coat of acrylic latex conforming to SSPC Paint 24 shall
be applied.
2. Top coat: a top coat of acrylic latex conforming to SSPC-Paint 24 shall be applied.
24.3.2.5 Paint System No. 5 – Low VOC Alkyd System

1. Primer coat on bare steel (not galvanized): Low VOC Alkyd primer, conforming to
composition and performance requirements of SSPC-Paint 31 standard.
Page 24-16
2. Intermediate coat: an intermediate coat of Low VOC alkyd conforming to SSPC- Paint 104
shall be applied.
3. Top coat: a top coat of Low VOC silicone alkyd conforming to SSPC-Paint 21 shall be
applied.
24.3.3 Paint Systems for Surfaces with Existing Sound Paint

The Contractor shall furnish one of the paint systems shown in Table 24-7. The required system or
choice of systems shall be shown on the Contract plans or in the Particular Specifications.
applied to all painted structural iron and steel surfaces shall be Paint System No. 6 Moisture-cured
Polyurethane System.
The Contractor shall confirm the selected paint system is compatible with the existing paint.
At least 14 days before ordering paint, the Contractor shall verify compatibility of the proposed
system with the existing system as follows:
a. Select a test area of at least 2.8 square meter in a condition representative of the condition
of the structure. Perform the specified level of surface preparation, and apply the proposed
system to the existing topcoat and to the existing primer. Observe for lifting, bleeding,
blistering, wrinkling, cracking, flaking, or other evidence of incompatibility.
b. Verify that no indication of incompatibility exists at least 14 days after the application of each
product. Perform adhesion tests according to ASTM D3359 - 09e2, method A. Notify the
Owner immediately if adhesion testing fails at the interface of the existing system and
substrate or between the existing finish coat and primer. An adhesion failure indicates
incompatibility. Choose a more compatible paint system.
Table 24-7: Structural iron and steel coating systems for surfaces with existing sound paint
Paint System1
6 7 8
Coat
Aggressive Less Aggressive Less Aggressive
Environments Environments
Environments
Aromatic Moisture-cured Low viscosity epoxy

Low VOC alkyd
Primer Polyurethane sealer
2-3 mils DFT
Aromatic Moisture-cured
Low VOC alkyd Epoxy
Intermediate Polyurethane
2-3 mils DFT
Aliphatic Moisture-cured Low VOC silicone- Aliphatic

Top Coat Polyurethane alkyd Polyurethane
Total
Thickness2
Note 1: System 6 is for the corrosion protection of iron and steel in aggressively corrosive
atmospheric environments such as marine, coastal, or industrial. System 7 or 8 is for use in those
Page 24-17
environments with less humidity and free from high concentrations of salts or pollutants that cause
aggressive corrosion environments.
24.3.3.1 Paint System No. 6 – Moisture Cured Polyurethane System

The moisture cured polyurethane paint system No. 6 shall consist of an aromatic moisture cured
polyurethane primer, an aromatic moisture cured polyurethane intermediate coat, and aliphatic
moisture cured polyurethane top coats conforming to the requirements of Article 24.3.2.3. It is
intended for field painting blast-cleaned existing structures.
24.3.3.2 Paint System No. 7 – Low VOC Alkyd System

The low VOC alkyd paint system No. 7 shall consist of Low VOC Alkyd primer, Low VOC Alkyd
intermediate coat, and a Low VOC silicone alkyd top coats conforming to the requirements of Article
24.3.2.324.3.2.5.
24.3.3.3 Paint System No. 8 – Low Viscosity Epoxy System

1. Primer coat: Two-pack low viscosity epoxy sealer with a polyamide or similar curing agent
conforming to the manufacturer recommendations and approved to APAS Specification
2971. It shall be physically and chemically compatible with the existing sound paint and later
coatings in the system.
2. Intermediate coat: an intermediate coat of epoxy polyamide conforming to SSPC- Paint 22
shall be applied.
3. Top coat: a top coat of an aliphatic polyurethane acrylic, conforming to SSPC-Paint 36 and
Paragraph 3 of Article 24.3.2.1 shall be applied.
24.3.4 Paint System No. 9 for New Internal Invisible Surfaces

1. Primer coat: Inorganic zinc dust pigment shall be a minimum of Type II in accordance with
ASTM D520 - 00(2011). Inorganic zinc rich primer shall meet the requirements of SSPC-
Paint 20, Type I, Level 2.
2. Top Coat: The top coat shall be one coat of white polyamide or cycloaliphatic amine epoxy
coating. The performance requirements for gloss and color retention are not applicable.
24.3.5 Surface Preparation of Iron and Steel Surfaces

All exposed structural iron and steel surfaces, except galvanised or metallised surfaces, shall be
cleaned and painted.
The Contractor shall not remove sound paint of existing structures unless specifically required by
the Contract documents.
24.3.5.1 New surfaces or Surfaces with all Existing Paint Removed

New surfaces of iron and steel to be painted, including galvanized surfaces and surfaces with paint
removed, shall be thoroughly cleaned to the condition specified herein by removing rust, loose mill
scale, welding slag, dirt, oil, grease, and other foreign substances.
The Contractor shall remove all dirt, mill scale, rust, paint, and other foreign material from exposed
surfaces by Blast Cleaning in accordance with Article 24.3.5.3, Method D, unless otherwise specified
in the Contract documents or approved in writing by the Engineer.
Page 24-18
The Contractor shall use compressed air that is free from oil or moisture and does not show black
or wet spots when tested according to D4285 - 83(2012). Unwashed sand or abrasives that contain
salts, dirt, oil, or other foreign matter shall not be used. Before blast cleaning near machinery, the
Contractor shall seal bearings, journals, motors, and moving parts against entry of abrasive dust.
The Contractor shall blast clean with clean dry slag, mineral grit, steel shot, or steel grit. A suitable
gradation shall be used to produce a dense, uniform anchor pattern. An anchor profile height of 1 to
2 mils shall be produced, but not less than that recommended by the paint system manufacturer's
product data sheet. The Contractor shall measure anchor profile height using the tape method
according to ASTM D4417 - 11.
The same day cleaning is performed, the Contractor shall remove dirt, dust, and other debris from
the surface by brushing, blowing with clean dry air, or vacuuming and shall apply the first coat of
paint to the blast cleaned surfaces. If the cleaned surfaces rust or become contaminated before
painting, the blast cleaning shall be repeated.
24.3.5.2 Surfaces with Existing Sound Paint

All areas to be painted shall be washed by the Contractor with pressurized water to remove dirt,
surface chalking, loose rust, and contaminants such as chlorides. A wash water pressure of at least
3.45 MPa shall be maintained. All wash water and removed waste shall be captured according to
appropriate regulations.
The Contractor shall clean surfaces having sound paint according to Method B (Hand Tool Cleaning),
Method C (Power Tool Cleaning), or Method E (Commercial Blast Cleaning) of Article 24.3.5.3 to
remove dirt, loose mill scale, loose rust, or paint that is not firmly bonded to the underlying surface.
The Contractor shall clean small areas that show pinhole corrosion, stone damage from traffic, or
minor scratches. At least 50mm shall be cleaned beyond the damaged areas.
The Contractor shall feather edges of remaining old paint to achieve a reasonably smooth surface.
The same day hand or power tool cleaning is performed, the Contractor shall remove dirt, dust, and
other contaminants from the surface with Method A (Solvent-cleaning) in accordance with Article
24.3.5.3, and shall spot paint all bare steel areas with the first coat of paint. If the cleaned surfaces
rust or become contaminated before painting, solvent cleaning shall be repeated. All damage to
sound paint shall be repaired by the Contractor by applying the entire system.
24.3.5.3 Cleaning Methods of Iron and Steel Surfaces

Methods used for cleaning iron and steel surfaces shall conform to the specifications in this article.
a. Method A: Solvent Cleaning
It is intended that solvent cleaning shall be used prior to the application of paint, and with other
methods of surface cleaning. Method A of cleaning shall be performed in accordance with SSPC-SP
1 and the following requirements:
Soil, cement spatter, drawing compounds, salts, soluble welding flux residues, or other foreign matter
(other than grease or oil) shall be removed by cleaning with solutions of alkaline cleaners, providing
brushing with stiff fibre or wire brushes, or by scraping, or by cleaners followed by a fresh water
rinse, or by a combination of these methods.
Oil or grease shall be removed by any of the following methods:
1. Wiping or scrubbing the surface with rags or brushes wetted with solvent.
2. Spraying of the surface with solvent. The final spraying shall be done with clean
solvent.
3. Vapor degreasing, using stabilized chlorinated hydrocarbon solvents.
4. Complete immersion in a tank or tanks of solvent.
Page 24-19
5. Emulsion cleaners or steam cleaning may be used in place of the methods above,
provided that after treatment the surface shall be washed with hot water to remove
detrimental residue.
b. Method B: Hand Tool Cleaning
Method B of cleaning shall be performed in accordance with SSPC-SP 2 and the following
requirements:
After oil, grease, soluble welding flux residues, or salts are removed by methods prescribed under
Method A, loose mill scale, loose rust, and other detrimental foreign matter shall be removed by
hand brushing, hand sanding, hand scraping, hand chipping, hand hammering, or other methods
using hand impact tools, or by a combination of these methods.
All accessible weld flux and spatter shall be removed by hand scraping or by hand impact tools
followed by wirebrushing.
Areas which will be inaccessible after assembly shall be cleaned before assembly.
All bolts, welds, corners, joints, and openings shall be properly cleaned. The steel wires of the wire
brushes shall have sufficient rigidity to clean the surface, shall be kept free of excess foreign matter,
and shall be discarded when they are no longer effective. Hand scrapers shall be kept sharp enough
to be effective. The tools shall be operated in such a manner that no burrs or sharp ridges are left
on the surface and no sharp cuts made into the steel.
After hand cleaning is completed, dust and other loose matter shall be removed from the surface.
Detrimental amounts of grease or oil still present shall be spot cleaned with solvent.
c. Method C: Power Tool Cleaning
Method C of cleaning shall be performed in accordance with SSPC-SP 3 and the following
requirements:
After oil, grease, soluble welding flux residues, or salts are removed by the methods prescribed
under Method A, loose mill scale, loose rust, weld flux, and spatter shall be removed with power wire
brushes, power impact tools, power grinders, power sanders, or by any combination of these
methods.
Power wire brushes shall be of the rotary cup type of suitable size for entering all accessible
openings, angles, joints, and corners. The steel wires of such brushes shall have sufficient rigidity to
clean the surface, shall be kept free of excess foreign matter, and shall be discarded when they are
no longer effective.
Power impact tools shall include power-driven chipping or scaling hammers, rotary scalers, single or
multiple piston scalers, or other similar impact cleaning tools. Cutting edges of all tools shall be kept
in effective condition.
Sanding or abrasive materials used in power sanding shall be discarded when they become
ineffective.
Rivet heads, cracks, crevices, lap joints, fillet welds, and re-entrant angles shall be cleaned by the
use of power wirebrushes, sharp chisels used in chipping, or scaling hammers, rotary grinders, or
sanders, or by a combination of such tools.
All tools shall be operated in such a manner that no burrs or sharp ridges are left on the surface and
no sharp cuts are made into the steel. Areas inaccessible for cleaning by power tools but accessible
for hand tool cleaning shall be cleaned by methods outlined under Method B.
After these cleaning operations are completed, dust and other loose matter shall be removed from
the surface. If detrimental amounts of grease or oil are still present, these areas shall be spot cleaned
with solvent.
Page 24-20
d. Method D: White Metal Blast Cleaning

Method D of cleaning shall be performed in accordance with SSPC-SP 5 and the following
requirements:
After heavy deposits of oil, grease, soluble welding flux residues, or salts are removed by the
methods prescribed under Method A, loose mill scale, rust-scale, and other foreign matter shall be
removed and the entire surface thoroughly cleaned by blasting except that excessive rust-scale shall,
preferably, be removed by impact tools, as prescribed under Methods B and C. Any of the following
blast cleaning methods may be used:
1. Dry sandblasting, using compressed air blast nozzles and dry sand.
2. Wet or water-vapor sandblasting, using compressed air blast nozzles and water and
sand.
3. Grit-blasting, using compressed air blast nozzles and grit made of crushed cast iron,
malleable iron, steel, or other metals.
4. Shot-blasting, using compressed air nozzles and cast-iron, malleable-iron, or steel
pellets.
5. Closed, recirculating nozzle-blasting using compressed air or vacuum with any of the
above named abrasives.
6. Grit-blasting using centrifugal wheels and grit made of crushed cast iron, malleable
iron, steel, or other metals.
7. Shot-blasting using centrifugal wheels and cast-iron, malleable-iron, or steel pellets.
Blast cleaning shall be performed with SAE No. S-330 shot or smaller, SAE No. C-25 grit or smaller,
or dry sand passing through No. 16 sieve (1.18 mm), U.S. Standard Sieve Series.
The surface, if dry blasted, shall be brushed with clean brushes made of hair, bristle, or fiber, or
blown off with compressed air (from which detrimental oil and water have been removed), or cleaned
by vacuum, for the purpose of removing any traces of blast products from the surface, and also for
the removal of abrasive from pockets and corners.
The surface, if wet sandblasted, shall be cleaned by rinsing with fresh water to which sufficient
corrosion inhibitor has been added to prevent rusting, or with fresh water followed immediately by
an inhibitive treatment. This cleaning shall be supplemented by brushing, if necessary, to remove
any residue.
The compressed air used for nozzle blasting shall be free of detrimental amounts of water or oil.
Adequate separators and traps shall be provided.
Blast cleaning operations shall be done in such a manner that no damage is done to partially or
entirely completed portions of the work.
The blast-cleaned surface shall be examined for any traces of oil, grease, or smudges deposited in
the cleaning operations. If present, they shall be removed as outlined under Method A. The Engineer
will assure that surfaces have been cleaned prior to painting.
e. Method E: Commercial Blast Cleaning
Method E of cleaning shall be performed in accordance with SSPC-SP 6 and the following
requirements:
Commercial blast cleaned surface, when viewed without magnification, shall be free of all visible oil,
grease, dust, dirt, mill scale, rust, coating, oxides, corrosion products, and other foreign matter,
except for staining as noted. Random staining shall be limited to no more than 33 percent of each
unit area of surface, which shall be 75 mm x 75 mm, and may consist of light shadows, slight streaks,
or minor discolorations caused by stains of rust, stains of mill scale, or stains of previously applied
coating.
Page 24-21
24.3.6 Sampling and Testing

Unless otherwise specified, sampling shall be performed by the Engineer in accordance with FSS
141 method 1021, and the testing of the paint properties will be according to the procedures and
methods listed in FSS 141, and as shown in
Table 24-8:
Table 24-8: Methods of testing Paint properties
Test Method
Percentage of pigment 4021
Isolation of vehicle 4032
Non-volatile in vehicle 40531
Ahthalic anhydride 7021
Uncombined water 4081 or 4082
Consistency: Krebs-Stormer 4281
Coarse particles and skins 4091
Weight per gallon 4184
Set to touch time 4061
Condition in container 3011
Brushing properties 2141, 4321
Skinning 4141
Rosin and resin derivatives 50312
Storage stability 4142
Dry through time 4061
Fineness of grind 4411
Note 1: A gravity convection oven may be used to determine the non-volatile content of the
supercentrifuged vehicle if the procedure outlined in FSS 141 method 4041 is modified as follows:
Weigh accurately from 0.8 to 1.2 g. of sample (by difference), heat for one hour, cool and weigh. Use
the lower value to calculate the percentage of non-volatile matter.
Note 2: Make the test on a portion of the isolated vehicle.
24.3.7 Time of Application

The prime coat of paint, or pretreatment when specified, shall be applied as soon as possible after
the surface has been cleaned and before deterioration of the surface occurs. Surfaces that have
been cleaned with power tool or blast cleaning shall be prime coated within 8 hours after cleaning
before visible or detrimental rusting occurs. Any oil, grease, soil, dust, or foreign matter deposited
Page 24-22
on the surface after the surface preparation is completed shall be removed prior to painting. In the
event that rusting occurs after completion of the surface preparation, the surfaces shall be again
cleaned.
Particular care shall be taken to prevent the contamination of cleaned surfaces with salts, acids,
alkali, or other corrosive chemicals before the prime coat is applied and between applications of the
remaining coats of paint. Such contaminants shall be removed from the surface. Under these
circumstances, the pretreatments or, in the absence of a pretreatment, the prime coat of paint shall
be applied immediately after the surface has been cleaned.
24.3.8 Storage of Paint and Thinner

All paint and thinner should preferably be stored in a separate building or room that is well ventilated
and free from excessive heat, sparks, flame, or the direct rays of the sun. Paints susceptible to
damage from excessive heat shall be kept in a cooled storage space when necessary. The
Contractor shall take all mitigation measures to minimize fire hazard, e.g. the storage of cloths or
cotton waste in metal containers or destroyed on daily basis.
All containers of paint shall remain unopened until required for use. Containers which have been
opened shall be used first.
Paint which has livered, gelled, or otherwise deteriorated during storage shall not be used.
Thixotropic materials which may be stirred to attain normal consistency are satisfactory.
24.3.9 Mixing and Thinning

All ingredients in any container of paint shall be thoroughly mixed before use and shall be agitated
often enough during application to keep the pigment in suspension.
Paint mixed in the original container shall not be transferred until all settled pigment is incorporated
into the vehicle. This does not imply that part of the vehicle cannot be poured off temporarily to
simplify the mixing.
Mixing shall be by mechanical methods, except that hand mixing will be permitted for containers up
to 20 liters in size.
Mixing in open containers shall be done in a well ventilated area away from sparks or flames.
Paint shall not be mixed or kept in suspension by means of an air stream bubbling under the paint
surface.
Where a skin has formed in the container, the skin shall be cut loose from the sides of the container,
removed, and discarded. If such skins are thick enough to have a practical effect on the composition
and quality of the paint, the paint shall not be used.
The paint shall be mixed in a manner which will ensure breaking up of all lumps, complete dispersion
of settled pigment, and a uniform composition. If mixing is done by hand, most of the vehicle shall
be poured off into a clean container. The pigment in the paint shall be lifted from the bottom of the
container with a broad, flat paddle, lumps shall be broken up, and the pigment thoroughly mixed with
the vehicle. The poured-off vehicle shall be returned to the paint with simultaneous stirring, or pouring
repeatedly from one container to another until the composition is uniform. The bottom of the
container shall be inspected for unmixed pigment.
Tinting pastes or colors shall be wetted with a small amount of thinner, vehicle, or paint and
thoroughly mixed. The thinned mixture shall then be added to the large container of paint and mixed
until the color is uniform.
Paint which does not have a limited pot life, or does not deteriorate on standing, may be mixed at
any time before using, but if settling has occurred it must be remixed immediately before using. Paint
shall not remain in spray pots, painters' buckets, or similar containers overnight, but shall be gathered
into a container and remixed before use.
Page 24-23
No thinner shall be added to the paint unless necessary for proper application. In no case shall more
than 0.5 liter of thinner be added per 4 liters unless the paint is intentionally formulated for greater
thinning.
The type of thinner shall comply with the paint specification.
When the use of thinner is permissible, thinner shall be added to paint during the mixing process.
Painters shall not add thinner to paint after it has been thinned to the correct consistency.
All thinning shall be done under supervision of one acquainted with the correct amount and type of
thinner to be added to the paint. Coating materials shall be stirred at all times when adding thinner.
24.3.10 Application of Paint

24.3.10.1 General
The Contractor shall apply each coat to the wet film thickness as recommended by the paint
manufacturer to obtain the specified dry film thickness. The application rate of each coat shall be
verified by the Contractor with a wet film paint thickness gauge immediately after applying paint to
the surface. The application rate shall be confirmed by measuring the dry film thickness after the
solvent has evaporated from the surface.
The oldest of each kind of paint shall be used first. Paint shall be applied by brushing or spraying or
a combination of these methods. Daubers or sheepskins may be used when no other method is
practicable for proper application in places of difficult access. Dipping, roller coating, or flow coating
shall be used only when specifically authorized by the Engineer.
Open seams at contact surfaces of built-up members which would retain moisture shall be caulked
with red lead paste or other approved material before the second undercoat of paint is applied.
Paint shall not be applied when the surrounding air temperature and surface temperature is below
10°C. Paint shall not be applied when the temperature is expected to drop to 0°C before the paint
has dried. Paint shall not be applied to iron and steel at a temperature over 32°C unless the paint is
specifically formulated for application at the proposed temperature, nor shall paint be applied to iron
and steel which is at a temperature that will cause blistering or porosity or otherwise will be
detrimental to the life of the paint.
Paint shall not be applied in fog or mist, or when it is raining or when the relative humidity exceeds
85 percent. Paint shall not be applied to wet or damp surfaces.
Any applied paint exposed to excess humidity, rain, or condensation shall first be permitted to dry.
The damaged areas of paint shall be removed, the surface again prepared and then repainted with
the same number of coats of paint of the same kind as the undamaged areas.
If stripe painting is stipulated or if the Contractor chooses to do so at his option, all edges, corners,
crevices, rivets, bolts, welds, and sharp edges shall be painted with the priming paint by brush before
the steel receives its first full prime coat of paint. Such striping shall extend for at least 25 mm from
the edge. When practicable, this stripe coat shall be permitted to dry before the prime coat is applied;
otherwise, the stripe coat shall set to touch before the full prime coat is applied. However, the stripe
coat shall not be permitted to dry for a period long enough to allow rusting of the unprimed steel.
When desired, the stripe coat may be applied after a complete prime coat.
To the maximum extent practical, each coat of paint shall be applied as a continuous film of uniform
thickness, free of pores. Any thin spots or areas missed in the application shall be repainted and
permitted to dry before the next coat of paint is applied.
Each coat of paint shall be in a proper state of cure or dryness before the application of the
succeeding coat.
Page 24-24
24.3.10.2 Brush Application

Brush application should always be undertaken using an appropriately sized, good quality synthetic
or natural fibre brush compatible with the product being applied and acceptable to the paint
manufacturer. This application technique shall be generally used for coating small areas with
decorative paints and for surface priming, where good penetration of rusty steel substrates is
required. It is particularly suitable for the application of stripe coats and for coating complex areas
where the use of spray methods would lead to considerable losses due to overspray and associated
dry spray problems.
The Contractor shall use brushes that have sufficient bristle body and length to spread the paint in
a uniform film. Round, oval shaped brushes, or flat brushes no wider than 115mm shall be used.
The Contractor shall evenly spread and thoroughly brush out the paint as it is applied.
Paint shall be worked into all crevices and corners where possible and surfaces not accessible to
brushes shall be painted by spray, daubers, or sheepskins. All runs or sags shall be brushed out.
There shall be a minimum of brush marks left in the applied paint.
Brush application shall require considerable care when applying non-convertible coatings over one
another, e.g. vinyl on top of vinyl. In these cases, the solvents in the wet coat readily redissolve the
previously dry bottom coat. Even a mild degree of the brushing out normally given to topcoats will
cause pick-up of the previous coat and result in a very poor finish. Even, light strokes shall be used
in these circumstances, covering a particular area with one or two brush strokes, and on no account
working the bristles into the previous coat.
24.3.10.3 Spray Application of Paint

The equipment used for spray application of paint shall be suitable for the intended purpose, shall
be capable of properly atomizing the paint to be applied, and shall be equipped with suitable pressure
regulators and gages. The air caps, nozzles, and needles shall be those recommended by the
manufacturer of the equipment for the material being sprayed. The equipment shall be kept in
satisfactory condition to permit proper paint application. In closed or recirculating paint spray
systems, where gas under pressure is used over the liquid, the gas shall be an inert one, such as
nitrogen.
Traps or separators shall be provided to remove oil and water from the compressed air. These traps
or separators shall be of adequate size and shall be drained periodically during operations. The air
from the spray gun impinging against the surface shall show no water or oil.
Paint ingredients shall be kept properly mixed in the spray pots or containers during paint application
either by continuous mechanical agitation or by intermittent agitation as frequently as necessary.
The pressure on the material in the pot and of the air at the guns shall be adjusted for optimum
spraying effectiveness. The pressure on the material in the pot shall be adjusted when necessary
for changes in elevation of the gun above the pot. The atomizing air pressure at the gun shall be
high enough to atomize the paint properly but not so high as to cause excessive fogging of paint,
excessive evaporation of solvent, or loss by overspray.
Spray equipment shall be kept sufficiently clean so that dirt, dried paint, and other foreign materials
are not deposited in the paint film. Any solvents left in the equipment shall be completely removed
before applying paint to the surface being painted.
Paint shall be applied in a uniform layer, with overlapping at the edge of the spray pattern. The spray
pattern shall be adjusted so that the paint is deposited uniformly. During application, the gun shall
be held perpendicular to the surface and at a distance which will ensure that a wet layer of paint is
deposited on the surface. The trigger of the gun shall be released at the end of each stroke.
All runs and sags shall be brushed out immediately or the paint shall be removed and the surface
repainted.
Page 24-25
Areas inaccessible to the spray gun shall be painted by brush. If not accessible by brush, daubers
or sheepskins shall be used. Brushes shall be used to work paint into cracks, crevices, and blind
spots which are not adequately painted by spray.
24.3.10.4 Shop Painting

Shop painting shall be done after fabrication and before any damage to the surface occurs from
weather or other exposure, and shall be applied in accordance with the procedures of AISC-420-
10/SPE-QP3 and SSPC-PA 1. The surface preparation shall be in accordance with SSPC-SP 10/
NACE No. 2.
Shop coats consisting of the prime coat, intermediate and finish coats shall be applied in the
manufacturer’s plant unless otherwise specified in the Contract documents. The prime Coat shall be
applied in the shop promptly after blast cleaning, but in no case shall the prime coat be applied more
than 8 hours after blast cleaning or after visible or detrimental rusting occurs. Only Nylon web slings
or padded lifting points shall be used to move shop primed steel to prevent damage to the coating.
Surfaces damaged during shipment and handling shall be repaired using the same paint system as
applied in the shop except that the primer coat shall be repaired using an Organic Zinc Primer when
the primer Coat is repaired in the field. No paint shall be applied to areas to be welded in the field.
No Vinyl paint (wash or finish coat) shall be applied to any faying surfaces.
The manufacturer and or Contractor shall be required to guarantee his work against defective
workmanship or the use of defective materials for a period of ten years from the completion of works.
A shop coat of paint shall have a minimum dry film thickness of 38 microns. Shop contact surfaces
shall not be painted unless specified.
Unless otherwise specified, surfaces to be in contact only after field erection shall be painted except
where the paint will interfere with assembly.
Surfaces not to be in contact but will be inaccessible after assembly shall receive either the full paint
coats specified or three shop coats of the specified primer before assembly.
The areas of iron and steel surfaces to be in contact with concrete shall not be painted. Unless
otherwise indicated on the Contract plans, the areas of iron and steel surfaces to be in contact with
wood shall receive either the full paint coats specified or three shop coats of the specified primer.
If the paint would be harmful to a welding operator or would be detrimental to the welding operation
or the finished welds, the iron and steel shall not be painted within a suitable distance from the edges
to be welded. Welding through inorganic zinc paint systems will not be permitted unless approved
by the Engineer.
Antiweld spatter coatings shall be removed before painting. Weld slag and flux shall be removed by
methods at least as effective as those specified for the cleaning.
Machine-finished or similar surfaces that are not to be painted, but do require protection, shall be
protected with a coating of rust inhibitive petroleum, or other coatings which may be more suitable
for special conditions.
Erection marks and weight marks shall be copied on areas that have been previously painted with
the shop coats.
24.3.10.5 Field Painting

Iron and steel structures shall be painted in accordance with SSPC-PA 1 as soon as practicable after
erection.
The applicator shall stir, strain, and keep coating materials at a uniform consistency during
application. Where the Engineer permits thinning, the applicator shall not reduce the coating material
more than is necessary to obtain the proper application characteristics and to obtain the specified
Page 24-26
dry film thickness. The applicator shall not exceed the maximum thinning rate allowed by the
manufacturer. Coating materials shall be stirred at all times when adding thinner.
Where measurement of the dry film thickness may become difficult or dangerous unless the
Contractor maintains or provides suitable means of access, wet film measurement may be
authorized. In such cases the Engineer will pre-determine and notify the Contractor of the required
wet film thickness, for each type of paint, to comply with the minimum dry film thickness specified.
Iron and steel which has been shop coated shall be touched up with the same type of paint as the
shop coat. This touch up shall include cleaning and painting of field connections, welds, rivets, and
all damaged or defective paint and rusted areas. The Contractor may at his option apply an overall
coat of primer in place of touch up or spot painting.
Surfaces (other than contact surfaces) which are accessible before erection but which will not be
accessible after erection shall receive all field coats of paint before erection.
If possible, the final coat of paint shall not be applied until all concrete work is finished. If concreting
or other operations damage any paint, the surface shall be cleaned and repainted. All cement or
concrete spatter and drippings shall be removed before any paint is applied.
Wet paint shall be protected against damage from dust or other detrimental foreign matter to the
extent practicable.
24.3.10.6 Drying of Painted Iron and Steel

The maximum practicable time shall be allowed for paint to dry before recoating or exposure. No
drier shall be added to paint on the job unless specifically called for in the specification for the paint.
No painted iron and steel shall be subjected to immersion before the paint is dried through. Paint
shall be protected from rain, condensation, and contamination, until dry, to the fullest extent
practicable.
24.3.10.7 Handling of Painted Iron and Steel

Painted iron and steel shall not be handled until the paint has dried, except for necessary handling
in turning for painting or stacking for drying.
Paint which is damaged in handling shall be scraped off and touched up with the same number of
coats and kinds of paint as were previously applied to the iron and steel.
Painted iron and steel shall not be loaded for shipment or shipped until it is dry.
Precautions shall be taken to minimize damage to paint films resulting from stacking members.
24.3.10.8 Measurement of Dry Film Thickness (DFT) of Paints

When a coating is applied to an iron or steel substrate, previously blast cleaned with abrasive grit or
shot, the measurement of its dry film thickness is more complicated than that of a coating applied to
a smooth steel substrate. The measurement results are influenced by the profile of the abrasive
blasted surfaces which changes from point to point, instrumentation, and dry film thicknesses to be
measured. The DFT shall be measured using a non-destructive magnetic gauge, which shall give a
value measured from the surface of the coating to the magnetic plane within the surface profile. The
magnetic plane shall be the theoretical point within the surface profile that the DFT gauge sees as
being the average position of the substrate.
a. Instrumentation
Dry film thickness (DFT) shall be measured using Pull-Off (Type 1) or Fixed- Probe (Type 2)
Magnetic Gages. Type 1 Gages include Tinsley, Elcometer, Microtest, and Inspector models. Type
2 Gages include Elcometic, Ninitector, General Electric, Verimeter, and Accuderm models. Other
types of non-destructive electronic devices may be used if approved by the Engineer.
Page 24-27
DFT gauges shall be calibrated on smooth or blasted steel panels and a correction factor for surface
profile shall be considered. BS EN ISO 2808:2007, BS 3900-C5:2007, ISO 19840:2012 and SSPC-
PA 2 are accepted standards for measuring DFT.
b. Calibration
i. Type 1 (Pull-off) Magnetic Gages measure the coating thickness on a series of
reliable standards covering the expected range of paint thickness. The Contractor
shall record the calibration correction either + or - required at each standard
thickness. To guard against gage drift during use, the Contractor shall re-check
occasionally with one or more of the standards.
When the gage adjustment has drifted so far that large corrections are needed, the Contractor is
advised to re-adjust closer to the standard values and recalibrate.
For Type 1 gages, the preferred basic standards are small, chrome-plated steel panels that may be
available from the National Institute of Standards and Technology (NIST) in coating thicknesses from
13 to 203 microns.
Plastic shims of certified thicknesses in the appropriate ranges may also be used to calibrate the
gages. The gage is held firmly enough to press the shim tightly against the steel surface. The
Contractor shall record the calibration correction as above.
ii. Type 2 (Fixed Probe) Magnetic Gages. Shims of plastic or of non-magnetic metals
laid on the appropriate steel base (at least 8 x 8 x 0.32 cm) are suitable working
standards. These gages are held firmly enough to press the shim tightly against the
steel surface. The Contractor shall avoid excessive pressure that might indent the
plastic or, on a blast cleaned surface, might impress the steel peaks into the
undersurface of the plastic.
As per the National Institute of Standards and Technology (NIST), standard panels shall not be used
to calibrate Type 2 gauges.
c. Measurement Procedures
To determine the effect of the substrate surface condition on the gauge readings, access is required
to some unpainted areas.
Repeated gage readings, even at points close together, may differ considerably due to small surface
irregularities. Three gage readings should therefore be made for each spot measurement of either
the substrate or the paint. The Contractor shall move the probe a short distance for each new gage
reading. The Contractor shall discard any unusually high or low gage reading that cannot be
repeated consistently. The average of the three gage readings shall be taken at the spot
measurement.
i. Measurement with Type 1 (Pull-Off) Gage. The Contractor shall:
•
Measure (A), the bare substrate, at a number of spots to obtain a representative
average value.
• Measure (B), the dry paint film, at the specified number of spots.
• Correct the (A) and (B) gage readings or averages as determined by calibration of
the gage. Subtract the corrected readings (A) from (B) to obtain the thickness of
the paint above the peaks of the surface.
ii. Measurement with Type 2 (Fixed Probe) Gage. The Contractor shall:
• Place a standard shim of the expected paint thickness on the bare substrate that
is to be painted. Adjust the gage in place on the shim so that it indicates the known
thickness of the shim.
• Confirm the gage setting by measuring the shim at several other areas of the bare
substrate. Re-adjust the gage as needed to obtain an average setting
representative of the substrate.
Page 24-28
• With the gage adjusted as above, measure the dry point film at three points. The
gage readings indicate the paint film thickness at the three points. The gage
readings indicate the paint thickness above the peaks of the surface profile.
• Re-check the gage setting at frequent intervals during a long series of
measurements.
• Make five separate spot measurements spaced evenly over each section of the
structure, 9.25 square meters in area, or of other area as may be directed by the
Engineer. The average of five spot measurements for each such section shall be
not less than the specified thickness. No single spot measurement (average of
three readings, in any section) shall be less than 80 percent of the specified
thickness.
• Since paint thickness is usually specified (or implied) as a minimum, greater
thickness that does not cause defects of appearance of functions, such as mud
cracking, wrinkling, etc., is permitted unless otherwise specified.
d. Special Notes
i. All of the above magnetic gages, if properly adjusted and in good condition, are
inherently accurate to within +15 percent of the true thickness of the coating.
ii. Much larger, external errors may be caused by variations in method of use of the
gages or by unevenness of the surface of the substrate or of the coating. Also, any
other films present on the steel (rust or mill scale or even a blast cleaned profile zone)
will add to the apparent thickness of the applied paint film.
iii. The surface of the paint and the probe of the gage must be free from dust, grease
and other foreign matter in order to obtain close contact of the probe with the paint
and also to avoid adhesion of the magnet. The accuracy of the measurement may
be affected if the coating is tacky or excessively soft.
iv. The magnetic gages are sensitive to geometrical discontinuities of the iron and steel,
as at holes, corners or edges. The sensitivity to edge effects and discontinuities
varies from gage to gage. Measurements closer than 25mm from the discontinuity
may not be valid unless the gage is calibrated specifically for that location.
v. Magnetic gage readings also may be affected by proximity to another mass of iron
and steel close to the body of the gage, by surface curvature, and by presence of
other magnetic fields.
vi. All of the magnets or probes must be held perpendicular to the painted surface to
produce valid measurements.
vii. Cleanup. Upon completion, and before final acceptance, the Contractor shall leave
the work site and adjacent areas in a neat and presentable condition satisfactory to
the Engineer.
24.4 Painting Galvanized Surfaces

The Contractor shall remove all oil, grease, or other contaminants on the surface by washing with a
mineral spirit solvent according to SSPC-SP 1. Unless otherwise specified in the Contract
documents, the Contractor shall apply one of the coating systems shown in Table 24-9, as selected
and approved by the Engineer.
Page 24-29
Table 24-9: Galvanized surface coating systems
Paint System
Coat
10 11
Aggressive Environment Less Aggressive Environment
Polyamide-cured, Rust-inhibitive Epoxy Vinyl Wash Primer

Primer
Epoxy Polyamide Exterior acrylic latex

Intermediate
Aliphatic Polyurethane Acrylic Exterior acrylic latex

Top Coat
Total
Thickness1

Test panels shall be galvanized in accordance with ASTM A123 / A123M – 12 prior to application of
subsequent coatings.
24.4.1 Paint System No. 10 – Polyamide Cured Rust Inhibitive

Epoxy System
1. Primer coat on galvanized surfaces: Polyamide-cured, rust-inhibitive epoxy primer
shall comply with the following minimum requirements:
Solids 47% by volume

Rust-inhibitive pigment 44% by weight
Non-volatile vehicle (epoxy resin) 20.7% by weight
All materials shall be applied in accordance with the manufacturer's directions. All surfaces
shall be thoroughly cleaned to remove any oil, soap or other deleterious material which may
affect the bond of the primer to the galvanized surfaces.
2. Intermediate coat: an intermediate coat of epoxy polyamide conforming to SSPC Paint

22 shall be applied.
3. Top coat: a top coat of an aliphatic polyurethane acrylic, conforming to SSPC-Paint 36
and Paragraph 3 of Article 24.3.2.1 shall be applied.
24.4.2 Paint System No. 11 – Vinyl Wash System

1. Primer coat on galvanized surfaces: Vinyl Wash primer, conforming to composition and
performance requirements of SSPC-Paint 27 standard.
2. Intermediate coat: an intermediate coat of acrylic latex conforming to SSPC-Paint 24 shall
be applied.
3. Top coat: a top coat of acrylic latex conforming to SSPC Paint 24 shall be applied.
Page 24-30
24.5 Painting Steel Sheet, H, Pipe Pilings, and other

Surfaces
Unless otherwise specified in the Contract documents, steel sheet, H and Pipe pilings that will be
installed in new fill, disturbed materials or fluctuating water tables shall be painted with amine-cured
coal tar epoxy coating. The H-piles and sheet piling shall be painted 76 mm above the stabilization
slab and to a 1.5 meter minimum below new fill material, disturbed soil or the lowest elevation of
fluctuating water tables. Steel piles exposed in water shall be coated the full height exposed to water
plus a 1.5 meter embedment length. The final painting requirements shall be approved by the
Engineer.
This work shall also include other metal and concrete surfaces specified in the particular
specifications or indicated in the Contract plans to be painted with tar epoxy coating.
Steel surfaces to be painted shall be coated with a minimum of 470 microns DFT of amine-cured
coal tar epoxy. The paint shall be applied in two coats. The first coat of coal tar epoxy shall be applied
to a dry film thickness of 65 microns. The Contractor shall thin this first coat in accordance with the
manufacturer's recommendations. The covered surface shall be lightly sand blasted to achieve
proper penetration before the application of first coat. The second coat of coal tar epoxy shall be
applied to a dry minimum film thickness of 405 microns. The performance of the amine-cured coal
tar epoxy coating shall be equivalent to SSPC-Paint 16.
The heavy-duty, high solid, amine-cured, two component coal tar epoxy coating shall be shipped in
two parts that must be mixed together before use.
Amine-cured coal tar epoxy is a solvent borne paint and care must be taken to avoid inhalation of
spray mist or vapour as well as contact between the wet paint and exposed skin or eyes.
24.5.1 Surface Preparation

The Contractor shall remove weld spatter, protrusions, and laminations in steel. Welds shall be
grinded smooth in accordance with NACE RP0178-2003 (21002). All surface contaminants, oil and
grease shall be removed in accordance with SSPC-SP 1.
The Contractor shall abrasive blast with angular abrasive to an SSPC-SP 10/ NACE No. 2
cleanliness or higher. A surface profile of 2.0-4.0 mils shall be achieved.
24.5.2 Application Requirements

The manufacturer shall furnish to the Engineer a notarized statement that verifies that each individual
performance test has been completed and the results have met or exceeded the required standards.
All testing for approval of coatings shall be paid for by the Contractor.
The Contractor shall take all possible precaution measures to protect the coating from damage
during the driving operation. Coating repair strategies during installation shall be submitted by the
Contractor for the Engineer’s approval.Table 24-10 shows the required characteristics of coal tar
epoxy coating.
Table 24-10: Characteristics of coal tar epoxy coating
Component A Minimum Maximum
Weight (kilograms per litre) 1.46 kg/litre 1.50 kg/litre
Pigment (percentage by weight) 42% 47%
Non-volatile content (percentage by weight) 82.7% 86.2%
Page 24-31
Component A Minimum Maximum
Component B Minimum Maximum
Weight (kilograms per litre) 0.960 kg/litre 1.000 kg/litre
Non-volatile content (percentage by weight) 82.7% 86.7%
Mixed components Value
Total solids (percentage by volume, in accordance with ASTM 70%

D2697 - 03(2008))
Flash point (SETA) 54o C
Appearance low sheen Black, smooth
Mixing rate of 19 parts component A to 1 part Component B.

For field application and capable of being applied at a 405 microns DFT in one coat.
Pot life at 25°C and 80% relative humidity: 4 hours minimum.
Drying or curing time at 25°C: Dry to touch after 6 1/2 hours.
Shelf life: Six months from date of shipment, without livering or more than one third increase in
viscosity with restoration to original viscosity by not more than 10% addition of thinner.
24.6 Painting Aluminium Surfaces

24.6.1 Surface Preparation
The preparation of aluminium and aluminium alloy surfaces for painting shall be performed in
accordance with the procedures of ASTM D1730 – 09. The type of treatment shall be one or a
combination of the following types, as indicated in the Contract plans or specified in the particular
specifications, or approved by the Engineer.
A. Type A - Solvent Cleaning.
B. Type B - Chemical Treatments.
C. Type C - Anodic Treatments.
D. Type D - Mechanical Treatments.
24.6.2 Paint Systems for Aluminium Surfaces

All aluminium shall be painted with one of the following systems. The required system or choice of
systems shall be shown on the Contract plans or in the Particular Specifications.
applied to all aluminium surfaces shall be Paint System No. 11 Polyvinylidene Difluoride System.
The Contractor shall specify the coating film thickness especially along cut ends and sharp 90 degree
bends that shall be sufficient to prevent the ingress of moisture. The paint manufacturer shall provide
the minimum acceptable dry film thickness on the product data sheet.
Page 24-32
24.6.2.1 Paint System No. 11 - Polyvinylidene Difluoride Coating

The Contractor shall apply a polyvinylidene difluoride (PVDF) coating to sheet aluminium and
extrusions to provide protection and a decorative organic coating in accordance with the following
requirements and test procedures of AAMA 2605-05 and AAMA 620-02.
Table 24-11: Polyvinylidene difluoride (PVDF) requirements
Thickness 20-30 Mils DFT
Chemical Resistance (ASTM D543 - 06) Excellent
Abrasion Resistance (ASTM D4060 - 10) Excellent
Tensile Strength at Break (ASTM D638 - 10) 45 MPa
Coefficient of Friction (ASTM D1894 - 11e1) 0.4 Static, 0.3 Dynamic
Dielectric Strength (ASTM D149 - 09(2013)) 260 Volts per mil
Hardness (ASTM D2240 - 05(2010)) 80 (shore D)
24.6.2.2 Paint System No. 12 - Epoxy

The Contractor shall apply an epoxy primer corrosion inhibiting lead and chromate free conforming
to MIL-P-53022D followed by a chemical agent resistant coatings (CARC), Aliphatic Polyurethane,
Single Component, Chemical Agent Resistant Coating in accordance with MIL-C-53039D.
The epoxy primer shall be sprayed to a dry film thickness between 1.0 and 2.0 mils, and the chemical
agent resistant coating shall be applied to a minimum dry film thickness of 2.0 mils.
24.6.3 Aluminium in Contact with Dissimilar Metals

Where aluminium will contact dissimilar metals, the Contractor shall protect against galvanic action
by painting contact surfaces as follows, unless otherwise indicated in the Contract plans or specifies
in the particular specifications.
1. Where aluminium members are in contact with steel, prime both aluminium and steel
members with one coat of paint meeting Federal Specification TT-P-645B. Paint aluminium
with an additional coat of varnish containing 1 kg of aluminium pigment per gallon.
2. Where aluminium members are in contact with porous materials, masonry or concrete, apply
to the contact surfaces of the aluminium members a heavy coat of alkali resistant bituminous
paint.
3. Where aluminium members are embedded in concrete containing admixtures which are
corrosive to aluminium, or in concrete subjected to highly corrosive environments, prime the
aluminium with one coat of paint meeting Federal Specification TT-P-645B.
24.7 Painting Exposed Surfaces of Concrete Structures

Except where waterproofing or ceramic tiling is specified in the Contract documents, all concrete
surfaces shall be protected by a painting system as specified here below.
Painting works shall include all exposed items or surfaces throughout the concrete structure, except
as otherwise indicated on the Contract plans. Such surfaces shall include bridge deck
superstructures, including barriers/railings; all exposed surfaces of underpasses, tunnel walls, and
retaining walls, including barriers/railings or other structural elements; and internal surfaces where
specified on the Contract plans. Extent of this painting shall be as indicated in the Contract plans, as
directed by the Engineer, and as specified herein.
Page 24-33
Painting system shall consist of all coating system materials, including primers, intermediate or top
coats, and other materials applied as surface treatment of concrete.
24.7.1 General Requirements for Concrete Painting

All materials shall be from a specialized manufacturer whose products have proven to be highly
satisfactory in similar works. The concrete protection system shall have a valid British Board of
Agreement (BBA) Certificate (or equally recognized certification).
The paint system shall be recommended by the manufacturer for the specific use intended and it
shall be applied in full accordance with the manufacturer's instructions.
The paint manufacturer shall provide evidence, in the form of relevant, independent test certification
prior to approval, that proposed coatings are sufficiently durable against temperature, humidity,
ultraviolet (UV) light, and salt exposure. The manufacturer shall retest the coats to verify durability if
found necessary and requested by the Engineer.
The concrete protection system shall have a minimum 10 year warranty for both the coating and its
application provided to the satisfaction of the Engineer.
The Contractor, when submitting for approval of the Paint proposed to be used, shall enclose also a
list of works, executed in the Gulf Region, in which the same make of paint was successfully used.
Consequently the following Specifications are meant to give the necessary information which shall
enable the Contractor to identify the works to be carried out and the material and equipment to be
proposed for the Engineer's approval.
The paint shall be applied by an applicator approved by the manufacturer. The Contractor shall
submit to the Engineer for approval the name of the proposed paint applicator and evidence that the
applicator has successfully completed similar structural painting and coating projects over the
preceding five years. The applicator shall verify this experience by citing at least two projects
comparable to the Project that have been successfully accomplished. The approved applicator shall
prepare a method statement for substrate preparation, including covering materials and methods,
coating application, quality assurance (QA), and quality control (QC). The material manufacturer
shall endorse this method statement.
The manufacturer or supplier shall provide technical representative as an expert supervisor of all
painting work undertaken.
Prior to applying the system in the works, trial applications shall be carried out on trial panels made
by the Contractor. The trials shall demonstrate the method proposed for applying the system,
coverage, coating thickness, colour and final appearance of the coating. Representatives of the
coating manufacturers shall be present at the trials and the surface preparation and application of
the coatings shall be carried out in accordance with their recommendations. The Contractor shall, at
his own expense, surface coat as many panels as required to satisfy the Engineer that the panel,
when accepted, will form the standard against which the corresponding coating in the works will be
judged. No application of the coating in the works shall be undertaken until trials have been
completed to the Engineer's satisfaction.
The Contractor shall not proceed with the surface finish or making good concrete surfaces until he
has received the Engineer's permission to do so and he shall not apply cement slurry or mortar or
any other coating to the concrete surfaces from which the shuttering has been struck until the
concrete has been inspected and approved by the Engineer.
The Contractor shall, on the written instruction of the Engineer, remove and reconstruct any such
portion of the work which, in the opinion of the Engineer, is unsatisfactory as regards quality of
concrete, incorrect dimension of the cast portion, badly placed or insufficient reinforcement,
honeycombing or other such cause as shall render the construction not up to the standard required
and which, in the opinion of the Engineer, may prejudicially affect the strength or durability of the
construction.
Page 24-34
To protect passing traffic and adjacent surfaces from unintentional paint application, the Contractor
shall provide protective shields, drop cloths, masking, and other protective covering devices. These
devices shall protect surfaces that are not to be painted and shall meet the approval of the Engineer.
Misapplied paint on unspecified surfaces shall be completely removed using compounds that are
recommended by the paint manufacturer.
Bearing devices, painted steel surfaces, exposed bituminous materials and joint sealants adjacent
to members to be painted shall be masked off. All masking shall be removed following completion of
painting process.
24.7.2 Paint Test Areas for the Engineer’s Approval

The Contractor shall furnish a coat color conform to FED-STD-595B or Classic RAL System as
approved by the Owner. The Contractor shall provide the Engineer with color chips from the paint
supplier. Based on the Owner selection of colours the manufacturer shall prepare test areas for
inspection and final approval by the Owner. The Owner’s acceptance of colours, tones, glosses, and
aesthetic appearance shall be based on observing samples of varying colours, tones, and glosses.
The Contractor shall prepare and paint test areas of at least 5 square metres in at least four
inconspicuous locations on the structure to be painted, as directed by the Engineer. The Contractor
shall use these test areas to determine absorption rates, achieve colour uniformity, and prove the
suitability of the application technique. The Contractor shall conduct tests under the direct
supervision of a technical representative who is familiar with appropriate application techniques for
the specific coating being applied.
The Engineer's approval must be obtained prior to applying the coating system in the works. Before
approval is given, the Engineer will need to be satisfied as to the following:
a. All construction work in the immediate vicinity of the structure to be coated has been
completed.
b. The surface preparation of the structure has been completed.
c. The whole of the structure can be coated in a continuous operation with paint from the same
batch.
d. Adequate measures have been taken to protect the property of third parties, including
vehicles from coating splatters.
e. The weather conditions are in accordance with the coating manufacturer's directions for
coating applications.
f. The timing of all coating operations.
24.7.3 Project and Weather Conditions

All materials shall be delivered to the jobsite in original, new, and unopened packages and containers
bearing the following information:
• Manufacturer's name and label
• Name of the material
• Stock number
• Date of manufacture
• Contents by volume for major constituents
• Thinning and application instructions
• Colour number and name
Paints shall be applied only when surface temperatures and the surrounding air temperatures are
between 10° C and 32° C, unless otherwise permitted by the paint manufacturer in printed
instructions.
Unless a paint manufacture’s printed instructions permit painting in such conditions and the Engineer
approves such activity, the Contractor shall not apply paint under any of the following conditions:
Page 24-35
• In rain, fog, or mist

• When the relative humidity exceeds 85%
• When surfaces to be painted are damp or wet.
At the time of applying paint, the concrete surface must be dry as per ASTM D4263 - 83(2012).
However, a moisture level of 2.5% or less may be acceptable by the Engineer depending on the
paint manufacturer's specification. In this case, the Contractor shall use the radio frequency method
to measure the moisture content in concrete, with other non-destructive measurement technique as
approved by the Engineer. The results shall be compared for accuracy and submitted to the Engineer
for approval.
24.7.4 Surface Preparation and Application

The Contractor shall prepare surfaces and paint the structure’s exposed surfaces in compliance with
the Contract plans, the specifications in this chapter, and any directions from the Engineer.
On concrete surfaces that extend into earth, concrete paint shall extend at least 150 mm below the
finished grade. The Contractor must also propose a proper paint termination edge protection to the
Engineer for approval.
The Contractor, who shall perform all work to complete painting, must provide all necessary
materials, labour, tools, equipment, and appurtenances.
The surface cracks, if any, need to be verified to determine if the cracks are wet or dry cracks and
the repair methodology shall be to suit the crack criteria as approved by the Engineer. Horizontal
and vertical cracks are to be treated with specific method statements/ITP (Inspection and Test Plan)
all as approved by the Engineer.
Conditions deemed detrimental to the proper and timely completion of the work by the Contractor
shall be reported to the Engineer, in writing. Work shall not proceed until the Contractor has corrected
unsatisfactory conditions in a manner that is acceptable to the Engineer.
Before painting, the Contractor shall prepare and clean all surfaces in strict accordance with the
manufacturer’s instructions and as specified herein. Preparation and cleaning of surfaces shall
include, but not be limited to, the removal of dust, dirt, rust, scale, oil, and grease by manual or
mechanical methods. Prior to any paint application, surfaces shall be inspected by the Contractor
and the Engineer to ensure that they are free of any cracks that could be detrimental to the structural
member and that they are suitable for the formation of a durable paint film.
All hardware, hardware accessories, machined surfaces, plates, and similar items shall be covered
to protect them from the painting operation. Details for protection shall be submitted to the Engineer
for approval prior to application.
Painting and cleaning operations shall be scheduled to prevent contaminates from the cleaning
process from falling onto wet or newly painted surfaces.
All paints shall be applied in accordance with the manufacturer’s directions.
All paints shall be applied using rollers. Spray painting shall not be permitted. The first-coat
application shall be applied to the cleaned, pretreated or otherwise prepared surface, as soon as
practical after the preparation, and before subsequent surface deterioration.
Where there is evidence of defects or unsealed areas in the first application, the surfaces shall be
repaired, grouted, and resealed or primed again to the satisfaction of the Engineer.
A prime coat of material shall be applied by the Contractor to all surfaces that are required to be
painted or finished, and that have not been prime-coated by an earlier application.
Additional coats of paint shall be applied when undercoats, stains, or other conditions show through
the final coat of paint.
Page 24-36
The Contractor shall ensure that all surfaces, including edges, corners, and crevices receive a dry
film thickness equivalent to that of the flat surface.
Sufficient time between successive coats shall be allowed by the Contractor to permit drying.
Previous coats shall have dried to a state where it feels firm, does not deform or feel sticky under
moderate thumb pressure, and when the application of another coat of paint will not cause lifting or
loss of adhesion of the undercoat.
24.7.5 Paint Materials

Materials for painting shall be as specified herein. Thinners, driers, and colour pigments shall be
manufactured, finished, or approved by the accepted manufacturer for use with his products.
Paint materials shall be handled, stored, mixed, and applied in compliance with the
recommendations of the manufacturer. In the event it appears that conflicts exist between such
recommendations and the Contract documents, the Contractor shall refer the matter to the Engineer
for clarification.
The following are the specifications for the coating systems for use on concrete surfaces on the
Project.
If any cracks observed have no structural significance, and would allow for any thermal cracks etc.
in the future, a suitable crack bridging surface coating conforming to BS EN 1504-9:2008 shall be
used as approved by the Engineer. This will safeguard the structure in unnoticed durability issues.
24.7.5.1 Exposed Concrete Surfaces

The coatings shall be pigmented water based, aliphatic acrylic polymer based elastomeric coatings
providing a barrier to water, carbon dioxide, oxygen, airborne acidic gases, chloride ions and
sulphates but with the ability to allow the outward passage of water vapour which may otherwise
become entrapped. The coating shall be completely opaque, and shall have very high U.V.
resistance. Solvent based coating may be used with proper justification if approved by the Engineer.
The minimum physical properties of the coating system shall be:
• Weight per litre: 1.23 kg.
• Solids by weight: 64%
• Solids by volume: 50%
• The total dry film thickness of the coating shall not be less than 250 microns for aboveground
structures, and 300 microns for belowground structures. The Coating shall be applied in two
coats on a Silane/Siloxane, impregnating, internal-membrane forming, concrete clear sealant
primer.
The minimum performance test requirements for the coating system and primer shall be as shown
in Table 24-12 and Table 24-13.
Table 24-12: Pigmented elastomeric aliphatic acrylic coating for exposed concrete surfaces
Property Value Method
CO2 diffusion resistance (DIN > 175 metres Taywood method

53122-1 (2001-08)) – Equivalent
Air Layer Thickness
CO2 diffusion resistance - > 500 mm Taywood method

Equivalent thickness of 30MPa
concrete.
Page 24-37
Water vapour diffusion resistance Sd Value = 1.0m at 200 BS 3177:1959, Taywood

microns DFT method
Chloride ion diffusion coefficient No chloride ion diffusion after BS 3177:1959, Taywood
600 days immersion method
Reduction in Water Absorption  82 percent ASTM C642 - 06
Colour Retention No Visible colour change after Taywood method

2,500 hour of accelerated
weathering of sample
Reduction in Chloride Ion  92 percent AASHTO T 277-07 (2011)

Penetration (ASTM C1202 – 12)
Adhesion  2 N/mm2 on concrete or 90% ASTM D4541 - 09e1

failure in concrete surface
Abrasion Resistance  25 mg/1,000 cycle ASTM D4060 - 10
Tear resistance  15N/mm ASTM D624 - 00(2012)
Tensile Strength 5 MPa ASTM D412 - 06a(2013)
Crack Bridging  2 mm (at 40°C) BRE method
Freeze-Thaw Salt Scaling, 50 Unaffected ASTM C672 / C672M - 12

cycles (ASTM C672)
Resistance to Salt, Alkalis, and Resistant

Acids
Application Method Roller
Table 24-13: Silane/Siloxane primer for exposed concrete surfaces
Nonvolatile Content (Vol.) 5% to 10%
Reduction in Absorption  80% BS 1881-122:2011
Moisture-Vapour Transmission  220 g/m2 / Day
Reduction in Cl ion Penetration 90% BS 1881-124:1988
Reduction in absorption for the whole system shall be equal to or better than 95%. Adhesion of the
whole system to concrete shall be ≥ 2 MPa or 90% failure in concrete surface.
Page 24-38
24.7.5.2 Concrete Surfaces in Splash Zones

The coatings shall be pigmented water based, aliphatic acrylic polymer based elastomeric coatings
conforming to the requirements of Article 24.7.5.1. Solvent based coating may be used with proper
justification if approved by the Engineer.
The total dry film thickness of the coating shall be 350 microns applied in two coats on a
Silane/Siloxane, impregnating, internal-membrane forming, concrete clear sealant primer
conforming to the performance test requirement of Table 24-13.
Adhesion of the whole system to concrete after 500 hours in salt water shall be ≥ 2 MPa as per
ASTM D4541 - 09e1or 90% failure in concrete surface. The whole system shall have no blistering,
peeling or disbonding when immersed in deionised water for 30 days at 24°C. Reduction in Water
Absorption shall be 99% as per ASTM C642 – 06. Reduction in Chloride Ion Penetration shall be
97% as per AASHTO T 277-07 (2011) (ASTM C1202 – 12).
Page 24-39
INDEX
adjacent property, 24-2 Magnetic Gages, 24-27, 24-28

Adjacent surfaces, 24-2 mechanical methods, 24-23, 24-36
aluminium, 24-1, 24-4, 24-32, 24-33 notarized statement, 24-31
blast cleaning, 24-3, 24-19, 24-21, 24-26 outdoor exposure testing, 24-10
bottle brushes, 24-4 paint debris, 24-2
Brush application, 24-25 paint manufacturer, 24-3, 24-10, 24-24, 24-32,
calibration, 24-28 24-34, 24-35
chromium, 24-1, 24-10 painting operations, 24-1, 24-2
cleaning products, 24-2 Painting services, 24-1
coat color, 24-10, 24-14, 24-15, 24-35 pressurized water, 24-19
coating systems, 24-10, 24-12, 24-17, 24-29, Protective devices, 24-1
24-30, 24-37 regulations, 24-1, 24-10, 24-19
cold weather, 24-3 removed material, 24-2
condensation, 24-15, 24-24, 24-27 Salt fog, 24-16
contamination, 24-2, 24-13, 24-23, 24-27 sheepskin daubers, 24-4
corrosion, 24-1, 24-12, 24-17, 24-19, 24-21, Shop painting, 24-26
24-33 site hazards, 24-2
Cyclic exposure, 24-16 solvent cleaning, 24-19
dehumidification, 24-3 spray application, 24-25
deleterious material, 24-2, 24-30 spray equipment, 24-3
deterioration, 24-1, 24-22, 24-36 steel sheet, 24-31
disfigurement, 24-2, 24-9 structural iron and steel, 24-1, 24-9, 24-12, 24-
engineering controls, 24-3 17, 24-18
galvanized, 24-1, 24-13, 24-14, 24-16, 24-18, surface preparation, 24-2, 24-3, 24-17, 24-22,
24-30 24-26, 24-34, 24-35
gravity convection oven, 24-22 surface temperatures, 24-35
H and Pipe pilings, 24-31 test area, 24-17
hazardous material, 24-1, 24-2 Thinning, 24-23, 24-35
incompatibility, 24-17 volatile organic compounds, 24-10
independent test laboratory, 24-2 waste materials, 24-1
ingredients, 24-23, 24-25 water based, 24-37, 24-39
lead, 24-1, 24-10, 24-24, 24-25, 24-33 workers, 24-2
Machine-finished, 24-26
Page 24-40
PART 2
ROAD STRUCTURES
CHAPTER 25 - BEARING DEVICES
DOCUMENT NO: TR-

FIRST EDITION
JANUARY 2018
Chapter 25: Bearing Devices

TABLE OF CONTENTS
25 Bearing Devices .............................................................................................................. 25-1
25.2 Working Drawings for Bearing Devices ........................................................................ 25-5
25.3 Special Design Requirements for Bearing Devices ...................................................... 25-6
25.3.1 Horizontal Restraint for Bearing Devices .............................................................. 25-6
25.3.2 Characteristic Requirements for Fuse Links .......................................................... 25-6
25.3.3 Lift-off Tolerance of Primary Bearings ................................................................... 25-6
25.3.4 Characteristic Requirements for Viscous Dampers ............................................... 25-6
25.3.5 Pot Type Bearings - Guided Expansion and Fixed Bearings ................................. 25-7
25.4 Materials for Bearing Devices ...................................................................................... 25-8
25.4.1 Rolled Steel for Bearing Devices .......................................................................... 25-8
25.4.2 Steel Laminates for Bearing Devices .................................................................... 25-8
25.4.3 Cast Steel for Bearing Devices ............................................................................. 25-8
25.4.4 Forged Steel for Bearing Devices ......................................................................... 25-8
25.4.5 Stainless Steel for Bearing Devices ...................................................................... 25-8
25.4.6 Elastomeric Bearings ............................................................................................ 25-8
25.4.6.1 Properties of Elastomeric Bearings ................................................................ 25-9
25.4.6.2 Fabric Reinforcement for Elastomeric Bearings ........................................... 25-13
25.4.6.3 Bond for Elastomeric Bearings..................................................................... 25-13
25.4.7 Pot and Disc Bearings ........................................................................................ 25-13
25.4.7.1 Steel for Pot and Disc Bearings ................................................................... 25-13
25.4.7.2 Stainless Steel for Pot and Disc Bearings .................................................... 25-13
25.4.7.3 Elastomeric Rotational Element for Pot Bearings ......................................... 25-13
25.4.7.4 Lubricating Elastomer for Pot Bearings ........................................................ 25-13
25.4.7.5 Sealing Rings for Pot Bearings .................................................................... 25-13
25.4.7.6 Polytetrafluorethylene Sheets & Strips for Pot and Disc Bearings ................ 25-14
25.4.7.7 Polyether urethane Structural Element for Disc Bearings............................. 25-14
25.4.8 Rocker and Roller Bearings ................................................................................ 25-14
25.4.9 Spherical Bearings.............................................................................................. 25-14
25.4.10 Masonry, Sole, and Shim Plates for Bearings ..................................................... 25-15
25.4.11 Polytetrafluorethylene Surfaces for Bearings ...................................................... 25-15
25.4.11.1 Polytetrafluorethylene Sheets and Strips ..................................................... 25-15
25.4.11.2 Polytetrafluorethylene Resin ........................................................................ 25-15
25.4.11.3 Filler Material for Polytetrafluorethylene Sliding Surfaces ............................ 25-16
25.4.11.4 Adhesive Material for Polytetrafluorethylene Sliding Surfaces...................... 25-16
25.4.11.5 Unfilled Polytetrafluorethylene Sheets for Sliding Surfaces .......................... 25-16
25.4.11.6 Filled Polytetrafluorethylene Sheets for Sliding Surfaces ............................. 25-16
25.4.11.7 Fabric Containing Polytetrafluorethylene Fibres ........................................... 25-17
25.4.11.8 Lubricants for Polytetrafluorethylene Sliding Surfaces ................................. 25-17
25.4.11.9 Interlocked Bronze and Filled Polytetrafluorethylene Structures .................. 25-17
25.4.11.10 Surface Treatment for Polytetrafluorethylene Sliding Surfaces .................... 25-17
25.4.11.11 Stainless Steel Mating Surface for Polytetrafluorethylene Sliding Surfaces . 25-17
25.4.12 Anchor Bolts for Bearing Devices ....................................................................... 25-17
25.4.13 Bedding of Masonry Plates for Bearing Devices ................................................. 25-17
25.4.13.1 Materials for Bedding Mortar ........................................................................ 25-18
25.4.13.2 Site Mixing, Placing and Curing for Bedding Mortar ..................................... 25-19
25.4.13.3 Laboratory Approval Tests for Bedding Mortar ............................................. 25-19
25.4.13.4 Site Control Tests ........................................................................................ 25-21
Page i
CHAPTER 25: BEARING DEVICES First Edition -January 2018
25.4.13.5 Tolerances ................................................................................................... 25-22

25.5 Fabrication of Bearing Devices .................................................................................. 25-22
25.5.1 Elastomeric Bearings Tolerance ......................................................................... 25-23
25.5.2 Other Fabrication Tolerances.............................................................................. 25-23
25.6 Testing and Acceptance of Bearing Devices .............................................................. 25-26
25.6.1 Bearing Device Testing Terminology .................................................................. 25-26
25.6.1.1 Adapter Plates and Attachments.................................................................. 25-26
25.6.2 Bearing Device Tests .......................................................................................... 25-26
25.6.2.1 Material Certification Tests .......................................................................... 25-27
25.6.2.2 Material Friction Test (Sliding Surfaces Only) .............................................. 25-27
25.6.2.3 Dimension Check for Bearing Devices ......................................................... 25-27
25.6.2.4 Clearance Test for Bearing Devices............................................................. 25-27
25.6.2.5 Short-term Compression Proof Load Test for Bearing Devices .................... 25-28
25.6.2.6 Long-term Compression Proof Load Test for Bearing Devices..................... 25-28
25.6.2.7 Bearing Friction Test (Sliding Surfaces Only)............................................... 25-28
25.6.2.8 Long-term Deterioration Test for Bearing Devices ....................................... 25-28
25.6.2.9 Bearing Horizontal Force Capacity (Fixed or Guided Bearings Only) ........... 25-29
25.6.3 Performance Criteria for Bearing Devices ........................................................... 25-29
25.6.4 Special Testing Requirements for Bearing Devices ............................................ 25-29
25.6.4.1 Testing Elastomeric Bearings ...................................................................... 25-29
25.6.4.2 Testing Pot and Disc Bearings ..................................................................... 25-31
25.6.4.3 Testing Rocker and Roller Bearing .............................................................. 25-33
25.6.4.4 Testing Polytetrafluorethylene Surfaces for Bearings ................................... 25-33
25.6.4.5 Testing Bronze or Copper-alloyed Plates for Bearings ................................. 25-34
25.6.4.6 Testing for Curved Sliding Bearing .............................................................. 25-34
25.6.5 Use of Tested Bearings in a Structure ................................................................ 25-34
25.7 Packaging, Handling, and Storing Bearing Devices ................................................... 25-34
25.8 Installing Bearing Devices .......................................................................................... 25-35
25.8.1 Installing Elastomeric Bearings ........................................................................... 25-35
25.8.1.1 Stress Relieving of Elastomeric Expansion Bearings ................................... 25-36
25.8.2 Installing Pot and Disc Bearings ......................................................................... 25-36
25.8.3 Installing Rocker and Roller Bearings ................................................................. 25-37
25.8.4 Installing Spherical Bearings ............................................................................... 25-37
25.8.5 Installing Bronze or Copper-alloyed Plates for Bearings ..................................... 25-37
25.8.5.1 Bronze Bearing and Expansion Plates ......................................................... 25-37
25.8.5.2 Rolled Copper-alloy Bearings and Expansion Plates ................................... 25-37
25.8.6 Installing Masonry, Sole, and Shim Plates for Bearings ...................................... 25-38
25.8.7 Installing Polytetrafluorethylene Surfaces for Bearings ....................................... 25-38
25.8.7.1 Attachment of Polytetrafluorethylene Material .............................................. 25-38
25.8.7.2 Stainless Steel Mating Surface .................................................................... 25-38
25.8.7.3 Lubrication for Polytetrafluorethylene Surfaces ............................................ 25-39
25.8.7.4 Installation of Polytetrafluorethylene Surfaces ............................................. 25-39
25.8.8 Installing Anchor Bolts for Bearing Devices ......................................................... 25-39
25.8.9 Installing Load Plates for Bearing Devices .......................................................... 25-39
25.8.10 Installing Guides for Bearing Devices ................................................................. 25-39
25.8.11 Installing Guide-ways and Restraints for Bearing Devices .................................. 25-39
25.8.12 Installing Seismic Buffer Blocks .......................................................................... 25-40
25.8.13 Installing Seismic Restraint Cables ..................................................................... 25-40
25.8.14 Installing Shear Transfer Units at Abutments ...................................................... 25-40
25.8.15 Load Cells........................................................................................................... 25-40
25.9 Bearing Replacement ................................................................................................ 25-40
25.10 Warranty and Maintenance for Bearing Devices ........................................................ 25-41
25.11 Documentation for Bearing Devices ........................................................................... 25-41
Index 25-42
Page ii
LIST OF TABLES
Table 25-1: Designations and titles for AASHTO and ASTM standards that apply to bearing devices
.................................................................................................................................................. 25-2
Table 25-2: Designations and titles for BS, BS EN, and DIN standards that apply to bearing devices
.................................................................................................................................................. 25-4
Table 25-3: Polychloroprene (neoprene) quality-control tests based on hardness (AASHTO M 251-
06 (R2011))................................................................................................................................ 25-9
Table 25-4: Polyisoprene (natural rubber) quality-control tests based on hardness (AASHTO M 251-
06 (R2011)).............................................................................................................................. 25-11
Table 25-5: Physical properties of polyether urethane ............................................................. 25-14
Table 25-6: Filled polytetrafluorethylene sheet ......................................................................... 25-16
Table 25-7: Temperature tolerances ........................................................................................ 25-22
Table 25-8: Fabrication tolerances ........................................................................................... 25-24
Table 25-9: Samples required for quality assurance testing ..................................................... 25-32
Page iii
25 BEARING DEVICES
This chapter outlines standards and requirements for furnishing and installing bridge bearings and
the bedding of materials used under masonry plates for the Project.
Bearing construction shall conform to the details shown in the Contract documents. When the
Contract documents do not provide complete details, bearings shall conform to the limited details
shown and shall support all required loads, movements, and specified performance characteristics.
The Contractor shall design, supply, and install bearings, in compliance with these specifications,
AASHTO LRFD Bridge Design Specifications, and Road Structures Design Manual (ADQCC TR-
516). Bearing devices shall suit limitations on space and access and shall meet the requirements for
transfer of bearing loads into the primary structure. The Contractor shall obtain approval from the
Engineer for bearing designs. The Owner requires a certificate of compliance from the bearing
Manufacturer.
The Owner approves the use of bearings of the following types:
a. Elastomeric pad bearings
b. Rocker bearings
c. Roller bearings
d. Pot bearings
e. Spherical bearings
f. Disc bearings
g. Sliding plate bearings
The Owner may approve the use of other types of bearings if proven suitable to the Project.
Bearing components include the following:
• Masonry
• Sole and shim plates
• Bronze or copper-alloyed bearing and expansion plates
• Anchor bolts
• Guide devices
• Polytetrafluorethylene (PTFE) sheets or surfacing
• Lubricants
• Adhesives

load and resistance factor design, Bridge Construction Specifications;
load and resistance factor design, Bridge Design Specifications;
AASHTO Guide Specifications for Seismic Isolation Design, 3rd Edition;
AASHTO/AWS Bridge Welding Code;
D1.5M/D1.5:2010
Page 25-1
ASME American Society of Mechanical Engineers;

ASME B46.1-2009: Surface Texture (Surface Roughness, Waviness, and Lay);
ISO 9001:2008 Quality management systems – Requirements;
UK (DFT) Department for Transport, Manual of Contract Documents for Highway
Works, Volume 3 - Highway Construction Details.
EN), and German (DIN) Standards that are related to materials for bearing devices. It also includes
designations and titles.
Table 25-1: Designations and titles for AASHTO and ASTM standards that apply to bearing
devices
AASHTO ASTM
Title
AASHTO M ASTM A709 /

Standard Specification for Structural Steel for Bridges
270M/M 270-12 A709M - 11
ASTM A802 /
Standard Practice for Steel Castings, Surface
A802M -
Acceptance Standards, Visual Examination
95(2010)e1
Standard Specification for Steel, Sheet and Strip, Hot-

ASTM A1011 / Rolled, Carbon, Structural, High-Strength Low-Alloy,
A1011M - 12a High-Strength Low-Alloy with Improved Formability, and
Ultra-High Strength
ASTM A788 / Standard Specification for Steel Forgings, General

A788M - 11 Requirements
ASTM A167 - Standard Specification for Stainless and Heat-Resisting

99(2009) Chromium-Nickel Steel Plate, Sheet, and Strip
Standard Specification for Chromium and Chromium-

ASTM A240 /
Nickel Stainless Steel Plate, Sheet, and Strip for
A240M - 12
Pressure Vessels and for General Applications

05(2010) Hardness

06ae2 Thermoplastic Elastomers—Tension
Page 25-2
AASHTO ASTM
Title
ASTM D573 - Standard Test Method for Rubber—Deterioration in an

04(2010) Air Oven
ASTM D395 - Standard Test Methods for Rubber Property—

03(2008) Compression Set
ASTM D1149 - Standard Test Methods for Rubber Deterioration-

07(2012) Cracking in an Ozone Controlled Environment
ASTM D746 - Standard Test Method for Brittleness Temperature of

07 Plastics and Elastomers by Impact
Standard Test Method for Stiffness Properties of Plastics

ASTM D1043 -
as a Function of Temperature by Means of a Torsion
10
Test
ASTM D429 - Standard Test Methods for Rubber Property—Adhesion

08 to Rigid Substrates
AASHTO M 251- ASTM D4014 - Standard Specification for Plain and Steel-Laminated
06 (R2011) 03(2007) Elastomeric Bearings for Bridges
ASTM B36 / Standard Specification for Brass Plate, Sheet, Strip, And
B36M - 08a Rolled Bar
ASTM B121 / Standard Specification for Leaded Brass Plate, Sheet,

B121M - 11 Strip, and Rolled Bar
ASTM D4895 - Standard Specification for Polytetrafluoroethylene

10 (PTFE) resin produced from dispersion
AASHTO M
ASTM C881 / Standard Specification for Epoxy-Resin-Base Bonding
235M/M 235-
C881M - 10 Systems for Concrete
2003(R2007)
ASTM D2256 / Standard Test Method for Tensile Properties of Yarns by

D2256M - 10e1 the Single-Strand Method
ASTM D638 -
10
ASTM D792 - Standard Test Methods for Density and Specific Gravity
08 (Relative Density) of Plastics by Displacement
ASTM D5977 - Standard Specification for High Load Rotational

03(2007) Spherical Bearings for Bridges and Structures
Standard Specification for Wrought Copper-Alloy

AASHTO M 108-
ASTM B100 - 08 Bearing and Expansion Plates and Sheets for Bridge
09
and Other Structural Use
Page 25-3
AASHTO ASTM
Title
ASTM B103 / Standard Specification for Phosphor Bronze Plate,

B103M - 10 Sheet, Strip, and Rolled Bar
Standard Specification for Carbon Steel Bolts and Studs,

ASTM A307 - 10
60 000 PSI Tensile Strength
ASTM B29 -
Standard Specification for Refined Lead
03(2009)
ASTM C920 -
Standard Specification for Elastomeric Joint Sealants
11
AASHTO M 107- ASTM B22 - Standard Specification for Bronze Castings for Bridges
09 09e2 and Turntables
ASTM D4894 - Standard Specification for Polytetrafluoroethylene

07(2012) (PTFE) Granular Molding and Ram Extrusion Materials
ASTM C939 - Standard Test Method for Flow of Grout for Preplaced-
10 Aggregate Concrete (Flow Cone Method)
ASTM C827 / Standard Test Method for Change in Height at Early

C827M - 10 Ages of Cylindrical Specimens of Cementitious Mixtures
Standard Test Method for Absorption of Chemical-

ASTM C413 -
Resistant Mortars, Grouts, Monolithic Surfacings, and
01(2012)
Polymer Concretes
ASTM C150 /
AASHTO M 85-12 Standard Specification for Portland Cement
C150M - 12
Table 25-2: Designations and titles for BS, BS EN, and DIN standards that apply to bearing
devices
BS BS EN DIN
Title
Designation Designation Designation
BS EN 197- Cement. Composition, specifications and

1:2011 conformity criteria for common cements
Testing hardened concrete. Shape,

BS EN 12390-
dimensions and other requirements for
1:2000
specimens and moulds
BS EN 12390- Testing hardened concrete. Making and

2:2009 curing specimens for strength tests
BS EN 12390- Testing hardened concrete. Compressive

3:2009 strength of test specimens
Page 25-4
BS BS EN DIN
Title
Designation Designation Designation
Testing of resin and polymer/cement

BS 6319-
compositions for use in construction. Method
1:1983
for preparation of test specimens
Testing of resin and polymer/cement

BS 6319-
compositions for use in construction. Method
2:1983
for measurement of compressive strength
The Contractor shall manufacture and test bearings devises in accordance with these specifications
and in compliance with AASHTO/ASTM standards. Where bridge bearings are manufactured and
tested by standards other than AASHTO/ASTM, products conforming to equivalent or higher
standards will be acceptable if proven to be suitable.
25.2 Working Drawings for Bearing Devices

The Contractor shall prepare and submit working drawings for bearings. Such drawings shall show
all details of the bearings and of the materials proposed for use, including bearing assembly. They
shall also include an installation procedure and procedures for the access, maintenance, and
replacement of the bearings during the operational life of the bridge.
The proposed bearing Manufacturer shall submit evidence of the successful installation and
operation of comparable bearings to the Engineer to get approval for use. Such evidence should
demonstrate the suitability of the proposed systems and materials for heavy traffic and high
temperatures. Bearings shall be dispatched only upon approval from accredited independent testing
lab.
Working drawings shall be approved by the Engineer before the fabrication of the bearings. Such
approval shall not relieve the Contractor of any responsibility under the Contract documents for the
successful completion of the work.
Working documents shall specify the following details:
a. Total quantity of each kind of bearing required (fixed, guided expansion, or non-guided
expansion), grouped first according to type (load range), then by actual design capacity
b. A plan view and section elevation view that show all relative dimensions for each type of
bearing
c. Location of base and upper part of the bearings drawn in a plan and in elevation on the deck
soffit and on the support showing edge distances and thickness of any grout pads, shim
plates, or adapter plates
d. A maximum design coefficient of friction, as noted in the Contract documents
e. Types of materials for all bearing elements
f. If applicable, a clear description and details for any welding process used in the bearing
manufacture that does not conform to the approved processes of the current version of the
AASHTO/AWS D1.5M/D1.5:2010 Bridge Welding Code.
g. Vertical and horizontal load, rotation, and movement capacity
h. Painting or coating requirements
i. Alignment plans showing bearing orientation with respect to the point of zero temperature
movement of the bridge deck or to other points of reference as appropriate.
j. Installation scheme
k. Complete design calculations that verify conformance with the requirements in this chapter,
if the Engineer requires such calculations
l. Anchorage details
m. Bearing preset details, if applicable
Page 25-5
25.3 Special Design Requirements for Bearing Devices

All bearings shall include components and materials that ensure operation without any maintenance
other than external painting over a bridge’s 100 year design life. Internal components shall be
corrosion resistant, stable, and appropriate for long life in the intended environment concerned. All
moving components shall ensure low wear.
25.3.1 Horizontal Restraint for Bearing Devices

A design may require that some primary bearings can resist a proportion of horizontal seismic loads.
Where so required, these loads shall be included in the extreme limit state load combination, as
given on the bearing schedule from the Contract documents.
Such primary bearings shall include guides that transmit longitudinal and transverse loads, as
indicated on the bearing schedule, for all combinations of service and strength loads.
Where primary bearings do not include required transverse and longitudinal restraints, transverse
and longitudinal loads will be resisted by rigid fuse link devices that separate under extreme condition
earthquakes.
Under extreme earthquake conditions, in which the horizontal load exceeds the capacity of the
primary bearings or fuse links, viscous seismic dampers shall resist seismic loads. A single device
may combine both the fuse link and viscous damping functions.
The Contractor shall design and detail such guides and their connections to main bearing plates so
that, when horizontal load guides are subjected to loads up to the extreme limit, they fail in a ductile
manner to minimize damage to other parts of the bearings. The Contractor shall demonstrate to the
Engineer’s satisfaction that the actual failure load of a guide does not exceed the extreme limit
designated on the bearing schedule by more than 10%.
Seismic restraint devices and fuse links shall provide the basic force, displacement, and velocity
characteristics and peak design loads, as shown on the bearings schedule. When designing seismic
restraint devices and fuse links, a supplier shall develop further details of their force, displacement,
and velocity characteristics and submit these details to the Engineer for approval.
25.3.2 Characteristic Requirements for Fuse Links

Fuse links shall deform less than 2 mm overall in an elastic mode (in which deflections are fully
recoverable on unloading) for all service condition loads. Each link shall separate in a ductile manner
with complete loss of resistance between 110% and 130% of specified strength condition loads. After
extreme loads separate a link, it shall allow further cyclic displacement of the structure without
interference or damage to other components. Links shall be double acting (supporting both tension
or compression), unless the Engineer approves otherwise.
Transverse fuse links shall be adjustable so that any parasitic effects caused by pre-stress,
shrinkage, or creep can be relieved during construction. As necessary, immediately after applying
pre-stresses and at the end of construction, the Contractor shall adjust these links to support a
minimal locked in-construction load.
25.3.3 Lift-off Tolerance of Primary Bearings

Certain primary bearings, as indicated on the Contract plans or working drawings, may be subject to
temporary lift-off in extreme conditions. By design, rather than resisting tension, such bearings shall
separate temporarily then reconnect without damaging or dislocating the bearing or its sliding
surface.
25.3.4 Characteristic Requirements for Viscous Dampers

A basic characteristic of bearing devices is tensile or compressive force. Equation 25-1 shows the
calculation.
Page 25-6
F = {K} (x) + {C}(v)

Equation 25-1: Tensile or compressive force
Where:
(x) is the relative displacement of the connection points of the device [m]
(v) is the relative velocity of the connection points of the device [m/s]
{K} is the stiffness of the device which shall satisfy the minimum requirements of the AASHTO Guide
Specifications for Seismic Isolation Design, 3rd Edition [kN/m]
{C} is the damping coefficient [kN/(m/s) ] 0.15
Characteristics in Equation 25-1 act in parallel (these forces are additive). Although all devices shall
have some stiffness in series with the damping force (deflections are additive), the Contractor shall
ensure that such stiffness is sufficient to render any associated extra deflections insignificant.
25.3.5 Pot Type Bearings - Guided Expansion and Fixed Bearings

The Contractor shall furnish and install pot type, guided expansion and fixed bridge bearings of the
sizes specified at the locations shown on the Contract plans. The bearing assemblies shall be
complete and ready for installation.
Pot expansion bearings shall have sliding surfaces as indicated in the Contract plans and shall
comply with the specifications in this chapter. Fixed bearings shall be rotational fixed units as shown
on the Contract plans, and purchased from an approved manufacturer.
When specified, Polytetrafluoroethylene (PTFE) sliding surfaces shall be designed by the Contractor
to translate or rotate by sliding of a self-lubricating PTFE surface across a smooth and hard stainless
steel mating surface.
Expansion bearings with sliding PTFE surfaces shall provide for rotation or equalization of the stress
on the PTFE sliding surface. Rotation shall be considered the sum of live load rotation, changes in
camber during construction, and misalignment of the bearing seats due to construction tolerances.
Rotational capability shall not be less than 1:50. Design, materials and construction of the means of
equalizing the stress or provision for rotation in the bearing shall comply with the specifications in
this chapter and on the Contract plans.
Unfilled or filled PTFE sliding surfaces shall be at least 1.6 mm thick, but not more than 4.8 mm thick.
The PTFE sliding surface shall be bonded under factory-controlled conditions to a rigid back-up
material (steel substrate) that can resist any bending stresses to which the sliding surface may be
subjected, and shall be recessed for half its thickness into the back-up material. The bonding shall
be performed at the factory of the bearing manufacturer of the expansion bearings under controlled
conditions and in accordance with the written instructions of the manufacturer of the approved
adhesive system. After completion of the bonding operation, the PTFE surface shall be smooth and
free from bubbles. Filled PTFE surfaces shall then be polished.
The mating stainless steel surface to the PTFE shall be accurate and flat in accordance with the
design. Such surfaces shall have a minimum Brinell hardness of 125 and a surface finish of less
than 0.5 micron rms (root mean square). The mating surface shall completely cover the PTFE
surface in all of the bearing’s operating positions, and shall be seal welded around the entire
perimeter to the back-up material.
Average bearing pressure on the PTFE sliding surface, from all loads, shall not exceed the following
values:
• Filled PTFE: 24.13 MPa
• Unfilled PTFE (Recessed): 24.13 MPa
• Unfilled PTFE (Not Recessed): 13.73 MPa
Page 25-7
The expansion bearing shall be manufactured to the dimensions, and the requirements of the
method of fastening to the structure as shown on the Contract plans. Guide bar to bearing clearance
of 3 mm maximum shall be maintained on all guided bearings.
25.4 Materials for Bearing Devices

All bearing materials for which the Contract documents do not define specific requirements shall
comply with the requirements for applicable materials that are outlined in this section and the
following specifications:
• Chapter 4, Concrete Works, of these Standard Specifications.
• Chapter 23, Steel Structures, of these Standard Specifications.
25.4.1 Rolled Steel for Bearing Devices

Rolled steel shall be of the type specified in the Contract documents and shall satisfy the testing
requirements of the standard to which it conforms. Unless otherwise specified, steel shall be grade
36 that conforms to AASHTO M 270M/M 270-12 or grade 250 that conforms to ASTM A709 / A709M
- 11. Such steel shall cause no adverse electrolytic or chemical reaction with other components of a
bearing and shall be free of all rust and mill scale.
25.4.2 Steel Laminates for Bearing Devices

Steel laminates shall meet the requirements of AASHTO M 251-06 (R2011). Unless otherwise
specified in the Contract documents, steel laminates used for reinforcement shall be grade 36 rolled
mild steel that conforms to AASHTO M 270M/M 270-12, grade 250 rolled mild steel that conforms to
ASTM A709 / A709M - 11, steel that conforms to ASTM A1011 / A1011M - 12a, or an equivalent.
Laminates shall have a nominal thickness of at least 3 mm. Laminate edges shall be deburred or
otherwise rounded prior to moulding the bearings. Holes through the laminated elastomeric bearings
for shear pins shall not be permitted.
25.4.3 Cast Steel for Bearing Devices

Cast steel shall satisfy the requirements of ASTM A802 / A802M - 95(2010)e1 and shall not have
any blow-holes and impurities larger than 3.2 mm. Interior walls for pot in pot bearings and contact
surfaces for metal rocker or roller bearings shall have neither blow holes nor impurities of any size.
25.4.4 Forged Steel for Bearing Devices

Forged steel shall satisfy the requirements of ASTM A788 / A788M - 11.
25.4.5 Stainless Steel for Bearing Devices

Stainless steel for bearing devices shall be type 304 that conforms to the requirements of ASTM
A167 - 99(2009) or ASTM A240 / A240M - 12. Stainless steel be at least 0.91 mm thick. A bearing’s
surface finish shall equal or exceed 0.2 μm. Stainless steel in contact with PTFE sheet shall be
polished to a finish no less than 0.50 μm.
25.4.6 Elastomeric Bearings

Elastomeric bearings shall include unreinforced pads that consist of elastomer only (plain pads) or
reinforced bearings with steel or fabric laminates (laminated bearing). The minimum and maximum
thicknesses of the elastomeric bearings shall be in accordance with the following.
1. Plain elastomeric pads shall have a minimum nominal thickness of 19 mm.
2. Cover layer of laminated bearings shall have a minimum nominal thickness of 3 mm, and a
maximum nominal thickness of 6 mm.
Page 25-8
3. Interior layers of laminated bearings shall have a minimum nominal thickness of 10 mm, and
a maximum nominal thickness of 16 mm.
All material used in the manufacture of bearing assemblies shall be new and unused with no
reclaimed material. All bonding of components shall be done under heat and pressure during the
vulcanizing process. Each bond shall be continuous throughout, with no voids or air spaces greater
than 0.25 mm within the bonding material. Bearing assemblies shall be furnished as complete units
from one manufacturing source.
Elastomeric bearings shall be furnished with the dimensions, material properties, elastomer grade,
and type of laminates specified in the Contract documents. The Contractor shall test the bearings to
verify that they comply with the design loads specified in the Contract documents. The Contractor
shall conduct load testing on such bearings as specified in this chapter. Unless the Contract
documents specify otherwise, bearings shall be steel-reinforced Grade 3, 60-durometer elastomer.
25.4.6.1 Properties of Elastomeric Bearings

Raw elastomer shall be either virgin Neoprene (polychloroprene) or virgin natural rubber
(polyisoprene). An elastomer compound shall be classified as being of low-temperature Grade 0, 2,
3, 4, or 5. Grades are defined by the testing requirements in Table 25-3 and Table 25-4. A higher
grade of elastomer may be substituted for a lower one.
The elastomer compound shall meet the minimum requirements shown in Table 25-3 and Table
25-4, except as otherwise specified by the Engineer. Test requirements may be interpolated for
intermediate hardness. If a material is specified by its shear modulus, its measured shear modulus
shall be within fifteen percent (15%) of the specified value. A consistent value of hardness shall also
be supplied for the purpose of defining limits for the tests in Table 25-3 and Table 25-4. If the
hardness is specified, the measured shear modulus shall comply with Section 14 of the AASHTO
LRFD Bridge Design Specifications and AASHTO M 251-06 (R2011). When test specimens are cut
from the finished product, physical properties may vary from those specified in Table 25-3 and Table
25-4 by ten percent (10%). All material tests shall be carried out at 23o Celsius plus or minus 2o
Celsius, unless the Contract documents note otherwise. When conducting shear modulus tests, the
manufacturer shall use the apparatus and procedure described in Annex A of ASTM D4014 -
03(2007).
Table 25-3: Polychloroprene (neoprene) quality-control tests based on hardness (AASHTO
M 251-06 (R2011))
ASTM test
Physical properties 50 60 70
method
ASTM D2240 - Hardness (shore A

50+5 60+5 70+5
05(2010) durometer)
Tensile strength,
15.5 15.5 15.5
minimum MPa
ASTM D412 -
06ae2
Ultimate elongation,
400 350 300
minimum %
Heat resistance
ASTM D573 - Change in durometer

04(2010), 70 hardness, maximum 15 15 15
hours at 100° C points
Page 25-9
ASTM test
method
Change in tensile
-15 -15 -15
strength, maximum %
Change in ultimate
elongation, maximum -40 -40 -40
%
Compression set
ASTM D395 -
22 hours at 100° C,
03(2008), 35 35 35
maximum %
Method B
Ozone
100 pphm ozone in air

by volume, 20% strain
ASTM D1149 - 38° C ± 1° C 100
No cracks No cracks No cracks
07(2012) hours mounting
procedure D 518,
procedure A
Low-temperature
brittleness
Grades 0 and 2 No tests required
Grade 3-brittleness at -
40° C
ASTM D746 -
07, Procedure B Grade 4-brittleness at -
Pass
48° C
Grade 5-brittleness at -
56.5° C
Instantaneous thermal stiffening
Grades 0 and 2-tested

at -32°C
Grade 3-tested at -40°

C
ASTM D1043 - Stiffness at test temperature shall not exceed four
10 times stiffness measured at 23° C
Grade 4-tested at -
45.5° C

C
Low-temperature crystallization
Page 25-10
ASTM test
method
Quad shear test Grade 0 (No test Stiffness at test time and temperature shall not exceed
as described in required) four times stiffness measured at 23° C with no time
Annex A of delay. Stiffness shall be measured with a quad shear
ASTM D4014 - Grade 2-7 days at - test rig in an enclosed freezer unit. Test specimens
03(2007) 18° C shall be taken from a randomly selected bearing. A
±25% strain cycle shall be used and a complete cycle
Grade 3-14 days at - of strain shall be applied with a period of 100 seconds.
26° C First 0.75 cycle of strain shall be discarded and the
stiffness shall be determined by slope of force
Grade 4-21 days at - deflection curve for next 0.25 cycle of loading.
37° C
Grade 5-28 days at -

37° C
Table 25-4: Polyisoprene (natural rubber) quality-control tests based on hardness (AASHTO
M 251-06 (R2011))
ASTM test
method
ASTM D2240 - Hardness (shore A

50+5 60+5 70+5
05(2010) durometer)
Tensile strength,
15.5 15.5 15.5
minimum MPa
ASTM D412 -
06ae2
Ultimate elongation,
450 400 300
minimum %
Heat resistance
ASTM D573 - Change in durometer

04(2010), 70 hardness, maximum 10 10 10
hours at 100° C points
Change in tensile
-25 -25 -25
strength, maximum %
Change in ultimate
elongation, maximum -25 -25 -25
%
Compression set
ASTM D395 -
22 hours at 100° C,
03(2008), 25 25 25
maximum %
Method B
Ozone
Page 25-11
ASTM test
method
25 pphm ozone in air

by volume, 20% strain
ASTM D1149 -
38°C ± 1° C 48 hours No cracks No cracks No cracks
07(2012)
mounting procedure D
518, procedure A
Low-temperature
brittleness
Grades 0 and 2 No tests required
Grade 3-brittleness at
-40° C
ASTM D746 -
07, Procedure
B Pass
-48° C
-56.5° C
Instantaneous thermal stiffening
Grades 0 and 2-tested

at -32°C

C
ASTM D1043 - Stiffness at test temperature shall not exceed four
10 times the stiffness measured at 23° C
Grade 4-tested at -
45.5° C

C
Low-temperature crystallization
Quad shear test Grade 0 (No test Stiffness at test time and temperature shall not
as described in required) exceed four times the stiffness measured at 23° C
Annex A of with no time delay. Stiffness shall be measured with
ASTM D4014 - a quad shear test rig in an enclosed freezer unit. Test
03(2007) specimens shall be taken from a randomly selected
bearing. A ±25% strain cycle shall be used and a
complete cycle of strain shall be applied with a period
of 100 seconds. First 0.75 cycle of strain shall be
discarded and the stiffness shall be determined by
the slope of the force deflection curve for the next
0.25 cycle of loading.
Page 25-12
25.4.6.2 Fabric Reinforcement for Elastomeric Bearings

Fabric reinforcement for elastomeric bearings shall be woven from 100% continuous E type
fibreglass yarn. Each thread in either direction shall have at least one thread per mm. Such fabric
shall have either a crowfoot or an 8 hardness satin weave. Each ply of fabric shall have a minimum
breaking strength of 140 N/mm of width in each thread direction. Unless the Contract documents
specify otherwise, fabric reinforcement for elastomeric bearings shall not have holes.
25.4.6.3 Bond for Elastomeric Bearings

Vulcanized bonds between fabric and reinforcement shall have a minimum peel strength of 5.3
N/mm. Steel laminated bearings shall have a minimum peel strength of 7.0 N/mm. The Contractor
shall perform peel strength tests in accordance with method B of ASTM D429 - 08.
25.4.7 Pot and Disc Bearings

Pot and disc bearings shall be adequate for the design loads and movements shown or specified in
the Contract documents. The Contractor shall test pot and disc bearings to the appropriate level in
accordance with Article 25.6.4.2.
All materials shall be new and unused, with no reclaimed material incorporated in the finished
bearing.
25.4.7.1 Steel for Pot and Disc Bearings

All steel for pot and disc bearings, except stainless steel components, shall conform to the
requirements outlined in Section 23.4.1 of Chapter 23, Steel Structures, for carbon steel or for high-
strength, low-alloy structural steel for welding.
25.4.7.2 Stainless Steel for Pot and Disc Bearings

Stainless steel shall conform to the requirements outlined in Section 25.4.5.
25.4.7.3 Elastomeric Rotational Element for Pot Bearings

Elastomeric rotational elements used in pot bearings shall contain only virgin, crystallization-resistant
polychloroprene (Neoprene) that conforms to AASHTO M 251-06 (R2011) (ASTM D4014 - 03(2007))
or virgin natural polyisoprene (natural rubber) that conforms with AASHTO M 251-06 (R2011) as the
raw polymer. Physical properties of Neoprene and natural rubber shall conform to the specifications
outlined in this chapter with the following modifications:
• Shore A Durometer hardness shall be 50+10 points.
• Samples for compression set tests shall be prepared using a Type 2 die.
25.4.7.4 Lubricating Elastomer for Pot Bearings

The manufacturer shall lubricate the elastomer between the steel pot and the top steel bearing plate
with a silicon grease that does not react chemically with the elastomer and does not alter its
properties when subjected to the expected environmental conditions for the Project site or as
recommended by the Manufacturer.
25.4.7.5 Sealing Rings for Pot Bearings

Sealing rings between the pot bearing’s steel piston and its elastomeric rotational element shall be
brass that conforms to ASTM B36 / B36M - 08a for rings of rectangular cross-section and to ASTM
B121 / B121M - 11 for circular sections. The Engineer, at their discretion, may approve other sealing
ring materials if tests provide evidence that such materials conform to AASHTO LRFD Bridge Design
Specifications and Abu Dhabi Road Structures Design Manual (AD-D-06).
Page 25-13
25.4.7.6 Polytetrafluorethylene Sheets & Strips for Pot and Disc

Bearings
Polytetrafluorethylene (PTFE) sheet and strip requirements for pot and disc bearings shall conform
to the provisions of Section 25.4.11.
25.4.7.7 Polyether urethane Structural Element for Disc Bearings

Polyether urethane structural elements in disc bearings shall be moulded from a monolithic polyether
urethane compound. Such polyether urethane shall have the physical properties listed in Table 25-5.
Table 25-5: Physical properties of polyether urethane
Physical properties ASTM test method Requirements
ASTM D2240 -
Hardness, type D durometer 45 55 65
05(2010)
Tensile stress, MPa ASTM D412 - 06ae2

At 100% elongation 10 13 16
At 200% elongation 19 23 28
Tensile strength, MPa ASTM D412 - 06ae2 28 35 41
Ultimate elongation, % ASTM D412 - 06ae2 350 285 220
Compression set, 22 hours at 70°

ASTM D395 - 03(2008) 40 40 40
C, %
25.4.8 Rocker and Roller Bearings

Steels in rocker and roller bearings shall be of the types and grades specified in the Contract
documents for the Project. Steel at a metal bearing’s contact surface may be hardened if, after
hardening, the steel satisfies the strength and ductility requirements of the Contract documents and
the material specifications.
The Contractor shall apply lubrication to all gear mechanisms and to all other components of roller
bearings for which lubrication is required. The Contractor shall comply with the Contract
specifications when selecting the type of lubricant and shall apply lubricant in accordance with its
Manufacturer's recommendations.
25.4.9 Spherical Bearings

Spherical bearings are most commonly utilized at locations where very high vertical loads and/or
large structural rotations are present.
Spherical bearings shall consist of a spherical rotational component, where typically stainless steel
convex surface slides against a concave steel plate covered with a lubricant or a maintenance-free
PTFE liner or other sliding material with suitable properties, as approved by the Engineer, to permit
angular rotation about a central point in two orthogonal directions within a specified angular limit
based on the bearing’s geometry. If the design of the other sliding material is not addressed in
AASHTO LRFD then the same shall be designed according to an internationally acceptable relevant
standard. Spherical bearings may have a locking feature in the axial direction.
The Contractor shall fabricate, test, and install spherical bearings as specified in the Contract
documents.
Page 25-14
25.4.10 Masonry, Sole, and Shim Plates for Bearings

Metal plates used in masonry, sole, and shim plates, unless otherwise specified in the Contract
documents, shall be grade 250 steel that conforms to AASHTO M 270M/M 270-12 or ASTM A709 /
A709M - 11. Bronze or copper alloy bearing and expansion plates shall conform to the requirements
outlined in Section 25.8.5.
During bridge construction, bearings may require shimming to allow for variability in assumed
material parameters and the final construction sequence. Shims shall consist of additional plates
either above or below the bearing plates. The Contractor shall be responsible for developing
proposals and methodologies for shimming bearings.
The Contractor shall include details of proposed jacking points and shall provide additional local
bursting reinforcement at jacking locations in permanent works.
25.4.11 Polytetrafluorethylene Surfaces for Bearings

Polytetrafluorethylene (PTFE) sheets and strips shall be one of the following materials:
a. Pure virgin (not reprocessed), unfilled PTFE resin
b. PTFE resin that is uniformly blended with either fifteen percent (15%) glass fibre or twenty-
five percent (25%) carbon (maximum filler, percent by weight)
c. Fabric that contains PTFE fibres
Horizontally installed PTFE sheet shall be bonded to and recessed into its steel substrate. Vertically
installed PTFE sheet shall be bonded to and recessed into or bonded to and mechanically fastened
to its steel substrate. PTFE sheet shall have a minimum thickness of 5 mm and shall be recessed
for at least one-half of its thickness into its steel substrate.
Finished PTFE sheets and strips shall have the following characteristics:
• Resistant to all acids, alkalis, and petroleum products
• Stable at temperatures up to 260° C
• Non-flammable
• Non water absorbent
Epoxy that bonds PTFE to its steel substrate shall be a heat cured high-temperature epoxy that can
withstand temperatures up to 260° C.
25.4.11.1 Polytetrafluorethylene Sheets and Strips

PTFE resin sheets, PTFE fabric, interlocked bronze and PTFE structures, PTFE perforated metal
composite, back-up materials, and all other parts of fixed or expansion bearings that contain PTFE
materials shall have the friction, mechanical, physical, and weathering properties specified in the
Contract documents.
25.4.11.2 Polytetrafluorethylene Resin

PTFE resin shall be 100% pure, new material that meets the requirements of ASTM D4894 -
07(2012) or ASTM D4895 - 10. PTFE resin shall satisfy the requirements outlined in Table 25-6. No
reclaimed material shall be used.
Any finished PTFE sheet, strip, or fabric shall have the following characteristics:
• Resistant to acids, alkalis, and petroleum products
• Stable at temperatures up to 260° C
• Non-flammable
• non water absorbent
Page 25-15
25.4.11.3 Filler Material for Polytetrafluorethylene Sliding Surfaces

Filler material, when used, shall be milled glass fibre, carbon fibre, or other approved filler material.
Such filler shall act compositely with PTFE and shall not have any chemical reaction with other
components or constituents.
25.4.11.4 Adhesive Material for Polytetrafluorethylene Sliding Surfaces

Adhesive material that bonds sheet PTFE shall be an epoxy resin that complies with the
requirements of AASHTO M 235M/M 235-2003(R2007) or ASTM C881 / C881M - 10, FEP film or an
equivalent, or some other adhesive that has been approved by the Engineer.
25.4.11.5 Unfilled Polytetrafluorethylene Sheets for Sliding Surfaces

Finished, unfilled PTFE sheets shall be made from virgin PTFE resin and shall conform to the
property requirements outlined in Table 25-6, with the exception that the ASTM test methods for
tensile strength and elongation shall conform to ASTM D2256 / D2256M - 10e1.
25.4.11.6 Filled Polytetrafluorethylene Sheets for Sliding Surfaces

Filled PTFE sheets shall be made from virgin PTFE resin that is uniformly blended with an approved
inert filler. Maximum filler content shall be fifteen percent (15%) for fibreglass and twenty-five percent
(25%) for carbon fibres. Maximum filler content for other materials shall be determined by the
Engineer.
Finished filled PTFE sheets that contain glass fibre or carbon shall conform to the requirements
outlined in Table 25-6, with the exception that the ASTM test methods for tensile strength and
elongation shall conform to ASTM D638 - 10.
Table 25-6: Filled polytetrafluorethylene sheet
Sheet with Sheet with

Mechanical Sheet Woven
ASTM method 15% glass 25% carbon
property unfilled fabric
fibres fibres
ASTM D638 - 10
Tensile strength or
19.3 13.78 8.96 16.54
minimum MPa ASTM D2256 /
D2256M - 10e1
ASTM D638 - 10
Elongation or
200 150 75 35
(minimum %) ASTM D2256 /
D2256M - 10e1
Specific gravity,
ASTM D792 - 08 623 ± 2 2.20 ± 0.03 2.10 ± 0.03 -
minimum
ASTM D4894 -
07(2012),
ASTM D4895 -
Melting point, °C 328 ± 2 328 ± 10 328 ± 10 -
10 or
ASTM D5977 -
03(2007)
Values for intermediate filler contents may be obtained by interpolation.
Page 25-16
25.4.11.7 Fabric Containing Polytetrafluorethylene Fibres

Woven fabric PTFE shall be manufactured from oriented multi-filament PTFE fluorocarbon fibres or
from a mixture of PTFE fibres made from twisted, slit PTFE tape and other fibres as required by
proprietary designs. Typical physical properties of the PTFE fibres shall be taken from Table 25-6,
with the exception that the ASTM Test Methods for tensile strength and elongation shall conform to
ASTM D2256 / D2256M - 10e1.
25.4.11.8 Lubricants for Polytetrafluorethylene Sliding Surfaces

Lubricants, if used, shall consist of a combination of solids that does not react chemically or
electrolytically with the PTFE and its mating surface and that remains stable when subjected to the
environmental conditions expected at the bridge site.
25.4.11.9 Interlocked Bronze and Filled Polytetrafluorethylene

Structures
Interlocking bronze and filled PTFE structures shall consist of a phosphor bronze plate with a porous
bronze surface layer that is 0.25 mm thick into which a lead and PTFE compound has been
interjected. Such structures shall have an overlay of compounded PTFE that is at least 25 mm thick.
Phosphor bronze back plates shall conform to AASHTO M 108-09 or ASTM B100 - 08. Porous
bronze layers shall conform to ASTM B103 / B103M - 10.
25.4.11.10 Surface Treatment for Polytetrafluorethylene Sliding Surfaces

Where PTFE sheets are to be epoxy-bonded, one side of the PTFE sheet shall be factory-treated
by an approved Manufacturer using the sodium naphthalene or sodium ammonia process.
25.4.11.11 Stainless Steel Mating Surface for Polytetrafluorethylene

Sliding Surfaces
Stainless steel shall conform to the requirements outlined in Section 25.4.5.
25.4.12 Anchor Bolts for Bearing Devices

Anchor bolts shall meet the requirements of ASTM A307 - 10 or the Contract documents. Anchor
bolts shall include anchorage details that permit development of the full tensile strength of each bolt.
The Owner recommends that anchor bolts also include hooks or end plates.
25.4.13 Bedding of Masonry Plates for Bearing Devices

The Contractor shall place filler or fabric materials as bedding under masonry plates when the
Contract documents indicate such placement. Such material shall be of the type specified in the
Contract documents or as ordered or approved by the Engineer. The Contractor shall install such
materials to provide full bearing on contact areas.
Immediately before placing the bedding material and installing bearings or masonry plates, the
contact surfaces of the concrete and steel shall be thoroughly cleaned.
Preformed fabric pads used as bedding shall be composed of multiple layers of 2.7 N/m2 cotton
duck that has been impregnated and bonded with high-quality natural rubber. Alternately, such pads
may be composed of equivalent and equally suitable materials that are compressed into resilient
pads of uniform thickness. Each pad shall have a sufficient number of plies to produce the specified
thickness, after compression and vulcanizing. Finished pads shall withstand compression loads that
are perpendicular to the plane of the laminations of not less than 70 MPa with no detrimental
reduction in thickness or extrusion.
Sheet lead used as bedding shall be common, desilverized lead that conforms to ASTM B29 -
03(2009). Such sheets shall be of uniform thickness and shall be free from cracks, seams, slivers,
Page 25-17
scale, and other defects. Unless otherwise specified, lead sheets shall be 3 mm thick with a tolerance
of ±1 mm.
Epoxy resin bearing mortar shall be manufactured under factory conditions certified to comply with
the ISO 9001:2008 Quality Assurance and Quality Control (QA/QC) procedure. The Contractor shall
comply with all Manufacturer instructions when preparing, priming, mixing, and applying mortar to
surfaces. The Contractor shall conduct grouting trials on site to demonstrate, to the satisfaction of
the Engineer, that the Contractor’s proposed methods and materials will meet the Project
requirements and specifications.
Caulking material used as bedding shall be a non-sag polysulfide or type II polyurethane material
that conforms to the provisions of ASTM’s Standard Specification for Elastomeric Joint Sealants
(ASTM C920 - 11).
Grout and mortar used for filling under masonry plates shall conform to Section 21.18 of Chapter 21,
Concrete Structures, and the following performance requirements:
i. Unless otherwise described on the Contract plans, bedding mortar shall have a cubical
compressive strength not less than 50 MPa when tested in accordance with Article 25.4.13.3.
ii. The flow characteristics shall be such that the volume of the bed or plinth as shown on the
Contract plans is completely filled with homogeneous material when placed within the range
of ambient temperature between 5o C and 35o C, or as otherwise described on the Contract
plans.
iii. The physical and chemical properties shall be compatible with those of the adjoining
surfaces.
The stress in the mortar shall not exceed that defined in the Contract documents or Contract plans.
Where the mortar is required to resist stress before attaining its 28-day strength the compressive
strength shall be confirmed by tests on mortar cubes stored under conditions that simulate the field
conditions or by a method approved by the Engineer. The assessment of the strength of the bedding
mortar and produced by the loads shall be subject to the agreement of the Engineer.
25.4.13.1 Materials for Bedding Mortar

The maximum aggregate size in bedding mortar shall be 2.36mm. Proprietary materials shall be
stored as follows:
The materials shall be stored in a dry environment at a temperature of between 10o C and 27o C.
The containers shall be damp-proof, leak-proof and readily emptied of their contents. Containers
shall be marked with the batch reference number, component identification, manufacturer's name,
net weight and such warnings or precautions concerning the contents as are required.
The material shall not be removed from the store for use in the Works until immediately prior to
mixing.
Material shall not be used more than six months after the date of manufacture or any lesser period
specified by the Manufacture or Supplier.
The Contractor shall supply with each batch or part of a batch of the material delivered to the site,
certificates furnished by the Supplier or the Manufacturer stating the following:
• The Manufacturer's name and address.
• The Manufacturer's agent's name and address.
• Description of material and brand name.
• Batch reference number, size of batch and number of containers in the delivery order.
• Date of manufacture.
• The chloride ion content, expressed as percentage by mass of cement.
Calcium chloride or admixtures containing chloride salts shall not be used and the total chloride ion
content shall not exceed 0.1% of the mass of cement.
Page 25-18
Portland cement shall comply with Section 4.3.1 of Chapter 4, Concrete Works, and with BS EN 197-
1:2011 or AASHTO M 85-12.
The total acid-soluble sulfate content of the mix expressed as SO3 shall not exceed 4% of the mass
of cement in the mix. The sulfate content shall be calculated as the total from the various constituents
of the mix.
Water shall be in accordance with Section 4.3.8 of Chapter 4, Concrete Works.
Resinous bedding mortars shall be based on thermosetting organic polymers consisting of stable
fluid and/or solid components which on mixing react chemically to form a hardened solid mass.
Products shall be formulated from epoxide, polyester, polyurethane or acrylic resin systems or such
other formulation as is approved by the Engineer. Fillers or aggregates to be incorporated in
accordance with the Manufacturer's recommendations, to extend or modify the properties of the
resinous compositions, shall be pre-bagged, dry and factory proportioned. The addition of other fillers
or aggregates shall not be permitted.
25.4.13.2 Site Mixing, Placing and Curing for Bedding Mortar

Mixing, placing and curing proprietary bedding mortar shall be carried out in accordance with the
Manufacturer's written instructions together with the following:
The material shall not be mixed or placed in the Works at ambient temperatures of less than 5o C. If
for 24 hours before during or after placing, the ambient temperature falls below 5o C the Contractor
shall maintain the temperature of the substrate and other adjoining surfaces at not less than 5o C for
the duration of the curing period recommended by the Manufacturer.
For cementitious bedding mortars the water/cement ratio shall not exceed 0.4. The water content
shall be confirmed during the approval tests, and maintained within ± 1 percent of the quantity
approved by the Engineer in mortars placed in the Works.
Only full packs of mortar as supplied shall be mixed. On-site proportioning shall not be permitted.
The temperature of the mortar on completion of mixing shall be between 5o C and 25o C. For
cementitious bedding mortars, the substrate shall be flushed clean with water two hours before
placing and maintained wet until placing commences. Any free water on the surface of the substrate
shall be removed before placing the mortar. The underside of the base plate shall be clean and free
from loose rust and loose mill scale at the time of bedding. The mortar shall be placed in its final
position within 25 minutes of commencement of mixing. Immediately after casting, the mortar shall
be protected to prevent evaporation for at least three days.
For resinous bedding mortars the substrate shall be dry, free from loose dirt and dust and shall meet
the conditions specified by the Manufacturer. The underside of the base plate shall be clean and
free from loose rust and loose mill scale at the time of bedding. The mortar shall be placed in its final
position within one hour, or lesser period specified by the Manufacturer, of commencement of mixing.
The mortar shall be poured in one corner of the plinth. The addition of mortar to the sides of the
plinth shall only be permitted after the mortar has flowed completely under the plinth.
When the mix proportions have been approved by the Engineer no variations shall be made in the
manufacture, supply, mix proportions or method of mixing of the material without the consent of the
Engineer.
No internal metal shims shall be allowed to remain in the hardened bedding mortar except where
permitted by the Engineer. The Contractor shall submit his proposals for shims for approval by the
Engineer.
25.4.13.3 Laboratory Approval Tests for Bedding Mortar

Mortar shall not be used in the Works until it has been approved by the Engineer. Every batch of
mortar to be used in the Works shall be tested by the Contractor. Where more than one batch of
Page 25-19
mortar is to be used in the Works the elastic stability test may be omitted, with the consent of the
Engineer, from the testing regime subsequent to the initial laboratory approval tests.
The Contractor shall state the water content to be used, expressed as a percentage by weight of the
material. Mixing shall be carried out in accordance with the Manufacturer's written instructions.
a. Flow Cone Test, Calibration of Flow

The flow characteristics of the mortar shall be determined by the flow cone test method described in
ASTM C939 - 10.
Tests shall be conducted at ambient temperatures of 5o C and 20o C within 15 minutes of
commencement of mixing.
For the test at 5o C the temperature of the flow cone and the mixer shall be 5o C, the temperature of
the dry material 10o C, and the temperature of the water where required, 20o C.
For the test at 20o C the temperature of the flow cone, the mixer, the dry material and the water
where required shall be 20o C.
For each temperature at least two tests having times of efflux within ±5% shall be made and the
average time of the efflux to the nearest 0.2 second shall be reported.
b. Flow between Glass Plates

The flow characteristics of the mortar between the glass plates shall be determined using the
apparatus shown in the UK (DFT) Department for Transport, Manual of Contract Documents for
Highway Works, Volume 3 - Highway Construction Details, Drawing Number K2.
Tests shall be conducted at ambient temperatures of 5o C and 20o C.
The temperature of the apparatus, dry material and water for each test shall comply with the relevant
article of this section.
The mortar shall be poured in one corner of the apparatus commencing between 18 minutes and 20
minutes after commencement of mixing.
A satisfactory flow shall be achieved when the mortar flows under the glass plate and rises at least
10mm above the underside of the top plate at all positions, without signs of segregation, bleeding,
effervescence or air inclusions.
c. Compressive Strength (Cementitious)

The compressive strength of cementitious bedding mortars shall be carried out on six 70mm cubes
at an age of 28 days.
The temperature of the mixer, the dry material, the water and the moulds shall be 20o C.
The 70mm cube moulds shall comply with BS EN 12390-1:2000 and BS EN 12390-2:2009. Test
specimens shall be made by filling the moulds carefully through a funnel to produce a void-free
mortar. The moulds shall be covered by a steel plate to prevent expansion of the mortar.
There shall be no compaction. Specimens shall be damp-cured for the first 24 hours, removed from
the moulds and then water cured. Curing shall comply with BS EN 12390-2:2009.
Testing shall comply with BS EN 12390-3:2009.
The strength requirement shall be satisfied if none of the compressive strengths obtained is lower
than 50 MPa and the difference between the highest and lowest values is not more than 20% of the
average. All results shall be reported.
d. Compressive Strength (Resinous)

The compressive strength for resinous bedding mortars shall be carried out on six 40mm cubes at
an age of 24 hours.
Page 25-20
The 40mm cube moulds shall comply with BS 6319-1:1983 and shall be carefully filled using a funnel
to ensure void-free cubes. There shall be no compaction.
Testing shall comply with BS 6319-2:1983.
The strength requirement shall be satisfied if none of the compressive strengths obtained is lower
than 50 MPa and the difference between the highest and lowest values is not more than 20% of the
average. All results shall be reported.
e. Expansion Test
Short term expansion shall be determined by the method described in ASTM C827 / C827M - 10.
Results shall be determined from the mean of two tests.
The expansion of cementitious bedding mortars at 24 hours shall be less than 2.5% and greater than
0.25%.
The volume change of resinous bedding mortars at 24 hours shall be between -0.6% and +1.0%.
f. Water Absorption Test

Absorption of water by resinous bedding mortars shall be determined by the method described in
ASTM C413 - 01(2012). The absorption shall not be more than 0.4%.
g. Elastic Stability Tests (Cementitious)

For cementitious bedding mortar, the elastic stability tests shall be carried out on one set of three
cubes made at 20o C as described in the relevant articles of this section.
Curing shall comply with BS EN 12390-2:2009. After a minimum of 28 days, the cubes shall be
placed in water at 200o C heated at a uniform rate to 450o C in 24 hours.
Upon attaining 450o C the cubes shall be sealed in a plastic bag and then loaded at a compressive
stress of 30 MPa maintained for 6 hours at 450o C and the strain measured.
The total compressive strain shall not exceed 1% on each cube.
h. Elastic Stability Tests (Resinous)

For resinous bedding mortar, elastic stability tests shall be carried out on one set of two 40mm cubes
complying with BS 6319-1:1983.
On removing the cubes from the moulds after 24 hours they shall be heated at a uniform rate to 45o
C in a further 24 hours.
Upon attaining 45o C the cubes shall be loaded at a compressive stress of 30 MPa maintained for 6
hours at 45o C and the strain measured.
The total compressive strain shall not exceed 1% on each cube.
25.4.13.4 Site Control Tests

a. Efflux Times
If the efflux times at 5o C and 20o C determined as described in the flow cone test of Article 25.4.13.3
are within 10% or 2 seconds of each other, whichever is the greater, then site control tests for flow
shall be carried out as described in (a) below. In other cases, when the air temperature is less than
10o C site control tests for flow shall be carried out as described in (b) below, and when the air
temperature is greater than 10o C site control tests for flow shall be carried out as described in (a)
below.
1. Each load of mortar mixed for placing in the Works shall be tested at ambient temperature
by the flow cone test method as described in Article 25.4.13.3. The results shall agree within
Page 25-21
±10% or ±2 seconds whichever is the greater, of the values obtained in the approval tests at
20o C.
2. Each load of mortar mixed for placing in the Works shall be tested at ambient temperature
by the flow cone test method as described in Article 25.4.13.3. The results shall agree within
±10% or ±2 seconds whichever is the greater, of the values obtained in the approval tests at
5o C.
b. Compressive Strength
Three cubes from each load of mortar mixed for placing in the Works shall be tested for compressive
strength as described in the relevant article of this section as appropriate.
The following tolerances shall apply to all temperatures referred to in this section:
Table 25-7: Temperature tolerances
Temperature Tolerance
5o C (-0o C + 2o C)
10o C (-0o C + 2o C)
20o C (-0o C + 2o C)
45o C (-2o C + 2o C)
110o C (-5o C + 5o C)
The tolerances applying to all linear dimensions shall be ±1% unless otherwise shown on the
Contract plans
25.5 Fabrication of Bearing Devices

The Contractor shall provide the Engineer with written notification 30 days before the Manufacturer
starts to fabricate bearings. Each bearing’s Manufacturer shall certify that it satisfies the
requirements of the Contract documents and the specifications in this chapter, and shall give a
certified copy of material test results to the Engineer.
Bearing assemblies shall be preassembled in the shop by the supplier and checked for proper
completeness and geometry, and shall be certified by a competent third party independent testing
agency before they are shipped to the site. Unless otherwise specified in the Contract documents,
steel bearing components, other than stainless steel, including anchor bolts, shall be galvanized in
accordance with the requirements outlined in Section 23.4.10 of Chapter 23, Steel Structures. The
following Bearing surfaces shall not be galvanised or painted:
1. The surface of the piston and the internal surfaces of the pot in pot bearings.
2. All areas where welding is required, such as where the stainless steel plate is welded to the
underside of the bearing top plate.
3. Machined female end of bolts in anchor studs.
4. The surface to come in contact with the PTFE at the top of the piston in pot bearings.
The finish of the moulds used to produce the elastomeric rotational element for pot bearings or the
polyether urethane structural element for disc bearings shall conform to good machine shop
practices.
Page 25-22
Polytetrafluorethylene (PTFE) sheets shall be bonded to a grit-blasted steel substrate using an epoxy
resin adhesive under controlled factory conditions in accordance with the instructions of the adhesive
Manufacturer. Such PTFE sheets shall be recessed into its steel substrate for at least one-half of its
thickness. If on a vertical surface, a PTFE sheet may be mechanically fastened to the substrate.
Attachment of a PTFE sheet to its substrate shall be done in accordance with the manufacturing
requirements and Section 25.4.11.
After fabrication, steel surfaces that are exposed to the atmosphere, except stainless steel surfaces,
shall be shop painted or coated to protect against corrosion as specified in the Contract documents.
Before coating exposed steel surfaces, the Contractor shall clean them in accordance with the
recommendations of the coating Manufacturer. For metal surfaces that are to be field-welded more
than three months after fabrication, the Contractor shall provide a coat of clear polish or other
protective coating that has been approved by the Engineer. The Contractor shall remove such
lacquer coating at the time of welding. Final painting or coating for these surfaces shall occur after
welding is complete.
Using an approved epoxy, the Contractor shall attach each stainless steel sheet to a steel substrate
to ensure complete contact. The Contractor shall then seal each sheet with a continuous weld.
All welding shall comply with the requirements outlined in the current version of the AASHTO/AWS
D1.5M/D1.5:2010 Bridge Welding Code. All welders shall be qualified to meet the requirements of
this same standard.
Except as noted, all bearing surfaces of steel plates shall be flat to within 0.0008 mm/mm, either
through machining or finishing. The Owner may reject any plate that does not meet this minimum
standard for flatness. A lower bearing plates (masonry plates) that rests on bearing pads shall have
a bottom surface that is flat to within 0.005 mm/mm. Oxygen-cut surfaces shall not exceed a surface
roughness value of 25 μm, as defined by the American Society of Mechanical Engineers (ASME) in
their Surface Texture (Surface Roughness, Waviness, and Lay) (ASME B46.1-2009).
Tolerances for gross bearing dimensions shall match the Manufacturers’ specifications.
Every bearing shall have its Project identification number, lot number, and individual bearing number
in indelible ink on a side that will be visible after erection.
25.5.1 Elastomeric Bearings Tolerance

Plain elastomeric pads and laminated bearings shall be built as specified in the Contract documents
within the tolerances of AASHTO M 251-06 (R2011) and as specified in this chapter.
An individual elastomer lamination’s thickness shall not vary by more than 3 mm within the width or
length of a bearing pad. Thicknesses for all elastomer laminations within a bearing pad shall ensure
that each metal or fabric lamination does not vary by more than 3 mm from a plane parallel to either
the top or bottom surface of the bearing pad.
A bearing pad’s total out-to-out thickness shall be at least as thick as indicated on the Contract plans
and not more than 6 mm greater than that thickness. An individual bearing pad’s total thickness shall
not vary by more than 3 mm.
A bearing pad’s length and width shall not vary more than 3 mm from the dimensions indicated on
the Contract plans.
Bonds between an elastomer and steel laminate shall be such that, when a sample is tested for
separation, failure shall occur within the elastomer and not between the elastomer and the steel.
Laminated elastomeric bearings shall be factory bonded.
25.5.2 Other Fabrication Tolerances

Other fabrication tolerances shall comply with the tolerances given in Table 25-8.
.
Page 25-23
Table 25-8: Fabrication tolerances
Item Thickness Dimension Surface

Flatness or Out-of-
Tolerance, Tolerance, Round Tolerance, Finish,
mm. μm. (rms)
mm. mm.
Metal Rocker & Roller Bearings
Single Roller Diameter — –1.6, +1.6 -0.02, +0.02 1.6
–0.05,
Nested Roller Diameter — +0.05 –0.02, +0.02 1.6
–3.17,
Rockers Diameter — +3.17 –0.02, +0.02 3.1
–0.13,
Pins Diameter — +0.00 –0.05, +0.05 0.8
–0.00,
Bushings Diameter — +0.13 –0.05, +0.05 0.8
Pot Bearings
–0.00, –0. 00,

Overall Dimensions +6.35 +3.17 — —
–0.00,
Pot Depth (Inside) — +0.64 — —
Pot Wall: Thickness and –0.00, –0.08,

Average Inside Diameter +3.17 +0.08 –0.02, +0.02 0.8
Pot Base: Top and Bottom –0.00,

Surfaces +0.64 — Class C 1.6
–0.00, –0.08,
Piston: Rim +1.60 +0.08 –0.02, +0.02 0.8
Piston: Top and Bottom –0.00,

Surfaces +0.64 — Class C 1.6
–0.00, –0.00,
Elastomeric Disc (Unstressed) +3.17 +1.60 — —
Disc Bearings
–0.00, –0.00,
Overall Dimensions +6.35 +3.17 — —
–0.00,
Shear-Restricting Element — +0.13 Class A 0.8
Page 25-24

Flatness or Out-of-
mm. μm. (rms)
mm. mm.
–0.00, –0.00,
Other Machined Parts +1.60 +1.60 Class B 1.6
–0.00, –0.00,
Urethane Disc +1.60 +3.17 Class B 1.6
Flat PTFE Sliding Bearings
–0.00, –0.00,
PTFE +1.60 +0.76 Class A —
–0.00, –0.00,
Stainless Steel +1.60 +3.17 Class A #8 Mirror
Flat Bronze and Copper Alloy Sliding Bearings
–0.00, –0.00,
Sliding Surfaces +3.17 +3.17 Class A 0.8
Curved PTFE Sliding Bearings
–0.25,
Convex Radius — +0.00 –0.05, +0.05 #8 Mirror
–0.00,
Concave Radius — +0.25 –0.05, +0.05 3.1
Curved Bronze and Copper Alloy Sliding Bearings
–0.25,
Convex Radius — +0.00 –0.05, +0.05 0.8
–0.00,
Concave Radius — +0.25 –0.05, +0.05 0.8
Guides
–0.00,
Contact Surface — +3.17 Class A 0.8
–0.00,
Distance between Guides — +0.76 — —
Parallelism of Guides — ±0.005 rad — —
Load Plates
–1.60, –6.35,
Overall Dimensions +1.60 +6.35 Class A 3.1
Page 25-25

Flatness or Out-of-
mm. μm. (rms)
mm. mm.
Bevel Slope ±0.002 rad — — —
25.6 Testing and Acceptance of Bearing Devices

Testing and acceptance criteria for bearings shall conform to the minimum requirements specified
in Section 25.6.2. The Engineer may impose more stringent standards.
Section 25.6.4 outlines minimum frequencies for testing for different bearing types.
When bearings are manufactured from a number of components, each component shall satisfy the
testing requirements from the applicable section.
The Manufacturer shall give the Engineer free access to inspect bearing manufacturing at any time
throughout the Project. The Contractor shall pay required expenses for a visit to the bearing
manufacturer plant for two persons representing the Owner before bearings are approved for the
Project.
25.6.1 Bearing Device Testing Terminology

Load Range: A range of load capacities in which the highest capacity is no more than 2.0 times as
large as the lowest.
Lot: A group of no more than 25 bearings of the same type (for example, a group of elastomeric and
pot bearings or a group of fixed, guided, and floating bearings) and the same load range.
Batch: A body of material in which the ingredients are uniformly blended together at one time.
Sample: A piece of material or a complete bearing that is tested to infer the properties of the batch
of material or group of bearing elements from which it is taken. A sample shall consist of at least one
bearing chosen randomly from each lot and material batch and shall comprise at least 10% of a lot.
25.6.1.1 Adapter Plates and Attachments

Each bearing that is sampled for testing with a tapered sole plate or other attachment that impedes
the application of a perpendicular loading to the bearing device shall be delivered to the test site
accompanied by an unattached adapter plate or attachment. For bearings with a tapered sole plate,
the adapter plate shall have a single bevel and be so constructed that, when placed in contact with
the tapered sole plate, the two shall form a single body, rectangular in shape and uniform in
thickness. For bearings with other attachments, the adapter plate or attachment shall be so
constructed as to permit the accurate application of perpendicular loading to the bearing device.
25.6.2 Bearing Device Tests

At their own expense, bearing device Manufacturers shall conduct all tests specified in this chapter.
The Engineer shall authorize an approved independent and disinterested testing agency to observe
all bearing device tests at the Contractor’s expense.
The Contractor shall prepare inspection and testing plans for all items and submit them to the
Engineer for approval. Such plans shall show materials, manufacturing, and proving inspections, as
well as tests and hold points for approvals.
The manufacturer shall also conduct any additional tests for specific types of bearings, as specified
in other sections and chapters of these specifications.
Page 25-26
25.6.2.1 Material Certification Tests

In accordance with appropriate specifications for each type of material, the Contractor shall conduct
material certification tests to determine the physical and chemical properties of all materials. The
Contractor shall provide all relevant test certificates to the Engineer.
25.6.2.2 Material Friction Test (Sliding Surfaces Only)

The manufacturer shall measure the coefficient of friction between the two mating surfaces. Such
tests shall be conducted either on samples taken from the same batch of materials as those used in
the prototype bearings or, at the Manufacturer's option, on finished bearings. The manufacturer shall
only test new materials; they shall not test any material that has been tested previously.
The manufacturer shall thoroughly clean all surfaces with a degreasing solvent. They shall not use
any lubrication other than that specified for the prototype bearings. Mating surfaces for test pieces
shall have a common area no smaller than the either the bearing area or 4500 mm2, whichever is
smaller.
The manufacturer shall load test pieces in compression to a stress that corresponds to their
maximum service dead load plus their live load, which shall be held constant for one hour before
and throughout a sliding test. The manufacturer shall apply at least 100 cycles of sliding, each
involving movement of at least ±25 mm, at a temperature of 50° C ± 1° C or the design temperature,
whichever is higher. Sliding speed shall be a uniform 65 mm per minute.
The manufacturer shall compute a breakaway friction coefficient for each direction of each cycle.
They shall compute a mean and standard deviation for the sixth through twelfth cycles. For the first
cycle, an initial static breakaway coefficient of friction shall not exceed twice the design coefficient of
friction. Coefficient of friction for all subsequent cycles shall not exceed the design coefficient of
friction. If a single sample fails such testing, the Engineer shall reject the entire lot.
Following the 100 cycles of testing, the manufacturer shall determine a breakaway coefficient of
friction again; it shall not exceed the initial value. No tested bearing or specimen shall show any
appreciable sign of wear, bond failure, or other defects. In addition, the bearing manufacturer shall
provide experimental evidence of the performance of proposed sliding materials for temperatures in
the range of 30° C to 70° C.
25.6.2.3 Dimension Check for Bearing Devices

Tests shall check each tested bearing’s standard and critical dimensions. The tested bearing’s
Manufacturer shall record its critical dimensions and provide these recorded values to the Engineer.
If any critical dimension of a tested bearing falls outside any dimensional tolerance, the Engineer
shall reject it. If any standard measurement for a tested bearing exceeds its allowable tolerance, the
Engineer may, at his own discretion, reject it.
To check flatness, the manufacturer shall place a precise straightedge on a tested bearing’s surface
while inserting feeler gauges between the two layers. Placing the straightedge at different
orientations, shall establish the worst condition. No more than three feeler gauges shall be stacked
on top of one another. Any straightedge used in such testing shall be as long as the largest dimension
of the flat surface.
All dimension checks shall satisfy the tolerances of Section 25.5.2.
25.6.2.4 Clearance Test for Bearing Devices

Components of each tested bearing shall be moved through their design displacements or rotations
to verify the required clearances. When testing a rotational component that is not under a
simultaneous full vertical load, the manufacturer shall make allowances for the displacements that
would be caused by such a load.
Page 25-27
1. When at 150% of maximum design rotation, the dimensions of the bearing elements shall be
sufficient to provide at least 5mm vertical clearance between rotating and non-rotating components
of the bearing assembly.
2. The sliding surface shall have an additional 50mm of spare displacement capacity after the bridge
reaches its maximum movement range taking into consideration all factors, such as creep,
shrinkage, elastic deformation, temperature, etc.
25.6.2.5 Short-term Compression Proof Load Test for Bearing Devices

The manufacturer shall load each tested bearing in compression to 150% of its rated service load. If
a bearing has a rotational element, the manufacturer shall introduce a tapered plate in the load train
to ensure that the bearing sustains the load at the maximum simultaneous design rotation. The
manufacturer shall maintain load for five minutes, remove it, then reapply it for another five minutes.
The manufacturer shall examine each bearing visually while it is under the second loading. Any
defects shall constitute cause for rejection. If the load drops below the required value during either
application, the manufacturer shall restart the test from the beginning.
25.6.2.6 Long-term Compression Proof Load Test for Bearing Devices

The manufacturer shall conduct long-term compression proof load testing in the same manner as
the short-term compression proof load testing, except that the second load shall be maintained for
15 hours. If the load drops below 90% of its target value during this 15-hour period, the manufacturer
shall increase the load to the target value and increase the test duration for a length of time equal to
the time during which the load was below the required value.
25.6.2.7 Bearing Friction Test (Sliding Surfaces Only)

Bearing friction tests verify that the friction generated during material friction tests are adequate
predictors of friction in finished bearings.
No lubrication shall be applied on the tested sliding surfaces. The bearing shall be loaded in
compression with 100% of the full service dead plus live load, which shall remain constant for one
hour before and throughout a sliding test. The manufacturer shall apply at least 12 cycles of sliding,
each consisting of either the design displacement or ± 26 mm of movement, whichever is smaller.
Average sliding speed shall be 65 mm/minute. When applying this test to curved sliding bearings,
the manufacturer shall use the design rotation in place of the displacement.
For flat sliding bearings, the manufacturer shall compute the breakaway friction coefficient for each
direction of each cycle. They shall also compute its mean and standard deviation for the sixth through
twelfth cycles. Neither the friction coefficient for the first movement nor the mean plus two standard
deviations for the sixth through twelfth cycles shall exceed the value used in design. For the sixth
through the twelfth cycles, the mean shall not exceed two thirds of the value used in design.
For curved sliding surfaces, the manufacturer shall determine the moment that corresponds to the
design rotation at each peak movement (positive and negative) during the first and last six cycles of
testing. To calculate a corresponding load eccentricity, the manufacturer shall divide the moment by
the total active compressive load. Eccentricity shall be small enough not to violate the allowable
design stresses on PTFE.
25.6.2.8 Long-term Deterioration Test for Bearing Devices

The manufacturer shall conduct long-term deterioration tests either on samples of the materials used
in the bearings or, at the Manufacturer’s option, on a pair of bearings, placed back-to-back. Tested
samples shall have an area of at least 4500 mm2. The manufacturer shall first load a test piece in
compression to a stress equal to 100% of the bearing’s maximum dead load plus its live service
load. Flat sliding systems shall then be displaced through at least 1000 cycles with amplitude of at
least ±25 mm (50 mm peak to peak.) Curved sliding systems and rotational systems that depend on
deformation of an elastomeric element shall be subjected to 5000 cycles or displacements
Page 25-28
corresponding to a rotation of plus or minus the design amplitude. Sliding may take place at up to
250 mm per minute, except when the manufacturer take readings of the coefficient of friction, when
sliding speed shall be 65 mm per minute.
The Engineer may reject a test bearing for either of the following reasons:
• Upon disassembly, a bearing has damage, such as excessive wear, cracks, or splits in the
material, that is visible to the naked eye.
• A coefficient of friction exceeds two-thirds the value used in design.
25.6.2.9 Bearing Horizontal Force Capacity (Fixed or Guided Bearings

Only)
To test fixed or guided bearings for horizontal force capacity, the manufacturer shall select one or
more loading combinations that consist of a horizontal and vertical service loading that could exist
simultaneously in the structure. The manufacturer shall apply vertical load first, at 1.0 times its
nominal value. The manufacturer shall then apply horizontal load, in stages, up to 1.5 times its
nominal value. The Engineer shall reject any bearing that fails this test or for which even one
component shows excessive deflection.
25.6.3 Performance Criteria for Bearing Devices

If one bearing of a sample fails, the Owner shall reject all the bearings of that lot, unless the
Manufacturer of that lot elects to test each bearing of the lot at his expense. Should one bearing fail,
the Engineer may require the Manufacturer to test all the bearings in that lot.
25.6.4 Special Testing Requirements for Bearing Devices

This section describes special testing requirements for bearing devices.
25.6.4.1 Testing Elastomeric Bearings

Materials for elastomeric bearings and finished bearings shall be subjected to the tests described in
this section. Material tests shall be within the parameters outlined in either Table 25-3 or Table 25-4,
as appropriate.
a. Frequency of Testing
The manufacturer shall conduct the ambient-temperature tests for an elastomer that are specified in
this section for the materials used in each lot of bearings. In lieu of performing a shear modulus test
for each batch of material, the Manufacturer may elect to provide certificates from tests performed
on identical formulations within the preceding year, unless the Engineer declines to accept such
certificates. A supplier shall provide test certificates for each lot of reinforcement.
The manufacturer shall conduct the three low-temperature tests for an elastomer that are specified
in this section on the material used in each lot of bearings for grades 3, 4 and 5 material. They shall
conduct an instantaneous thermal stiffening test on material of grades 0 and 2. For Grade 3 material,
in lieu of the low temperature crystallization test, the Manufacturer may choose to provide certificates
from low-temperature crystallization tests performed on identical material within the last year, unless
the Engineer declines to accept such certificates. Low temperature brittleness and crystallization
tests shall not be required for materials of grades 0 and 2, unless the Engineer specifically requests
such tests.
The manufacturer shall visually inspect each finished bearing as specified in this section.
The manufacturer shall subject every steel reinforced bearing to the short-duration compression test
From each lot of bearings designed in accordance with the AASHTO LRFD Bridge Design
Specifications and Road Structures Design Manual (ADQCC TR-516), the manufacturer shall
Page 25-29
subject a random sample to the long-duration compression tests outlined in this section. Such a
sample shall consist of at least one bearing that is chosen randomly from each size and material
batch and shall comprise at least 10% of the lot. If one bearing in this sample fails, the Owner shall
reject all the bearings of that lot, unless the Manufacturer elects to test each bearing of the lot at their
own expense. The Engineer may require such testing for every bearing of a lot.
The Engineer may require shear modulus tests on material from a random sample of the finished
bearings in accordance with the requirements outlined in this section.
b. Ambient-temperature Tests on an Elastomer

Each elastomer used shall satisfy or exceed the criteria specified in either Table 25-3 or Table 25-4,
as appropriate. Any bond to the reinforcement shall also satisfy the provisions outlined in Article
25.4.6.3. Using the apparatus and procedure described in Annex A of ASTM D4014 - 03(2007), the
manufacturer shall record the shear modulus for material at 23° C. It shall fall within 15% of the value
specified in the Contract documents. If the Contract documents do not specify shear modulus, the
range of hardness shall conform to the AASHTO LRFD Bridge Design Specifications and Road
Structures Design Manual (ADQCC TR-516).
c. Low-temperature Tests on an Elastomer

The manufacturer shall perform low-temperature tests in accordance with the requirements outlined
in Table 25-3 and Table 25-4. Each compound shall satisfy all criteria for its grade.
d. Visual Inspection of Finished Bearings

The manufacturer shall inspect each finished bearing for compliance with dimensional tolerances
and for overall quality of manufacture. In steel reinforced bearings, steel edges shall be protected
everywhere from corrosion.
e. Short-duration Compression Test on Bearings

For short-duration compression testing, the manufacturer shall load a bearing in compression to
150% of its rated service load. If a bearing has a rotational element, the manufacturer shall introduce
a tapered plate in the load train so that the bearing sustains the load at the maximum simultaneous
design rotation. The manufacturer shall sustain this load for five minutes, remove it, then reapply it
for another five minutes. While a bearing is under this second load, the manufacturer shall visually
examine it. If load drops below the required value during either application, the manufacturer shall
restart the test from the beginning.
The Engineer shall reject any tested bearing with any of the following characteristics:
• A bulging pattern that suggests laminate parallelism
• A layer thickness that is outside the specified tolerances
• A laminate is poorly bonded
• Any visible cracks on the surface.
f. Long-duration Compression Tests on Bearings

For long-term compression testing, the manufacturer shall follow the ambient-temperature test
procedure outlined in this section, but will maintain the second load for 15 hours. At the end of this
15 hours, while a bearing is still under load, the manufacturer shall visually examine it. If the bearing
indicates any visual patterns or cracks, it fails this test. The Engineer shall reject any bearing that
fails this test.
g. Shear Modulus Tests on Material from Bearings

The manufacturer shall determine the shear modulus of a material in the finished bearing by cutting
a specimen from this materials and using the apparatus and procedure described in Annex A of
ASTM D4014 - 03(2007), amended where necessary in either Table 25-3 or Table 25-4, as
Page 25-30
appropriate. The Engineer has discretion to ask the manufacturer to conduct a comparable
nondestructive stiffness test on a pair of finished bearings. A material’s shear modulus shall fall within
±15% of the value specified for it in the Contract documents. If the Contract documents do not specify
a shear modulus for a material, its range for hardness shall conform to the details outlined for such
materials in the AASHTO LRFD Bridge Design Specifications and Abu Dhabi Road Structures
Design Manual (AD-D-06). When applying this test on material from finished bearings, the
manufacturer shall compute shear modulus from the measured shear stiffness of the bearings, taking
into account the influence of bearing geometry and compressive loading.
25.6.4.2 Testing Pot and Disc Bearings

Tests for pot and disc bearings shall comply with the requirements outlined in this section.
a. Lot Sizes for Pot and Disc Bearing Tests

The Contractor shall conduct sampling and testing for each lot, and shall apply acceptance criteria
for each lot as a whole. To determine the quantity of bearings in a lot, the Contractor shall apply the
following criteria:
• A lot shall not exceed a single Contract document or Project quantity.
• A lot shall not exceed 25 bearings.
• A lot shall consist of bearings of the same type, regardless of load capacity. A lot may contain
fixed or expansion bearings. The Contractor shall consider guided and non-guided expansion
bearings to be a single type.
b. Sampling and Acceptance

The Manufacturer shall sample, at random, a minimum of two (2) bearings and, as permitted or
required, a minimum of two (2) individual bearing components from each completed lot of bearings
for material certification and performance testing by the Manufacturer. Individual bearing
components sampled for material certification or performance testing shall be sampled from the
materials used to fabricate a lot of bearings, and not from completed bearings. The Manufacturer
shall complete the required testing and determine compliance with this specification before
submitting the lot(s) for quality-assurance inspection, testing, and acceptance consideration. The
results of the Manufacturer's tests shall be furnished to the Engineer.
c. Material Certification Tests for Pot and Disc Bearings

Material certification tests shall be conducted in accordance with Article 25.6.2.1.
The Manufacturer shall also provide certification for all elastomeric and polyether urethane elements.
These material’s properties shall satisfy the requirements specified in the Contract documents.
These material’s properties shall also pass the tests for pot bearings described in Article 25.4.7.3
and the tests for disc bearings described in Article 25.4.7.7. The Engineer may also require additional
tests.
d. Dimension Check and Clearance Test for Pot and Disc Bearings
Dimensions and clearances shall be checked for all bearings according to Articles 25.6.2.3 and
25.6.2.4.
The clearance test between the piston and the pot on a pot bearing and the clearance between the
shear-restricting element and disc on a disc bearing are critical clearances that shall be verified
through the clearance test, described in Article 25.6.2.4, to ensure proper functioning of the bearing
through its entire design displacement and rotation.
e. Long-Term Deterioration Test

The long-term deterioration test shall satisfy the requirements of Article 25.6.2.8. When testing is
specified by the Owner to be on a per lot basis, the long-term deterioration test shall be performed
Page 25-31
on one (1) sampled disc bearing of each lot and one (1) sampled pot bearing of each lot. For such
testing, sealing rings with rectangular cross-sections and sealing rings with circular cross sections
shall meet the specifications outlined in the AASHTO LRFD Bridge Design Specifications and Road
Structures Design Manual (ADDQC TR-516).
f. Quality Assurance Testing for Pot and Disc Bearings

When the Contract documents specify quality assurance testing, the Manufacturer shall give the
required number of complete bearings and component samples to the Engineer for quality-
assurance testing in accordance with Table 25-9.
The Engineer shall test at least one elastomeric element per lot of bearings for pot bearings. For pot
bearings, the Engineer shall conduct at least one set of material property tests per lot. All exterior
surfaces of sampled production bearings shall be smooth and free from irregularities or protrusions
that might interfere with testing procedures.
The Project schedules shall allocate at least 30 days for inspection, sampling, and quality assurance
testing of production bearings and component materials.
Bearings with tapered sole plates shall conform to the provisions outlined in Article 25.6.1.1.
The Engineer may select, at random, required sample bearings from completed lots and samples of
elastomeric and PTFE materials for quality assurance testing.
The Contractor shall assume the cost of transporting all samples from the place of manufacture to
the test site and then either back to the place of manufacture or, if applicable, to the Project site.
Table 25-9 shows the sample required for different quality assurance testing.
Table 25-9: Samples required for quality assurance testing
Test Samples required
Proof load One production bearing per lot
Coefficient of Friction One production bearing per lot
Physical Properties of Elastomeric

One elastomeric element per lot
Rotational Element
Physical Properties of PTFE Sheet One 0.25 m×0.38 m sheet of PTFE material per project
Physical Properties of Polyether

One 0.25 m×0.38 m sheet of polyether urethane material
Urethane Structural Element (except
(thickness of 1.6 mm to 3.1 mm per lot)
compression set)
One 0.10 m×0.10 m sheet of polyether urethane per lot,

Compression Set of Polyether
moulded or cut to the thickness requirements of ASTM
Urethane Structural Element
D395 - 03(2008), Method B
g. Proof Load Test for Pot and Disc Bearings

Sampled bearings shall be short-term load-tested to 150% of its specified rated capacity at an angle
of 1.14 degrees. If a bearing’s size prohibits adequate testing with available equipment, the Owner
and Manufacturer may agree to test a prototype bearing that has characteristics that are comparable
with those required for the Project. The load shall be held for 5 minutes, removed, then reapplied for
5 minutes. If the load drops below the required value during either application, the test shall be
restarted from the beginning.
Page 25-32
At the discretion of the Owner, a long-term proof load test may also be specified or substituted for
the short-term proof load test. Except as specified below, the magnitude of the loading, test
procedures, and failure criteria for the long-term test shall be identical to that of the short-term test.
The first loading shall be held for 5 minutes and the second loading shall be held for 15 hours. If the
load drops below 90 percent of its target value during this time, the load shall be increased to the
target value and the test duration shall be increased by the period of time for which the load was
below the required value.
Throughout this test, the bearing’s steel bearing plate and steel piston shall maintain continuous and
uniform contact.
The manufacturer shall visually examine each bearing both during the test and upon disassembly
after the test. The Owner shall reject an entire lot for which such testing has caused visual defects
to even a single bearing. Causes for rejection include any of the following resultant visual defects:
• Extruded or deformed elastomer, polyether urethane, or PTFE
• Damaged seals or limiting rings
• Evidence of metal-to-metal contact between the pot wall and the top plate
• Cracked steel
Throughout tests for disc bearings, continuous and uniform contact shall be maintained between the
polyether urethane element and the bearing plates and between the sliding steel top plate and the
upper bearing plate. The Owner may reject an entire lot for which any lift-off has been observed for
even a single bearing during such testing.
h. Sliding Coefficient of Friction Test for Pot and Disc Bearings

For all guided and non-guided expansion-type bearings, the manufacturer shall measure the sliding
coefficient of friction at the bearing's design capacity in accordance with the specifications outlined
in Article 25.6.2.2 and Article 25.6.2.7. The manufacturer shall also take addition measurements on
the fifth and fiftieth cycles at a sliding speed of 25 mm per minute.
To calculate a bearing’s sliding coefficient of friction, the manufacturer shall divide the horizontal
load required to keep the bearing sliding continuously by the bearing's vertical design capacity.
A bearing’s measured sliding coefficients of friction shall not exceed 3%.
The manufacturer shall visually examine each tested bearing both during and after testing. The
Owner shall reject an entire lot for which such testing has caused visual defects to even a single
bearing. Causes for rejection include any of the following resultant visual defects:
• Bond failure
• Physical destruction
• Cold flow of PTFE to the point of de-bonding
• Damaged components
The Contractor may use bearings that are not damaged during testing in the Project work.
25.6.4.3 Testing Rocker and Roller Bearing

The manufacturer shall conduct material certification tests for rocker and roller bearings to verify that
their material properties meet the Project’s requirements.
25.6.4.4 Testing Polytetrafluorethylene Surfaces for Bearings

The Engineer may require inspection of completed bearings or representative samples of bearings
with PTFE surfaces. Inspectors, if appointed, shall be allowed free access to the necessary part of
the Manufacturer's plant and test facility. If the Manufacturer performs testing, they shall submit
copies of the test results to the Engineer.
Page 25-33
The Manufacturer is required to perform material tests, as defined in Article 25.6.2.2, on the materials
used in the sliding surface. The manufacturer shall perform at least one test for each lot of bearings.
If the Engineer requests such testing and test facilities permit such testing, the manufacturer shall
conduct complete bearing friction tests as defined in Article 25.6.2.9. If a test facility does not permit
testing complete bearings, the Engineer may direct the Contractor to manufacture extra bearings
and to prepare samples of at least 450 KN Capacity at normal working stresses by sectioning the
bearings. As soon as all bearings have been manufactured for the Project, the Contractor shall notify
the Engineer, who shall randomly select prescribed test bearings from the lot. The Contractor shall
also provide the Manufacturer's certification of the steel, elastomeric pads, preformed fabric pads,
PTFE, and other materials used in the construction of the bearings.
After such testing, the Engineer may inspect tested bearings on site for visible defects. After such
inspection, the Engineer may approve the use of bearings that passed such testing for use in the
structure under construction.
25.6.4.5 Testing Bronze or Copper-alloyed Plates for Bearings

The manufacturer shall conduct material certification tests for bronze or copper-alloy bearings to
verify that their material properties meet the Project’s requirements.
25.6.4.6 Testing for Curved Sliding Bearing

Curved PTFE sliding surfaces shall satisfy all of the test requirements specified for PTFE sliding
surfaces in Article 25.6.4.4. If, however, a prototype bearing is too large to test, the Contractor may
manufacture a test bearing using materials and fabrication methods that are identical to those used
for the prototype, rather than sectioning the bearing. When bearings are too large for testing, the
Engineer shall determine the size of any test bearings to be specially manufactured.
Critical dimensions shall include the difference between the average radii of the two elements and
the variation of the actual curved surface from the average one. The Engineer may require the
Contractor to verify these critical dimensions by following the procedure described in Article 25.6.2.3.
25.6.5 Use of Tested Bearings in a Structure

The Contractor may use bearings that have been satisfactorily tested in accordance with the
requirements of this chapter in the structure under construction. As the Engineer so requires, the
Contractor shall equip such tested bearings with new deformable elements, sliding elements, and
seals.
25.7 Packaging, Handling, and Storing Bearing Devices

Each bearing shall be assembled at the plant, shall be marked for identification, and shall be
delivered to the construction site as a complete unit.
Before shipment from the point of manufacture, bearings shall be packaged to protect them against
damage from handling, weather, or other normal hazard during shipment and storage. The
Contractor shall clearly mark the components of each completed bearing. They shall also securely
bolt, strap, or otherwise fasten completed bearings to prevent any relative movement. In compliance
with the Contract documents, the Contractor shall mark the top of each bearing to clearly indicate its
location, orientation, and preset in each structure in the Project.
All bearing devices and components shall be stored at the work site in an area that provides
protection from environmental and physical damage. When installed, bearings shall be clean and
free of all foreign substances.
The Contractor shall not open or dismantle bearings at the site unless doing so is absolutely
necessary for inspection or installation.
Page 25-34
25.8 Installing Bearing Devices

Qualified personnel shall install bearings in the positions shown in the Contract documents. When
installing bearings, the Contractor shall set them to the dimensions and offsets prescribed by the
Manufacturer, the Engineer, and the Contract documents, making any necessary adjustments to
account for anticipated temperatures, future movements of the bridge caused by temperature
changes, release of falsework, and shortening caused by pre-stressing. The Contractor shall use
the approved working drawings which locate the bearings taking into account the size of the top
plate, preset, etc that ensures that the bearing does not encroach to close to the deck concrete
edges. The centre line of the bottom part of the bearings shall be in line at any one support.
Each bridge bearing shall be located within ±3 mm of its correct position in the horizontal plane and
oriented to within an angular tolerance of 1.14 degrees. Guided bearings and bearings that rotate
about only one axis shall be oriented in the direction specified in the Contract documents to within
an angel tolerance of 0.28 degrees. All bearings except those that are placed in opposing pairs shall
be set horizontal to within an angular tolerance of 0.28 degrees, and must have full and even contact
with load plates, where these exist. A superstructure supported by a bearing shall be set so that,
under full dead load, its slope lies within an angular tolerance of 0.28 degrees of the design value.
Any departure from this tolerance shall be corrected by means of a tapered plate or by other means
approved by the Engineer. If the Contractor uses shim stacks to level a bearing, they shall remove
the shim stacks after grouting and before the weight of the superstructure acts on the bearing.
Metallic bearing assemblies that are not embedded in concrete shall be bedded on the concrete with
a filler or fabric material that conforms to the specifications outlined in Section 25.4.13.
Where bearings are seated directly on steel work, the Contractor shall machine the supporting
surface to provide a level surface upon which a bearing is placed.
Bearings or masonry plates that rest on steel supports may be directly installed on the supports,
given that the support is flat within a tolerance of 0.002 times its nominal dimension and is sufficiently
rigid to resist deformation under specified loads.
25.8.1 Installing Elastomeric Bearings

Elastomeric bearings without external load plates may reside directly on a concrete or steel surface
if such surface is flat to within a tolerance of 0.005 mm of the nominal dimension for steel reinforced
bearings and within 0.01 mm of the nominal dimension for other bearings. Bearings shall reside on
surfaces that are horizontal to within 0.6 degrees. The Contractor shall correct any lack of parallelism
between the top of the bearing and the underside of the girder that exceeds 0.6 degrees by grouting
or by applying another method as directed by the Engineer.
All concrete bearing surfaces on which elastomeric bearing pads are to be placed shall be wood
float finished to a level plane that shall not vary more than 3 mm from a straightedge placed in any
direction across the area. A finished bearing seat shall not vary more than 3 mm from the elevation
shown on the Contract plans.
Concrete or metal surfaces on which the bearing pads are to be set shall be dry, clean, and free
from dirt, grease, laitance, and contaminants. The Contractor shall not place any bearing pad until
the Engineer has inspected and approved the seat conditions.
Using an approved epoxy mortar pad, with surface roughness no smoother than gr.40 sand-particles,
in accordance with the recommendations of each elastomeric bearing pad’s Manufacturer, the
Contractor shall fix all elastomeric bearing pads in position on the bearing seat.
For expansion bearings only, the Contractor shall use polyethylene sheeting or another removable
bond-breaking material that has been approved by the Engineer to prevent concrete from bonding
to the top surface of each bearing pad.
Page 25-35
The Contractor shall not weld exterior plates of the bearing unless at least 40 mm of steel resides
between the weld and the elastomer. In no case shall an elastomer or bond be subjected to
temperature higher than 200° C.
25.8.1.1 Stress Relieving of Elastomeric Expansion Bearings

No sooner than 30 days after the final stressing and grouting of the pre-stressing steel, the Contractor
shall use jacks to raise the concrete superstructure at expansion bearings to relieve the shear strain
in the elastomeric bearing pads that results from elastic shortening and shrinkage of the concrete.
The Contractor shall provide steel flat jacks with steel shims for jacking between the superstructure
end diaphragm and the abutment seat. Flat jacks shall have a maximum outside diameter of 600
mm, a minimum capacity of 350 metric tons, and minimum travel of 25 mm. The Contractor shall
obtain written approval from the Engineer for the specifications of such flat jacks.
The Contractor shall place jacks at the locations shown on the Contract plans and shall operate them
simultaneously through a manifold to equalize pressure. To relieve the load and shear deflection
from the bearing pads and to allow removal of the bond breaking material, the Contractor shall extend
jacks no more than the minimum. Stress relief for bearing pads shall occur only at expansion
bearings. For the two span continuous structures, the Contractor shall only jack one abutment at a
time.
To avoid compounding stresses in bearing pads with stresses caused by temperature changes, the
Contractor shall only perform a jacking operation when the abutment air temperature is between 20°
C and 32° C. After completing a jacking operation, the Contractor shall immediately release the
pressure in the jacks and remove them to avoid complications that can result when temperature
changes cause the superstructure to expand or contract.
To ensure reliability, the Contractor shall use only new jacks. Before reusing any jacks, the
Contractor shall get approval from the Engineer. The Contractor shall operate jacks only under the
Engineer’s direct supervision.
25.8.2 Installing Pot and Disc Bearings

The Contractor shall certify to the Engineer that a skilled representative of the bearing Manufacturer
will be available to the Contractor to give aid and instruction in the installation of bearings to ensure
satisfactory results.
This skilled representative shall be present during the initial installation of the bearings and shall
remain on the job until the Engineer declares that the bearing installation is proceeding smoothly
and that workers involved are familiar with the work required for each installation. The Engineer may
also require the Contractor to arrange to have this representative present at any other times.
The Contractor shall install pot and disc bearings in accordance with the Contract documents and
approved working drawings. After final installation of bearings, the Engineer, in the presence of the
Manufacturer's representative, shall inspect all bearing components to ensure that they are level and
parallel to within 2.6 mm/m. The Contractor shall correct any deviations in excess of the allowed
tolerances.
Using templates, the Contractor shall monolithically cast anchor bolts with the substructure concrete
to the exact locations and with precise bolt projections above a bearing seat, as shown on the
Contract plans and approved working drawings.
Using an epoxy and quartz sand grout, the Contractor shall place bearing grout pads in accordance
with the Contract plans, these specifications, and the bearing Manufacturer’s recommendations. Top
surfaces of epoxy grout pads shall be perfectly level; the Contractor shall correct any perceptible
deviations from a straightedge by filling them as necessary with epoxy mortar and grinding such
deviations until they are level. Alternatively, a high strength self levelling grout below bearings may
be used in accordance with the bearing Manufacturer’s recommendations.
Page 25-36
The Contractor shall place bearings when erecting the superstructure form, and shall remove all
temporary restraints as directed by the bearing Manufacturer.
Bearings shall reside in the exact alignment shown on the Contract plans for each location and shall
have proper directional orientation. To prevent wedging actions in a bearing that may result from
movements of a superstructure, the Contractor shall carefully align both the base and upper part of
a guided expansion bearing to be parallel to the expansion axis of the structure. The Contractor shall
adjust the location of the upper part of a bearing relative to the base to accommodate for temperature
at the time of erection.
If bearings are disassembled for any reason, the Contractor shall be extremely careful to ensure that
the rubber pads and piston rings are properly seated in the recess with piston ring gaps 180° apart.
25.8.3 Installing Rocker and Roller Bearings

When setting rocker and roller bearings, the installer shall take into account how the support span
may by impacted by variations from mean temperature and otherwise change in length. The installer
shall ensure that at mean temperature, after release of falsework and any shortening due to pre-
stressing force and shrinkage, the supported span’s rockers and rollers will be vertical. The installer
shall be careful to properly set and adjust bearings to avoid restricting the full and free movement of
the superstructure at movable bearings.
The Contractor shall coat all contact surfaces thoroughly with oil and graphite before placing roller
bearings.
Positions of cylindrical bearings shall ensure that their axes of rotation are in alignment and coincide
with the superstructure’s axis of rotation.
25.8.4 Installing Spherical Bearings

Spherical bearings shall be installed as specified in the Contract documents.
25.8.5 Installing Bronze or Copper-alloyed Plates for Bearings

Installation of bronze or copper-alloyed plates for bearings shall comply with the requirements
25.8.5.1 Bronze Bearing and Expansion Plates

Bronze bearing and expansion plates shall conform to the requirements for C91100, C86300, or
C90500 alloys as outlined in the Specification for Bronze Castings for Bridges and Turntables
(AASHTO M 107-09) or (ASTM B22 - 09e2). Unless the Contract documents specify otherwise,
bronze bearing and expansion plates shall be alloy C91100. Components may be cast, rolled, or
forged. Castings shall be free of blow-holes that are larger than 3 mm. Contact surfaces shall be free
of blow-holes of any size.
Casting for bronze plates shall comply with details shown in the Contract documents. Unless the
Contract documents indicate otherwise, sliding surfaces shall be polished and shall reside in a plane
that parallels the movement of the spans.
25.8.5.2 Rolled Copper-alloy Bearings and Expansion Plates

Rolled copper-alloy bearing and expansion plates shall conform to the Specification for Rolled
Copper-Alloy Bearing and Expansion Plates and Sheets for Bridge and Other Structural Uses
(AASHTO M 108-09) or (ASTM B100 - 08). Unless the Contract documents specify otherwise, rolled
copper bearings and expansion plates shall be C51000 alloy or C51100 alloy.
The Contractor shall provide copper-alloy plates in accordance with the Contract documents. Rolled
plates with plane, true, and smooth surfaces shall not require finishing.
Page 25-37
25.8.6 Installing Masonry, Sole, and Shim Plates for Bearings

To form holes in bearing plates, the Contractor may apply drilling, punching, or accurately controlled
oxygen-cutting. The Contractor shall remove all burrs by grinding.
Bearing plates shall be level, as shown in the Contract documents and shall have a uniform bearing
over an entire area. When plates are embedded in concrete, installers shall ensure that the plates
remain in their correct positions while concrete is placed.
25.8.7 Installing Polytetrafluorethylene Surfaces for Bearings

25.8.7.1 Attachment of Polytetrafluorethylene Material
Mechanically fastening for PTFE sheets, when applied, shall be as shown in the Contract
documents; sizes, types, and numbers of fasteners shall be as required. The installer shall ensure
that any fastener used for a PTFE sheet and its back-up material provide full bearing.
a. Flat Sheet Polytetrafluorethylene

All flat PTFE sheets that are attached to a metal backing plate shall be attached by recessing into
the backing of the plate for one-half of the PTFE thickness and bonding. PTFE attached to other
materials, such as elastomers, shall be attached by a method specified in the Contract documents
or as directed by the Engineer.
All PTFE shall be factory-bonded, using an adhesive that is approved by the Engineer, in accordance
with the instructions of the adhesive's Manufacturer. Before bonding, the approved Manufacturer
shall use a sodium naphthalene or sodium ammonia process to etch a PTFE sheet’s surface. When
a backing plate is metal, bonding shall be conducted under a uniform pressure greater than 0.7 MPa.
A bond’s peel strength shall not be less than 3.5 N/mm, tested in accordance with method B from
ASTM D429 - 08. A PTFE sheet’s finished surface shall be smooth and free from bubbles. It shall
also conform to the tolerances shown in Table 25-6. Filled PTFE sheets shall be polished after
bonding.
b. Curved Sheet Polytetrafluorethylene

Curved PTFE sheets, such as those used in spherical bearings, shall be attached by recessing for
one-half the PTFE thickness. A PTFE element’s dimensions shall enable it to fit tightly in its recess
even when a bearing is subjected to its lowest design temperature.
c. Fabric Containing Polytetrafluorethylene Fibres

Fabric made from woven PTFE fibres shall be bonded or mechanically attached to a rigid substrate.
A fabric shall be capable of carrying unit stress of 70 MPa without cold flow. A fabric-substrate bond
shall be capable of withstanding, without delamination, a shear force equal or greater than (0.1+μ)
P at the same time as the normal load, where μ is the design coefficient of friction between a PTFE
sheet and its mating surface and P is the design load acting perpendicularly to the interface.
25.8.7.2 Stainless Steel Mating Surface

When the Contract documents specify that a stainless steel element specified is a single piece, the
Contractor shall comply. Each sheet shall be attached to its backing material by seal welding around
the entire perimeter, preventing moisture from entering between the stainless steel and the backing
material. Welds shall conform to the current AASHTO/AWS D1.5M/D1.5:2010 Bridge Welding Code.
After welding, a stainless steel sheet shall be flat, free from wrinkles, and in continuous contact with
its backing plate.
Page 25-38
25.8.7.3 Lubrication for Polytetrafluorethylene Surfaces

If the Contract documents so specify or the Engineer so directs, installers shall apply lubrication to
an entire PTFE surface. If PTFE is dimpled, installers shall apply enough lubricant to fill all the
dimples.
25.8.7.4 Installation of Polytetrafluorethylene Surfaces

Installation of PTFE surfaces shall comply with the specifications outlined in Section 25.8.3.
25.8.8 Installing Anchor Bolts for Bearing Devices

The Contractor shall drill holes for anchor bolts and set them in Portland cement grout. As an
alternative, installers may preset anchor bolts as shown in the Contract documents or as directed by
the Engineer.
To locate anchor bolts, installers shall take into account any mean temperature variations that could
impact the superstructure at time of setting, as well as any anticipated lengthening of a bottom chord
or bottom flange causes by the dead load after setting. As much as practicable, at mean temperature
and under dead loads, anchor bolts at expansion bearings shall be centred in their slots. Installers
shall be careful to ensure that anchor bolts and nuts do not restrict the superstructures full and free
movement at movable bearings.
25.8.9 Installing Load Plates for Bearing Devices

The Contractor may make load plates from either a single plate or from several steel laminates that
are each oriented in a plane perpendicular to the direction of the load. Installers shall use seal
welding to join such built-up load plates and to prevent the ingress of moisture. Such welds shall
also provide sufficient shear strength to resist applied loads. A load plate shall have no sharp corners
or edges. To form holes, the installer may apply drilling, punching, or accurately controlled oxygen
cutting. Installers shall remove all burrs by grinding.
25.8.10 Installing Guides for Bearing Devices

When attaching guide bars to the body of a bearing, installers shall minimize distortion and shall
ensure that all parts of a bearing remain within the tolerance for flatness. A guide system’s sliding
surfaces shall be flat and parallel.
Bolts or threaded fasteners that attach guide bars to their supporting plates shall have a sufficient
embedded thread length to develop their strength.
To attach low-friction material at a contact interface, the installer shall simultaneously use two or
more of the following methods to attach it to its backing piece:
a. Bonding
b. Recessing
c. Mechanical attachment with countersunk fasteners
If material is bonded, the installer shall affix it using a method recommended by either the
Manufacturer of the material or the bonding agent. Recessing shall be one-half of the material
thickness. Fasteners shall be countersunk to a depth that ensures that they will not touch the mating
material after allowing for wear.
25.8.11 Installing Guide-ways and Restraints for Bearing Devices

Guided bearings and bearings that rotate about only one axes shall be oriented in the direction
specified on the Contract plans to within an angular tolerance of 0.3 degrees.
Page 25-39
25.8.12 Installing Seismic Buffer Blocks

Installation of seismic buffer blocks, if used, shall comply with the Contract plans. Buffer blocks shall
be elastomeric blocks that are vulcanised to steel plates that, in turn, are anchored into concrete.
Elastomeric blocks shall comply with the stiffness requirements given on the Contract plans.
25.8.13 Installing Seismic Restraint Cables

The Contractor shall provide and install seismic restraint cables in accordance with the Contract
plans. The Contractor may propose alternative proprietary systems for approval from the Engineer.
Restraint cables shall be unstressed and positioned with no more than 10 mm slack between
anchorages. The Contractor shall prepare detailed method statements that describe the installation
methods that will achieve this requirement and submit these statements to the Engineer for approval.
Retaining plates shall prevent slippage of the wedges.
25.8.14 Installing Shear Transfer Units at Abutments

The Contractor shall furnish and install shear transfer units between the superstructure abutment
shear blocks and where indicated on the Contract plans, as specified herein, as detailed on the
Contract plans and as directed by the Engineer.
• Shear transfer units shall be elastomeric materials complying with the requirements as
specified in Section 25.4.6.
• All steel components shall comply with the requirements of all applicable clauses in Section
25.4 and Section 30.5 of Chapter 30, Miscellaneous Metals, of these Standard Specifications.
• The PTFE layers shall comply with the requirements as specified in Section 25.4.11.
• Installation of shear transfer units shall comply with the details as indicated on the Contract
plans and the manufacturer’s printed directions.
25.8.15 Load Cells

Load cells for measuring applied vertical load, shall be provided for the bearings indicated on the
Contract plans and others as proposed by the Contractor and approved by the Engineer for
monitoring of load transfer during construction. The loads cells shall comprise a pressure transducer
connected for instance to the elastomer in the pot bearing (or by other suitable method approved by
the Engineer for disc or spherical bearings) giving an instantaneous reading to a local Windows-
based personal computer (PC) for display. The computer shall be provided with a suitable Data
Acquisition System (DAS) for storing, analysing and displaying the data in graphical format.
Graphical output shall be given in terms of the variation of vertical load over time. The DAS shall be
capable of recording and displaying results at a minimum rate of 1Hz.
All load cells shall be operational during construction to enable monitoring of loads throughout that
phase. Load cells, by design, shall enable replacement of damaged units during construction or at
any time thereafter.
The Contractor shall design, supply, maintain, and operate the system during construction, recording
loads to an accuracy of +/-5%.
25.9 Bearing Replacement

The Contractor shall provide fully detailed proposals for bearing replacement, including all related
components at all bearing positions. These proposals shall include sizes and positions of jacking
equipment, a methodology for removing existing bearings, details for installing the new bearings,
and descriptions of all temporary works that are necessary to enable replacement of bearings. The
Contractor shall describe any modifications to the outlines of permanent works and any additional
local reinforcement in permanent works at jacking locations. Bearing replacement proposals shall
provide all necessary information and facilities to enable subsequent bearing replacement without
Page 25-40
adding attachments or fixings to the permanent works. The Contractor shall ensure that permanent
works provide all necessary additional reinforcement and cast-in sockets; the Contractor shall also
supply any additional materials, as necessary to support the bearing replacement proposal.
The Contractor shall make necessary provisions to reinstate fuse links after an earthquake occurs
that exceeds the capacity of fuse links, but that is less than the extreme event. Fuse link devices and
seismic devices shall be designed for ease of reinstatement and to support any jacking that would
be necessary to adjust a deck back to its original horizontal alignment with minimal temporary works.
25.10 Warranty and Maintenance for Bearing Devices

The Contractor shall obtain the specified warranty period from the Manufacturer for all bearing
devices that are installed for the Project. Such warranties shall extend to all elements of covered
bearings. The Manufacturer warranties shall cover any defective workmanship and product failure.
The required warranty periods for each category of bearings shall be as follows:
- 25 years for spherical type
- 20 years for pot, disc, rocker and roller type
- 15 years for laminated elastomeric type
- 10 years for plain elastomeric type
The Contractor shall provide certification from the Manufacturer of the bearing devices that shows
that all materials in the bearings conform to the requirements stated in Section 25.4 of this chapter.
The Contractor shall transfer to the Owner the Manufacturer’s warranty on each installation.
The Contractor shall inspect the bearing devices that are installed on the Project within one year of
its opening to traffic. The Contractor shall be responsible for required maintenance to ensure such
bearings’ functionality and durability.
For the rest of the warranty period, if deficiencies are found, the Owner may inform the Manufacturer
through the Contractor in writing of any defects and specify a required completion date for repairs.
The bearing Manufacturer shall provide guidelines and manuals to support routine maintenance and
replacement of the bearing devices and to support resolution of any concerns during the warranty
period.
25.11 Documentation for Bearing Devices

The Contractor shall provide all necessary documentation for approval of the design, manufacture,
and installation of bearing devices and for the long term inspection, maintenance, and potential
replacement of such bearings. Such documentation shall include the following:
• Design
• Working drawings
• Inspection and test plans
• A certificate of compliance from the Manufacturer
• Certified documentation of the structure’s loading criteria and load tests
• Quality records
• As installed details, including tabulated benchmark measurements that will allow the
movement of the structure to be monitored during operation
• procedures for the inspection of bearings
• Procedures for maintenance
• A fully detailed method statement for the replacement of bearings
• Risk assessments and appropriate safety information.
Page 25-41
INDEX
Absorption of water, 25-22 load cells, 25-41

acid-soluble sulfate content, 25-20 load combination, 25-6
actual design capacity, 25-5 load range, 25-5, 25-27
Adhesive material, 25-17 long-term, 25-29, 25-31
aggregate size, 25-19 low-temperature tests, 25-30, 25-31
ambient-temperature tests, 25-30 Lubricants, 25-1, 25-18
Anchor bolts, 25-1, 25-18 Masonry, 25-1, 25-15, 25-18, 25-38
axes, 25-38, 25-40 masonry plates, 25-1, 25-18, 25-19, 25-24, 25-
Bearing assemblies, 25-10, 25-23 36
bearing elements, 25-5, 25-27 mating surface, 25-8, 25-18, 25-39
bearing schedule, 25-6 Mechanical attachment, 25-40
bedding, 25-1, 25-18, 25-19, 25-20, 25-21, 25- Metal plates, 25-15
22 minimum peel strength, 25-14
blow-holes, 25-9, 25-38 movement capacity, 25-5
Bonds, 25-24 necessary documentation, 25-42
bridge bearings, 25-1, 25-5 non-guided expansion, 25-5
cementitious, 25-20, 25-21, 25-22 Portland cement, 25-20, 25-40
chemical properties, 25-19, 25-27 Pot bearings, 25-1
chloride ion content, 25-19, 25-20 Qualified personnel, 25-36
chloride salts, 25-20 random, 25-30, 25-31, 25-33
coefficient of friction, 25-5, 25-28, 25-29, 25- Recessing, 25-40
30, 25-34, 25-39 relative displacement, 25-8
compression, 25-6, 25-14, 25-18, 25-28, 25- relative velocity, 25-8
29, 25-30, 25-31, 25-33 representative samples, 25-34
compressive strength, 25-5, 25-19, 25-21, 25- Risk assessments, 25-42
22, 25-23 Rocker bearings, 25-1
countersunk fasteners, 25-40 Roller bearings, 25-1
critical dimensions, 25-28, 25-35 rotation, 25-5, 25-8, 25-15, 25-29, 25-31, 25-
cubes, 25-19, 25-21, 25-22, 25-23 38
damping coefficient, 25-8 seal weld, 25-8
design calculations, 25-5 Sealing rings, 25-14
deterioration tests, 25-29 seismic buffer blocks, 25-40
disassembly, 25-30, 25-34 seismic loads, 25-6
Disc bearings, 25-1 seismic restraint cables, 25-41
Durometer hardness, 25-14 Seismic restraint devices, 25-6
elastic stability tests, 25-22 shear modulus, 25-10, 25-30, 25-31
Elastomeric pad bearings, 25-1 shimming, 25-16
environmental conditions, 25-14, 25-18 Shims, 25-16
expansion bearings, 25-8, 25-16, 25-32, 25- shipment, 25-35
36, 25-37, 25-40 Short term expansion, 25-22
expansion plates, 25-1, 25-15, 25-38 Sliding plate bearings, 25-1
Fabric reinforcement, 25-13 sliding surfaces, 25-8, 25-29, 25-35, 25-38,
Filler material, 25-16 25-40
flatness, 25-24, 25-28, 25-40 Sole and shim plates, 25-1
Forged steel, 25-9 Spherical bearings, 25-1, 25-38
fuse links, 25-6, 25-41 stainless steel, 25-8, 25-14, 25-23, 25-24, 25-
Guide devices, 25-1 39
guided expansion, 25-5, 25-32, 25-34, 25-38 steel laminates, 25-9, 25-40
horizontal load, 25-5, 25-6, 25-30, 25-34 steel piston, 25-14, 25-34
inspections, 25-27 stiffness, 25-8, 25-11, 25-13, 25-31, 25-40
Installation scheme, 25-5 tapered sole plates, 25-33
load capacities, 25-27 temporary lift-off, 25-6
Page 25-42
testing requirements, 25-9, 25-10, 25-27, 25- vulcanizing process, 25-10

30 warranty, 25-42
thickness, 25-9, 25-18, 25-24, 25-31, 25-33, Water, 25-20, 25-22
25-39, 25-40 welding, 25-5, 25-14, 25-24, 25-39, 25-40
tolerances, 25-8, 25-23, 25-31, 25-37, 25-39 welding process, 25-5
vertical load, 25-28, 25-30 Woven fabric, 25-17
Visual Inspection, 25-31 written notification, 25-23
Vulcanized bonds, 25-14
Page 43
PART 2
ROAD STRUCTURES
CHAPTER 26 - BRIDGE DECK JOINT SYSTEMS
DOCUMENT NO: TR-

FIRST EDITION
JANUARY 2018
Chapter 26: Bridge Deck Joint Systems

TABLE OF CONTENTS
26 Bridge Deck Joint Systems .............................................................................................. 26-1
26.1 General Description ..................................................................................................... 26-1
26.1.1 Compression Seal Expansion Joints ..................................................................... 26-1
26.1.2 Other Type of Expansion and Fixed Joints............................................................ 26-1
26.1.3 Asphaltic Plug Joint (APJ) ..................................................................................... 26-2
26.1.4 Poured Joint Seals................................................................................................ 26-2
26.1.5 Dimensions and Movement Ratings...................................................................... 26-2
26.1.6 Water-tightness..................................................................................................... 26-2
26.1.7 Strength ................................................................................................................ 26-3
26.1.8 Proposed Subcontractor ....................................................................................... 26-3
26.1.9 Materials Compliance ........................................................................................... 26-3
26.3 Submittals for Bridge Deck Joint Systems.................................................................... 26-6
26.3.1 Working Drawing Submissions ............................................................................. 26-6
26.3.2 Submittals for Joint Sealing Systems .................................................................... 26-7
26.3.3 Submittals for Strip Seal Type Expansion Joints ................................................... 26-7
26.3.4 Submittals for Finger Type Expansion Joints ........................................................ 26-8
26.3.5 Submittals for Elastomeric Expansion Joints ......................................................... 26-8
26.3.6 Submittals for Modular Bridge Joint System.......................................................... 26-8
26.3.7 Submittals for Fixed Joint Seals ............................................................................ 26-9
26.3.8 Submittals for Asphaltic Plug Type Joint ............................................................... 26-9
26.4 Materials for Bridge Deck Joint Systems .................................................................... 26-10
26.4.1 Compression Seal Expansion Joints ................................................................... 26-10
26.4.2 Preformed Elastomeric Neoprene Profile Seal Expansion Joints ........................ 26-10
26.4.3 Low-density, Closed Cell, Cross-Linked, Nitrogen-blown Seal Expansion Joints 26-10
26.4.4 Strip Seal Type Expansion Joints ....................................................................... 26-12
26.4.5 Finger Type Expansion Joints ............................................................................. 26-12
26.4.6 Elastomeric Expansion Joints ............................................................................. 26-13
26.4.7 Modular Bridge Joint Systems ............................................................................ 26-15
26.4.8 Fixed Joint Seal .................................................................................................. 26-16
26.4.9 Asphaltic Plug Joint (APJ) ................................................................................... 26-16
26.4.10 Header Materials ................................................................................................ 26-16
26.5 Manufacturing and Fabrication of Bridge Deck Joint Systems.................................... 26-21
26.5.1 Manufacturing Joint Sealing Systems ................................................................. 26-21
26.5.2 Manufacturing Strip Seal Type Expansion Joints ................................................ 26-22
26.5.3 Manufacturing Finger Type Expansion Joints ..................................................... 26-22
26.5.4 Manufacturing Elastomeric Expansion Joints ...................................................... 26-22
26.5.5 Manufacturing Modular Bridge Joint Systems ..................................................... 26-22
26.5.6 Manufacturing Fixed Joint Seal ........................................................................... 26-24
26.5.7 Manufacturing Asphaltic Plug Type Joint ............................................................ 26-24
26.6 Construction of Bridge Deck Joint Systems ............................................................... 26-24
26.6.1 Construction of Compression Seal Expansion Joints .......................................... 26-24
26.6.2 Construction of Preformed Elastomeric Neoprene Profile Seal Expansion Joints 26-25
26.6.3 Construction of Low-density, Closed Cell, Cross-linked, Nitrogen-blown Seal
Expansion Joints ............................................................................................................... 26-27
26.6.4 Construction of Strip Seal Expansion Joints ........................................................ 26-27
26.6.5 Construction of Finger Type Expansion Joint ...................................................... 26-28
26.6.6 Construction of Elastomeric Expansion Joints .................................................... 26-28
26.6.7 Construction of Modular Bridge Joint Systems .................................................... 26-29
Page i
CHAPTER 26: BRIDGE DECK JOINT SYSTEMS First Edition -January 2018
26.6.8 Construction of Fixed Joint Seal ......................................................................... 26-31

26.6.9 Construction of Asphaltic Plug Joint .................................................................... 26-32
26.7 Warranty and Maintenance for Bridge Deck Joint Systems ........................................ 26-32
26.8 Documentation for Bridge Deck Joint Systems .......................................................... 26-32
Index ........................................................................................................................................... 34
Page ii
LIST OF TABLES
Table 26-1: Designations and titles for AASHTO and ASTM standards that apply to bridge deck joint
systems ..................................................................................................................................... 26-4
Table 26-2: Physical properties for low-density, closed cell, cross-linked, ethylene vinyl acetate,
polyethylene copolymer, nitrogen-blown seal......................................................... 26-11
Table 26-3: Physical properties for the adhesive used with the low-density, closed cell, cross-linked,
ethylene vinyl acetate, polyethylene copolymer, nitrogen-blown seals ..................... 26-11
Table 26-4: Physical properties of the strip seal gland ............................................................. 26-12
Table 26-5: Physical properties of the neoprene for elastomeric expansion joints .................... 26-13
Table 26-6: Physical properties of black two component flexible epoxy sealant ....................... 26-14
Table 26-7: Physical properties of grey two component flexible epoxy ..................................... 26-14
Table 26-8: Physical properties for elastomeric concrete cured binder material (without filler) . 26-17
Table 26-9: Physical requirements for elastomeric concrete binder material (with filler) ........... 26-18
Table 26-10: Physical properties of epoxy concrete material ................................................... 26-21
Table 26-11: Gradation requirement for aggregate used in epoxy concrete ............................. 26-21
Table 26-12: Cure time for epoxy mortar .................................................................................. 26-26
Page iii
26 BRIDGE DECK JOINT SYSTEMS

This chapter outlines standards and requirements for furnishing and installing bridge deck joint
systems for the Project. Such systems shall be furnished as specified in the Contract documents at
the locations shown on the Contract plans where significant movements are expected across the
joint or at fixed joints. The furnishing and installing or application of all necessary hardware including
structural steel angles, anchor bolts and studs, sealants, adhesives, epoxies, and other accessories
are included in this work.
26.1 General Description
26.1.1 Compression Seal Expansion Joints

This chapter applies to compression seal expansion joints consisting of preformed elastomeric
material that is compressed and installed in specially prepared joints and joint seal assemblies
consisting of assemblies of metal and elastomeric materials that are installed in recesses in deck
surfaces. Compression seals shall be compression stressed during all movement phases for a joint.
They maintain water tightness and seal the joint by maintaining sidewall pressure on the joint
interface (joint armouring). Other type of bridge deck joint sealing systems include the preformed
elastomeric neoprene profile seal, and the low-density, closed cell, cross-linked, ethylene vinyl
acetate, polyethylene copolymer, nitrogen-blown seal.
26.1.2 Other Type of Expansion and Fixed Joints

This chapter also applies to furnishing and constructing other type of expansion and fixed joints for
concrete bridge decks consisting of strip seal type expansion joints, finger type expansion joints,
elastomeric expansion joints, modular bridge joint systems, and fixed joint seals of the quality, types,
and sizes designated in the Contract plans or as directed by the Engineer and shall comply with
these specifications.
26.1.2.1 Strip Seal Type Expansion Joints

Strip seal type expansion joints shall consist of two extruded steel channels that extend across the
full width of the bridge roadway and support neoprene seal inserts. The gland that folds below the
deck’s surface shall enable strip seals to move.
26.1.2.2 Finger Type Expansion Joints

The finger type expansion joints shall consist of steel finger plates which cantilever between the ends
of the expansion opening to provide for the expansion and contraction of the superstructure due to
temperature variations and subsequent shrinkage and creep movements after the joint has been
installed. The steel finger plates cantilevering between the joint gap shall be of sufficient capacity to
carry the wheel loads as indicated on the Contract plans across the joint.
26.1.2.3 Elastomeric Expansion Joints

The elastomeric expansion joints shall be integrally molded units of neoprene and bonded steel. The
elastomeric joint shall comply with the details indicated on the Contract plans shall meet the material
requirements as specified herein.
26.1.2.4 Modular Bridge Joint Systems (MBJS)

Modular bridge joint systems (MBJS) are sealed joints with two or more elastomeric seals held in
place by edgebeams that are anchored to the structural elements (deck, abutment, etc.) and one or
more transverse centerbeams that are parallel to the edgebeams. The MBJS shall accommodate
large movement ranges, and shall use one or more transverse centerbeams to separate two or more
seals. The MBJS must structurally support the wheel-loads across the gap between bridge elements,
and shall continue into the traffic barriers with an upturn angle as shown on the Contract plans.
Page 26-1
The Multiple-support-bar (MSB) MBJS shall have the centerbeams rigidly connected to the support
bars, and each support bar shall support only one centerbeam. The MSB system shall have a support
box to hold as many support bars as there are centerbeams.
The single-support-bar (SSB) MBJS shall have transverse centerbeams that are attached to only
one support bar at each support box location using steel yokes and elastomeric springs and
bearings. In the special type “swivel-joist system”, the support bar swivels as well as slides in the
support boxes.
In MBJS that use a support bar that slides on bearings, the support bar shall have a thin stainless
steel cover plates joined to the top and bottom of the support bar to provide smooth sliding surfaces.
The support bars shall slide between elastomeric bearings and springs that are fixed in the support
boxes by a round boss or protrusion that fits into a hole in the steel plate of the support box. The
bearings and springs shall have low-friction polytetrafluorethylene (PTFE) pads bonded to the sliding
surface of the spring or bearing.
The elastomeric bearings and springs shall be both precompressed and located atop and below the
support bar, with the bearing on the bottom and the spring on top. The springs shall exert
compression to keep the bearing in place. The vertical component of each wheel-load applied to the
centerbeam and transmitted through the support bar compresses the bearings and reacts against
the support box and the deck. There is a significant upward rebound of each wheel-load cycle that
compresses the springs and reacts on the top plate of the support box, imposing an upward load on
the deck.
The wheel-load may also impart a horizontal force to the centerbeam and an associated rebound.
The horizontal load is transmitted through the centerbeam, into the support bar, and into the springs
and bearings through friction. Ultimately, the horizontal force is resisted by the small bosses in the
springs and bearings into the support box and deck. These small bosses are subjected to millions of
cycles of this reversible shearing action. Shear failure of the bosses leads to systemic failure of the
MBJS. The movements of bridge elements provide the necessary forces to open and close the
MBJS. The MBJS shall be provided by an equidistant device to maintain an approximately equal gap
between centerbeams and between centerbeam and edgebeam. The equidistant device shall be
comprised of a series of horizontal elastomeric springs (control springs).
26.1.2.5 Fixed Joint Seal

The joint sealer shall be of a neoprene, preformed or extruded type, of essentially the size and shape
indicated on the Contract plans.
26.1.3 Asphaltic Plug Joint (APJ)

Field molded asphaltic plug joints (APJs) used in expansion joint sealing on asphalt concrete overlay
and portland cement concrete decks shall consist of multilayer, or single layer, or both, application
systems depending upon individual manufacturing requirements. The asphaltic binder to be used
shall be thermoplastic polymeric-modified asphalt. APJs shall not be used for movement applications
exceeding ± 25 mm from the installation width.
26.1.4 Poured Joint Seals

Joint seals that the Contract documents specify to be poured joint seals shall conform to the
specifications for expansion and contraction joints outlined in Article 21.9.1.4 of Chapter 21,
26.1.5 Dimensions and Movement Ratings

At each designated location, types, dimensions, and movement ratings for bridge deck joint systems
shall comply with the Contract documents or directions from the Engineer.
26.1.6 Water-tightness
All bridge deck joint systems shall prevent the intrusion of material and water through the joint
system. Water-tightness shall be ensured across the full width of the bridge deck, from barrier to
barrier and across raised walkways and medians if exist.
Page 26-2
26.1.7 Strength
The bridge deck joint system shall have sufficient strength in all positions to support the Abu Dhabi
Vehicular Load (ADVL) and corresponding impact in accordance to Road Structures Design Manual
(ADQCC TR-516). The Contractor shall also ensure that the system can accommodate all
movements indicated in the Contract plans.
26.1.8 Proposed Subcontractor

Before a subcontract is awarded for the expansion joints, the Contractor shall submit to the Engineer
for approval the prequalification documents of the organization proposed for the installation of the
expansion joints in accordance with these standard specifications. The proposed subcontractor shall
submit evidence that he has at least five years of experience in the Gulf Region of successful
installation and operation of bridge deck joints comparable to the propriety expansion joints work
specified in these standard specifications. The subcontractor shall verify his experience by citing at
least five projects, comparable to the Project, which have been successfully accomplished. The joint
manufacturer shall be ISO 9001:2000 certified with at least 30 years of experience in designing and
fabricating expansion joint systems.
26.1.9 Materials Compliance

No shipment of materials will be accepted by the Engineer for use in the Project unless the materials
comply with the requirements of these standard specifications. The materials shall not be used or
installed until the Contractor has been notified by the Engineer that they meet the requirements of
these standard specifications.

resistance factor design, Bridge Construction Specifications;
resistance factor design, Bridge Design Specifications;
AASHTO Standard Specifications for Transportation Materials and Methods of Sampling
and Testing;
AISC American Institute of Steel Construction;
AISC 204-08 AISC Certification Program for Bridge and Highway Metal Component
Manufacturers;
ANSI B18.2.1-1981Square and Hex Bolts and Screws;
ANSI/AWS D1.1/ Structural Welding Code-Steel;
D1.1M:2010
ASNT American Society for Nondestructive Testing;
AWS QC1:2007 Standard for AWS Certification of Welding Inspectors;
ISO 9001:2015 Quality management systems – Requirements.
The Contractor shall manufacture and test bridge deck joint systems in accordance with these
specifications and in compliance with AASHTO/ASTM standards. Where joint systems are
Page 26-3
manufactured and tested by standards other than AASHTO/ASTM, products conforming to

equivalent or higher standards will be acceptable if proven to be suitable.
Table 26-1 below presents American Association of State Highway and Transportation Officials
(AASHTO) and American Society for Testing and Materials (ASTM) Standards that are related to
bridge deck joint system materials. It also includes designations and titles.
Table 26-1: Designations and titles for AASHTO and ASTM standards that apply to bridge
deck joint systems
AASHTO ASTM
Title
Standard Specification for Adhesive Lubricant for
ASTM D4070 -
Installation of Preformed Elastomeric Bridge
08
Compression Seals in Concrete Structures
AASHTO M 220- ASTM D2628 - Standard Specification for Preformed Polychloroprene
84 (2012) 91(2011) Elastomeric Joint Seals for Concrete Pavements
ASTM D3575 - Standard Test Methods for Flexible Cellular Materials
08 Made From Olefin Polymers
ASTM C881 / Standard Specification for Epoxy-Resin-Base Bonding
C881M - 10 Systems for Concrete
ASTM A240 /
Nickel Stainless Steel Plate, Sheet, and Strip for
A240M - 12
Pressure Vessels and for General Applications
06ae2 Thermoplastic Elastomers—Tension
Standard Test Method for Compressive Properties of
ASTM D695 - 10
Rigid Plastics
ASTM D570 -
98(2010)e1
ASTM C882 / Standard Test Method for Bond Strength of Epoxy-Resin
C882M - 12 Systems Used With Concrete By Slant Shear
ASTM D395 - Standard Test Methods for Rubber Property—
03(2008) Compression Set
Standard Test Method for Rubber Property—Effect of
ASTM D471 - 12
Liquids
ASTM D573 - Standard Test Method for Rubber—Deterioration in an
04(2010) Air Oven
ASTM D1149 - Standard Test Methods for Rubber Deterioration—
07(2012) Cracking in an Ozone Controlled Environment
05(2010) Hardness
Test Method for Shrinkage of Molded and Laminated
ASTM D1299-
Thermosetting Plastics at Elevated Temperature
55(1979)E01
(Withdrawn 1992)
Page 26-4
AASHTO ASTM
Title
AASHTO M 297- ASTM D3542 - Standard Specification for Preformed Polychloroprene
10 08 Elastomeric Joint Seals for Bridges
Standard Specification for Elastomeric Strip Seals with
ASTM D5973 -
Steel Locking Edge Rails Used in Expansion Joint
97(2007)
Sealing
ASTM D3574 - Standard Test Methods for Flexible Cellular Materials—
11 Slab, Bonded, and Molded Urethane Foams
ASTM C39 / Standard Test Method for Compressive Strength of
C39M - 12 Cylindrical Concrete Specimens
ASTM C884 /
Standard Test Method for Thermal Compatibility
C884M -
Between Concrete and an Epoxy-Resin Overlay
98(2010)
Standard Test Methods for Preformed Expansion Joint
AASHTO T 42-
ASTM D545 - 08 Fillers for Concrete Construction (Nonextruding and
10
Resilient Types)
AASHTO T 27- Standard Method of Test for Sieve Analysis of Fine and
ASTM C136 - 06
11 Coarse Aggregates
ASTM A307-10
ASTM A588 /
Structural Steel, up to 50 ksi [345 MPa] Minimum Yield
A588M - 10
Point, with Atmospheric Corrosion Resistance
Standard Test Method for Brittleness Temperature of
ASTM D746 - 07
Plastics and Elastomers by Impact
ASTM A1011 / Rolled, Carbon, Structural, High-Strength Low-Alloy,
A1011M - 12b High-Strength Low-Alloy with Improved Formability, and
Ultra-High Strength
ASTM A36 /
A36M - 08
ASTM D6297 - Standard Specification for Asphaltic Plug Joints for
13 Bridges
Standard Test Methods for Sealants and Fillers, Hot-
ASTM D5329 -
Applied, for Joints and Cracks in Asphaltic and Portland
09
Cement Concrete Pavements
ASTM D36 / Standard Test Method for Softening Point of Bitumen
D36M - 12 (Ring-and-Ball Apparatus)
Standard Test Method for Ductility of Bituminous
ASTM D113 - 07
Materials
ASTM D6690 - Standard Specification for Joint and Crack Sealants, Hot
12 Applied, for Concrete and Asphalt Pavements
ASTM D5167 - Standard Practice for Melting of Hot-Applied Joint and
13 Crack Sealant and Filler for Evaluation
Page 26-5
AASHTO ASTM
Title
Standard Specification for Backer Material for Use with
ASTM D5249 -
Cold- and Hot-Applied Joint Sealants in Portland-Cement
10
Concrete and Asphalt Joints
ASTM D5 / D5M - Standard Test Method for Penetration of Bituminous
13 Materials
Standard Test Methods for Cone Penetration of
ASTM D217 - 10
Lubricating Grease
AASHTO T
Method of Test for Tensile Strength of Hydraulic Cement
132:1987
Mortars
(R2013)
AASHTO M 85- ASTM C150 /
Standard Specification for Portland Cement
12 C150M - 12
Method of Test for Tensile Strength of Hydraulic Cement
ASTM C190-85
Mortars
26.3 Submittals for Bridge Deck Joint Systems

The Contractor shall submit complete shop drawings of all expansion and fixed joints. The Engineer
may request the Contractor to furnish whatever samples may be required to perform the tests
specified to qualify the material. Acceptance of the joint system to be used in the Project shall be
subject to written approval of the Engineer. The shop drawings shall include a movement chart
showing the total anticipated movement of the structure and the required setting width of the joint
assembly at various temperatures. All movements due to shrinkage, creep, mid-slab deflection, and
similar data, shall not be incorporated into this chart but shall be considered by the Contractor and
approved by the Engineer prior to final installation and adjustment.
Submittals for bridge deck expansion and fixed joints used on the Project shall comply with the
26.3.1 Working Drawing Submissions

If the Contract documents do not include details that show joint settings that are required for their
installation, the Contractor shall submit calculations to the Engineer for approval before installing
joints in any bridge deck. The Contractor shall submit working drawings to the Engineer that cover
the installation procedure and joint assembly for bridge decks using proprietary joint systems. The
Contractor shall submit shop drawings for the Engineer’s approval for all joints.
The Contractor shall not perform any work on a deck joint system before receiving approval for
working drawings from the Engineer. Such approval shall not relieve the Contractor of any
responsibility under the Contract documents for successful completion of the work.
The Contractor shall assume responsibility for conforming to these specifications and the Contract
plans, and shall include the following items in the submission to the Engineer:
• The Manufacturer’s brochure on the proposed joint, showing physical dimensions for
components, installation procedures, material certifications, and a table of variable
temperatures and dimensions.
• Presetting details.
• Drawings that detail the joint’s installation and indicate the lengths of component members,
treatment of directional changes, and shop splices for steel locking rails.
• Expansion joint fabricator documentation.
The Contractor shall ensure that the expansion joint fabricator have American Institute of Steel
Construction (AISC) certification, as defined in their AISC 204-08, AISC Certification Program for
Page 26-6
Bridge and Highway Metal Component Manufacturers, or equivalent. The Contractor shall supply
documentation with the shop drawings.
26.3.2 Submittals for Joint Sealing Systems

This article shall apply to following joint sealing systems:
1. Compression seal expansion joints
2. Preformed elastomeric neoprene profile seal expansion joints
3. Low-density, closed cell, cross-linked, nitrogen-blown seal expansion joints
As with all bridge deck joint designs, a critical factor is accurately predicting the anticipated
movement. If a compression seal is too big for an opening, it will bulge above a deck’s surface and
become exposed to traffic, which can cause premature wear. If a compression seal is too small for
an opening, it will lose compression and fall out.
The Contractor shall provide the Manufacturer of the joint sealing system with a working drawing for
each installation. Such drawings shall include all of the following information:
a. Identification and orientation of each joint
b. Length of each joint, including a turn up of at least 150 mm at both barrier faces
c. Total projected movement range of each joint
If the Project involves the installation of bridge deck joints across the bridge’s full width, working
drawings shall indicate the use of a full-length seal. If traffic conditions require joint seal installation
in stages, working drawings shall indicate splice points.
If existing edge beams are to remain as joint headers, the Contractor shall also give the Manufacturer
of the seal the following information:
• Joint width measurements taken at 600 mm intervals along the full length of the joint, plus a
measurement of the joint width of each barrier in the area of the turn ups
• Ambient temperature, taken at the same times as the width measurements
The Manufacturer of the joint sealing system shall use this information to determine required
quantities of materials and each joint’s profile size. The Manufacturer shall enter this data on working
drawings, verify that the data is accurate, and submit a copy to the Engineer for review. Drawings
from the Contractor shall indicate such verification. The Engineer’s approval is required before the
Contractor installs a joint seal. Such approval shall not relieve the Contractor of any responsibility
for conforming to specifications and plans.
26.3.3 Submittals for Strip Seal Type Expansion Joints

The strip seal joint Manufacturer shall be prequalified with a five year proven history of successful
product manufacture and have AISC certification, as defined in their AISC 204-08, or equivalent.
Before fabricating any joints, the Contractor shall submit shop drawings and expansion joint details
and requirements to the Engineer for review and approval. Shop drawings shall meet all
requirements outlined in this chapter. Before final acceptance of an expansion joint, the Contractor
shall submit the Manufacturer certifications that verify that the entire expansion joint assembly and
all its accessories meet the requirements of the Contract plans, specifications, and approved shop
drawings.
The Contractor shall provide shop drawings for any proposed joint installation. The Engineer must
approve all shop drawings, which must indicate such approval, before installation of a joint. The
Engineer shall review the Contractor's working drawings to ensure that the Contractor properly
interprets the Contract plans. The Owner shall assume no responsibility for the accuracy of the
drawings. The Owner approval for the Contractor’s drawings shall not relieve the Contractor of any
responsibility for conformity to specifications and Contract plans.
Page 26-7
Shop drawings that the Contractor submits for review and approval by the Engineer shall specifically
include the following items:
a. The Manufacturer’s brochures related to the proposed joint. Such brochures shall include all
physical dimensions for components, installation procedures, material certifications, and a
table of variable temperatures and dimensions.
b. Drawings that detail installation of the joint. Such drawings shall indicate lengths of
component members, treatments for any directional changes, shop splices for steel channels
(gland components shall not be spliced in the field), and the fabrication of metal components
at barriers, curbs, and parapets.
As with compression seal designs, movement ratings must be correctly anticipated. Openings, as
measured along the centreline of the bridge, should not exceed the preferred maximum of 100 mm.
This limitation improves the ride, reduces live load impact, and reduces danger to motorcyclists and
bicyclists. For sealing element installations, the Owner prefers joint opening dimensions of 50 mm.
The Engineer may require the Contractor to furnish whatever samples are needed to perform
specified materials qualification tests. The Engineer shall provide written acceptance of any joint to
be used in the Project work.
Joint movements and construction material temperatures are vital to designing expansion joints. The
joint’s complete expansion-contraction cycle must be known before selecting the proper system and
Manufacturer.
26.3.4 Submittals for Finger Type Expansion Joints

The Contractor shall submit to the Engineer shop drawings prepared by the joint manufacturer
showing the finger size and spacing and configuration of the assembly which shall satisfy the skew
alignment and expansion requirements for each joint as indicated on the Contract plans. Special
considerations shall be taken in providing the proper precautions to ensure the water-tightness of
this type of joints.
26.3.5 Submittals for Elastomeric Expansion Joints

The Contractor shall submit a certification by the Manufacturer, stating that the joint and the
accessory items meet the requirements of these standard specifications. The Engineer will request
the Contractor to furnish whatever samples may be required to perform the tests specified to qualify
the material. Acceptance of the elastomeric expansion joint to be used in the Project shall be subject
to written approval of the Engineer. Special considerations shall be taken in providing the proper
precautions to ensure the water-tightness of this type of joints.
26.3.6 Submittals for Modular Bridge Joint System

The Contractor shall submit details of any modular bridge joint system (MBJS) to the Engineer for
approval before the Contractor fabricates an MBJS. With these details, the Contractor shall also
submit installation and waterproofing shop drawings. At a minimum, shop drawings shall include the
following details:
a. Plan and section views of the MBJS for each movement rating and roadway width, showing
dimensions and tolerances
b. All welded centerbeam (support) bar joints, with all shop and field splices, only full strength
welds meeting the strict requirements of fatigue shall be acceptable
c. Complete details of all components and sections, with all material incorporated into the MBJS
d. All ASTM, AASHTO, or other material designations
e. A corrosion protection system for the MJS
f. Lifting locations and lifting mechanisms (as parts of an integral installation plan)
g. Temperature adjustment devices and opening dimensions relative to temperature
Page 26-8
The Contractor shall also submit the following test reports and certificates to the Engineer for review
and approval:
1. The Manufacturer’s certificate of compliance with the AISC’s quality certification program for
simple steel bridges.
2. Certification that welding inspection personnel are qualified and certified as welding
inspectors in accordance with the American Welding Society’s Standard for Certification of
Welding Inspectors (AWS QC1).
3. Documentation that any personnel performing nondestructive evaluation (NDE) are certified
by the American Society for Nondestructive Testing (ASNT).
4. The Manufacturer’s certificate of compliance for polytetrafluoroethylene (PTFE) sheeting and
fabric.
5. Certification that the MBJS passed prequalification tests (as outlined in Section 26.4.7).
6. Certification that bearings, springs, and equidistant devices are the same formulation,
Manufacturer, and configuration as those used in prequalification tests, as required in Section
26.4.7. Each certification shall provide the name and address of the Manufacturer of the
springs, bearings, and equidistant devices.
7. Design calculations sealed by a registered professional engineer. The design calculations
shall include a fatigue design and a load factor design for all structural elements, connections,
and splices.
8. Plan for replacement of parts that are subject to wear, as allowed for in the design.
9. A written maintenance and part replacement plan prepared by the joint’s Manufacturer. This
plan shall include a list of parts and instructions for maintenance inspection, acceptable wear
tolerances, methods for determining wear, and procedures for replacing worn parts.
10. Method of installation that, at a minimum, includes a sequence, installation gap settings for
various temperatures, support methods during placement of the concrete, and details for
installation at curbs.
11. Recommendations for storage of the MBJS.
12. Details for temporary support when shipping and handling the joint.
13. Welding procedure specifications.
14. Any required changes to the blockout reinforcement to accommodate the MBJS.
15. Temporary bridging plan for any MBJS for which construction traffic is anticipated after
installation.
26.3.7 Submittals for Fixed Joint Seals

The Contractor shall submit a certification by the Manufacturer, stating that the joint and the
accessory items meet the requirements of these standard specifications. The Engineer will request
the Contractor to furnish whatever samples may be required to perform the tests specified to qualify
the material. Acceptance of the fixed joint seal to be used in the Project shall be subject to written
26.3.8 Submittals for Asphaltic Plug Type Joint

The Contractor shall submit details of previous projects within the U.A.E. These should demonstrate
the suitability of the system and materials proposed, in particular, for heavy traffic and high
temperature.
The supplier shall provide the Engineer with the following information, in a printed form, for each APJ
system:
1. Description or proprietary name of joint
2. Horizontal movement capacity
Page 26-9
3. Vertical movement capacity

4. Composition – aggregate, binder, bridging plate, caulking, and flashing.
26.4 Materials for Bridge Deck Joint Systems

Unless the Contract documents specify otherwise, the Contractor shall use one of the following
systems of expansion joints as approved by the Engineer:
1. Compression seal expansion joints
2. Preformed elastomeric neoprene profile seal expansion joints
3. Low-density, closed cell, cross-linked, nitrogen-blown seal expansion joints
4. Strip seal type expansion joints
5. Finger type expansion joints
6. Elastomeric expansion Joints
7. Modular bridge joint system
Materials for bridge deck joint systems shall meet the requirements outlined in this section.
26.4.1 Compression Seal Expansion Joints

In general, bridge deck compression seal expansion joint materials shall conform to the following
specifications:
a. Preformed elastomeric joint seals of multiple web design shall conform to AASHTO M 220-
84 (2012), (ASTM D2628 - 91(2011)).
b. Lubricant-adhesive for use with preformed elastomeric seals shall conform to ASTM D4070
- 08.
c. Deck joint seal assemblies shall be of an approved type for each size required and shall
conform to the specifications provided by the Manufacturer at the time of approval.
d. All Steel and fabricated steel components shall be galvanised and conform to the
requirements outlined in Section 23.4.10 of Chapter 23, Steel Structures.
26.4.2 Preformed Elastomeric Neoprene Profile Seal Expansion Joints

At a minimum, a preformed elastomeric neoprene profile seal shall meet the following requirements:
a. Capability to be evacuated of air during installation
b. Capability to be pressurized with air during the adhesive curing time
c. Compatibility with the epoxy adhesive, and header material (if required)
d. Ability to withstand 50% expansion and 50% contraction (total 100%)
e. Ability to withstand the effects of vertical and lateral movements, skew movements, and
rotational movements without adhesive or cohesive failure
The Contractor shall ensure that preformed elastomeric neoprene profile meets the requirements of
ASTM D2628 - 91(2011) and that the adhesive used with preformed elastomeric neoprene profile
seals is a two-component epoxy-based thixotropic paste that meets the seal manufacturer’s
requirements.
26.4.3 Low-density, Closed Cell, Cross-Linked, Nitrogen-blown Seal Expansion Joints

At a minimum, a low-density, closed cell, cross-linked, ethylene vinyl acetate, polyethylene
copolymer, nitrogen-blown seal shall meet the following requirements:
a. Held in place by a two-component, 100% solid, modified epoxy adhesive
b. Compatibility with the epoxy adhesive, and header materials (if required)
Page 26-10
c. Preformed, resistant to abrasion, oxidation, oils, gasoline, salt, and other materials that may
be spilled on or applied to the surface
d. Grooved, with grooves approximately 3 mm wide by 3 mm deep, spaced from 6 mm to 13
mm apart, and running along the entire length of the seal’s bonded surface
e. Designed so that, when compressed to 50% of original width, the centre portion of its top
does not extend upward above the seal’s original height by more than 6 mm
f. Recessed below the riding surface throughout the normal limits of joint movement
g. Resistant to ultra violet rays
h. Beige or gray
i. Shop-marked such that the top and bottom are clearly visible during installation
The Contractor shall ensure that a low-density, closed cell, cross-linked, ethylene vinyl acetate,
polyethylene copolymer, nitrogen-blown seal has a working range of 30% tension and 60%
compression. Such seals shall have physical properties that comply with the details shown in Table
26-2.
Table 26-2: Physical properties for low-density, closed cell, cross-linked, ethylene vinyl
acetate, polyethylene copolymer, nitrogen-blown seal
Test Requirements Test method

ASTM D3575 - 08
Tensile strength 0.80 MPa
(Suffix T)
ASTM D3575 - 08
Elongation at break 255% min.
(Suffix T)
Weather-related AASHTO T 42-10
No deterioration for at least 10 years
deterioration (Accelerated Weathering)
0.069 MPa min., 0.414 MPa maximum @ ASTM D3575 - 08
Compression/Set
50% deflection of original thickness (Suffix D)
Tear strength 20 kN/m ASTM D624 - 00(2012)
Density 45 to 54 kg/m3 ASTM D3575 - 08
Low-density, closed cell, cross-linked, ethylene vinyl acetate, polyethylene copolymer, nitrogen-
blown seals shall use a two-component, 100% solid, modified epoxy adhesive that meets the
requirements of ASTM C881 / C881M - 10, Grade 2, Class C. Such adhesives shall have physical
properties as shown in Table 26-3.
Table 26-3: Physical properties for the adhesive used with the low-density, closed cell,
cross-linked, ethylene vinyl acetate, polyethylene copolymer, nitrogen-blown seals
0 ASTM Value
Tensile strength ASTM C881 / C881M - 10 24 MPa (minimum)
Compressive strength ASTM D695 - 10 48 MPa (minimum)
Shore D hardness ASTM D2240 - 05(2010) 75
Water absorption ASTM D570 - 98(2010)e1 0.25% by weight
Bond strength ASTM C882 / C882M - 12 2.97 MPa
For applications on moist or hard to dry concrete surfaces, an adhesive shall be as specified by the
joint material’s Manufacturer.
Page 26-11
26.4.4 Strip Seal Type Expansion Joints

Each bridge deck strip seal joint, shall have a continuous elastomeric strip seal gland with extruded
steel channels. Such glands shall be a vulcanized elastomeric compound that uses only polymerized
chloroprene as its basic elastomer.
The Contractor shall provide to the Engineer certified test results from the strip seal gland’s
Manufacturer that verify that the gland has the properties shown in Table 26-4.
Table 26-4: Physical properties of the strip seal gland
Physical property ASTM test method Requirements

Tensile strength (minimum) ASTM D412 - 06ae2 13.8 MPa
Elongation @ break % (minimum) ASTM D412 - 06ae2 250 %
ASTM D2240 - 05(2010)
Hardness, Type A durometer, points 55 ± 5 points
(Modified)
Oven aging, 70h @ 100° C:

20% maximum
Tensile strength loss
ASTM D573 - 04(2010) 20% maximum
Elongation loss
0 to +10 change in
Hardness (Type A durometer) points
Oil swell, ASTM oil no. 3, 70h @ 100° C,
ASTM D471 - 12 45%
maximum weight change
Ozone resistance, 20% strain, 300 pphm in ASTM D1149 - 07(2012)
no cracks
air 70h @ 40°C (Modified)
Low temperature stiffening, 7 days @ -10° C: 0 to +15 change in
ASTM D2240 - 05(2010)
Hardness (Type A durometer) points
ASTM D395 - 03(2008)
Compression Set, 70h @ 100° C maximum Method B 40%
(Modified)
Steel channels shall be extruded in one piece from grade 50W (Grade 345 W) steel that complies
with ASTM A588 / A588M - 10. Such elements shall not be exposed aluminium.
A lubricant or adhesive shall bond a seal to steel elements. Such lubricant or adhesive shall be a
one-part moisture curing polyurethane and hydrocarbon solvent mixture that meets the requirements
of ASTM D4070 - 08.
Studs in an anchorage system shall meet the requirements outlined in Section 30.5 of Chapter 30,
Miscellaneous Metal. Straps that the Contractor uses to erect the bridge deck joint sealing system
shall be grade 36 (Grade 250) steel as defined in ASTM A588 / A588M - 10.
All steel surfaces not embedded in concrete shall be treated for corrosion protection in accordance
with the Manufacturer’s recommendations. Backer rod shall be placed in the steel anchoring
element’s’ seal cavity if painting is required.
26.4.5 Finger Type Expansion Joints

Each joint element shall be anchored to the concrete with galvanized high strength bolts. The finger
joint assembly shall be drained by installation of a 2-layer-thick hypalon-neoprene membrane placed
at the base of the joint and across the expansion gap as indicated on the Contract plans. Materials
used in the manufacture of the finger type expansion joints shall comply with the requirements of
ASTM A307-10 and ASTM A588 / A588M - 10. In general, the materials incorporated in the finger
type expansion joint shall comply with the following:
Drainage Collector: A hypalon-neoprene double layer sheet (European commercial name
Coverlight TH4 26/26) having the following characteristics:
Page 26-12
Weight 0.600 kg/m²

Thickness 5.5 to 6.0 mm
Tensile strength (on a 5 x 20 cm specimen) 330 kg
Tear strength 28 kg
Compression resistance (Nullen test) 5.4 MPa
Hypalon is a commercial name for chlorosulphonated polyethylene (CSM), Neoprene is a
commercial name for chloroprene (CR).
Steel: All steel components shall comply with ASTM A588 / A588M - 10.
Bolts, Washers and Accessories: Class 8.8 complying with American National Standard Institute
ANSI B18.2.1-1981, Square and Hex Bolts and Screws, Including Askew Head Bolts, Hex Cap
Screws and Lag Screws.
Corrosion Protection: Zinc metal spraying thickness 102 microns.
Coupling Sleeve: American Iron and Steel Institute (AISI) Type 410.
26.4.6 Elastomeric Expansion Joints

The elastomeric expansion joints shall consist of integrally molded units of neoprene and bonded
steel components so arranged as to provide for the expansion and contraction movements of the
bridge deck with one of the steel components bridging the joint gap and of sufficient strength to carry
wheel loads across the joint.
The expansion joints shall seal the deck surface to prevent moisture and other contaminants from
descending onto the abutment and pier caps and shall have provisions for adequate anchoring of
the joint assembly to the bridge deck. There shall be no appreciable change in the deck surface with
the bridge expansion and contraction movements. All the expansion and contraction movements of
the bridge deck shall be taken entirely by deformation of the neoprene.
The elastomer portion of the expansion joints shall be neoprene having the following physical
properties as determined by the following ASTM requirements shown in Table 26-5:
Table 26-5: Physical properties of the neoprene for elastomeric expansion joints
ASTM Test Performance

Property
Method Requirements
ASTM D412 -
Tensile Strength 12.3 MPa minimum
06ae2
ASTM D412 -
Elongation at break 400%, minimum
06ae2
ASTM D2240 -
Hardness, Type A Durometer 50 ± 5 points,
05(2010)
ASTM D395 -
03(2008) 20%, maximum
Compression Set 22 hours at 70°C
(Method B)
Low Temperature ASTM D746 - 07 Not brittle at -40°C

Ozone Resistance
ASTM D1149 -
Exposure to 100 pphm ozone for 70 hours @ No failure cracks
07(2012)
38°C sample under 20% strain
Oil Deterioration
Volume increase after immersion in ASTM Oil #3 ASTM D471 - 12 120%, maximum
for 70 hours @ 100°C
The dimensional tolerances of the neoprene portion of the elastomeric joint shall be minus zero mm
to plus 6 mm for the width and length, and minus zero mm to plus 3 mm for the thickness of the
exterior dimensions required on the Contract plans measured at 21°C.
Page 26-13
The sealant for sealing joints between the expansion joint units, along the edges of the expansion
joint, and the bolts and plugs shall be a high solids, one-part polyurethane based sealant that cures
quickly, without shrinkage, into a rubber with high elongation characteristics and excellent "memory."
The sealant shall be capable of bonding to concrete, steel, and neoprene without the use of a primer.
When cured, the sealant shall possess excellent abrasion resistance and shall resist attack by salt,
oil, and road chemicals. The sealant to be used shall meet with the approval of the manufacturer of
the neoprene expansion joint.
When test specimens are cut from the finished product a 10 percent variation in "Physical Properties"
may be allowed by the Engineer.
The flexible epoxy for filling void space around the nut fasteners shall consist of a black two
component flexible epoxy sealant having the following physical properties as shown in Table 26-6:
Table 26-6: Physical properties of black two component flexible epoxy sealant
Base Material Flexibilized Epoxy Resin

Color Black
Weight/Liter (Mixed materials) 1.05 kgs./liter
Mixing Time 2 min. @ 24°C with 50 strokes minimum
Pot Life 10-15 minutes @ 24°C
Initial Cure 4 hours @ 24°C
Final Cure 48 hours @ 24°C
Shelf Life 12 months minimum (components separate)
Hardness Shore A Durometer 80 ± 10
The flexible epoxy shall be supplied either in cans or preassembled cartridges. Flexible epoxy shall
meet with the approval of the manufacturer of the expansion joint. Flexible epoxy must also be a
material compatible with and having the physical characteristic, when cured, similar to the neoprene
of the joint.
The adhesive/sealant bedding epoxy for bonding the expansion joint to concrete or steel shall be
supplied in premeasured cartridges or cans and shall consist of a grey, two component flexible epoxy
having the following physical properties as shown in Table 26-7:
Table 26-7: Physical properties of grey two component flexible epoxy
Base Material Epoxy Resin

Color Concrete Grey
Weight/Liter (Mixed Materials) 1.44 kgs./liter
Solids Content 98% minimum by weight
Mixing Time 2 min. @ 24°C with 50 strokes minimum
Pot Life 25-30 minutes @ 24°C
Initial Cure 4 hours @ 24°C
Final Cure 48 hours @ 24°C
Shelf Life 12 months minimum (components separate)
Tensile Strength 20.6 MPa
Elongation 7% @ 24°C
Water Absorption 1.0% maximum
Bond Strength to Concrete Concrete fails before bond
All structural steel for use in elastomeric expansion joints as detailed on the Contract plans shall
comply with the requirements of ASTM A1011 / A1011M - 12b or ASTM A36 / A36M - 08.
Structural steel angles and anchors shall be fabricated and hot dip galvanized in accordance with
the requirements of ASTM A123 / A123M – 12 and Section 23.4.10 of Chapter 23, Steel Structures,
of these Standard Specifications.
Page 26-14
a. Anchor Bolts
Anchor bolts for joint seals shall be hot dip galvanized in accordance with ASTM A153 / A153M - 09,
commercial grade bolts set in epoxy mortar in holes cored in the deck in accordance with approved
shop drawings.
Surfaces of holes cored in the concrete shall be carefully prepared to provide a cleaned, textured
surface to which the epoxy mortar can successfully bond. Faces shall be mechanically tooled until
surface glaze and contamination have been removed; dusted to remove all residue; dried thoroughly;
and then primed with hydrophobic epoxy resin immediately prior to setting the anchor bolts in epoxy
mortar. Bolts shall be degreased with white spirit alcohol and dried thoroughly. Coring and setting of
anchor bolts shall not be done until a minimum of 7 days after concrete is poured.
b. Epoxy Mortar
Epoxy mortar shall consist of a mixture of aggregate and epoxy binder. Aggregate shall consist of
well graded, clean, hard quartzite particles of 2 mm maximum size. Aggregate shall be dried till the
moisture content is less than 0.2 percent by weight and then shall be sealed in plastic containers
until required for mixing on site. Binder for epoxy mortar shall be two part, cold curing, solventless
epoxy resin supplied by an approved Manufacturer. Primer shall be compatible with the epoxy resin
binder and shall be supplied by the same Manufacturer. The type of resin selected shall be
recommended by the Manufacturer for this application and shall meet with the approval of the
supplier of the component on which it is to be used.
Components of the epoxies shall be proportioned, mixed, applied and cured strictly in accordance
with the Manufacturer's printed recommendations. Mixing shall be carried out in an efficient
mechanical device which ensures that all components are fully dispersed and wetted. The two parts
of the epoxy binder for the mortar shall be thoroughly mixed first without frothing and the aggregate
added progressively. Mixed epoxy mortar which has begun to cure before it has been placed and
compacted shall be rejected and a fresh batch mixed.
Anchor bolts shall not be set in epoxy mortar when the ambient temperature is less than 10 degrees
Celsius. Concrete surfaces shall be primed. Bolts shall be coated with epoxy mortar and assembled
in such a way as to avoid trapping air bubbles in the mortar. Epoxy mortar shall be compacted around
the anchor bolts and trowelled level with the concrete surface. The anchor bolts shall be located
using a template and securely held in place until the epoxy mortar has cured.
26.4.7 Modular Bridge Joint Systems

Materials for a modular bridge joint system (MBJS) shall conform to the following specifications:
a. MBJS shall conform to the specifications provided by its Manufacturer.
b. MBJS shall be prequalified by satisfying all of the testing requirements detailed in Appendix
A19 in Section 19 of the AASHTO LRFD Bridge Construction Specifications, which validate
the use of an approved MBJS for a limited range of applications.
c. MBJS designs shall comply with Article 14.5, “Bridge Joints,” of the AASHTO LRFD Bridge
Design Specifications.
d. Preformed elastomeric joint seals of multiple-web design shall conform to AASHTO M 297-
10 (ASTM D3542 - 08).
e. Preformed elastomeric joint seals of the strip type shall conform to ASTM D5973 - 97(2007).
f. Seals shall be continuous; seals shall not include splices unless such are specifically
g. Lubricant-adhesive for use with preformed elastomeric seals shall conform to ASTM D4070
- 08.
h. Springs, bearings, and equidistant devices (sometimes referred to as control springs) shall
have the same material composition, formulation, and configuration as control springs used
in prequalification tests. Their Manufacturer and fabrication procedure shall also match
control springs used in such test.
Page 26-15
i. Urethane foam shall conform to ASTM D3574 - 11.

j. Polytetrafluorethylene (PTFE) shall be 100-percent virgin Teflon, woven PTFE fabric, or
dimpled PTFE that conforms to the requirements for PTFE sliding surfaces outlined in
Section 25.4.11 of Chapter 25, Bearing Devices. Every sliding surface shall be PTFE.
k. Sliding surfaces shall have type 304 stainless steel sheets as defined in ASTM A240 / A240M
- 12. In severe environments, such sheets shall be type 316 steel as defined in ASTM A240
/ A240M - 12.
l. Steel and fabricated steel components for members that are not fracture-critical shall conform
to the applicable requirements of Chapter 23, Steel Structures, with the following exceptions:
• Welding shall conform to the requirements of ANSI/AWS D1.1/D1.1M:2010 Structural
Welding Code-Steel,
• Fasteners and their holes can deviate from the requirements in Chapter 23, Steel
Structures, if they were used in the prequalification tests.
m. The Contractor shall furnish manufacturing certificate to the Engineer stating that the
materials have been sampled, tested and inspected in accordance with this specifications
and have met the requirements.
26.4.8 Fixed Joint Seal

The joint sealer shall be of a neoprene, preformed or extruded type, of essentially the size and shape
indicated on the Contract plans. The preformed joint sealer material shall comply with the
requirements of AASHTO M 220-84 (2012) (ASTM D2628-91 (2011)). The joint sealer shall be such
that it will repel the intrusion of stones, dirt, etc., into the joint or into the material itself. Lubricant
adhesive for use with preformed sealer shall conform to ASTM D4070 – 08.
All structural steel for use in the fixed joint shall comply with the requirements of ASTM A36 / A36M
- 08, and as specified in Chapter 23, Steel Structures, for fabrication and welding. All structural steel
assemblies shall be hot dip galvanized in accordance with ASTM A123 / A123M – 12 and with
Section 23.4.10 of Chapter 23, Steel Structures.
26.4.9 Asphaltic Plug Joint (APJ)

Material, testing and application requirements for field molded asphaltic plug joints (APJs) used in
expansion joint sealing on asphalt concrete overlay and portland cement concrete decks shall
comply with the requirements of ASTM D6297 – 13. The asphaltic binder to be used shall be a
thermoplastic polymeric-modified asphalt or hot laid elastomer modified bitumen bound material. The
aggregates shall be crushed, washed, and dried. Physical properties of the asphalt such as softening
point, tensile adhesion, ductility, resilience, and flexibility shall also be tested and shall conform to
ASTM D36 / D36M – 12, ASTM D113 – 07, ASTM D5 / D5M – 13, and ASTM D217 - 10.
Rubber bitumen sealant shall comprise a hot applied sealant composed of bitumen, rubber extender
and filler conforming to the requirements of ASTM D6690 – 12, ASTM D5167 – 13, ASTM D5249 –
10, and ASTM D5329 – 09.
The Contractor shall propose and submit for the Engineer’s review and approval practical means of
testing the watertightness aspects of the individual systems, either in the field or at approved testing
laboratory.
26.4.10 Header Materials

The Contractor shall use elastomeric concrete or epoxy concrete for header material where indicated
in the Contract plans or specified in the particular specifications. Otherwise, the usage of these
materials shall be strictly in accordance with the direction of the Engineer for the intended application.
Mixes and uses of elastomeric and epoxy concrete materials shall be in accordance with this section
and in compliance with the Manufacturers’ guidelines.
Page 26-16
By consulting the most reliable forecasts, the Contractor shall ensure that ambient temperatures will
fall between 7º C and 38º C throughout the installation of elastomeric concrete material, and will not
be less 13º C during the installation of epoxy concrete material.
The Contractor shall not permit traffic to drive over sealed joints until the header material has
hardened enough to prevent deck movement and other vibrations from displacing the seal.
Elastomeric concrete shall cool and solidify for at least one hour before a bridge roadway is open for
traffic. Epoxy concrete shall cure for at least two hours before a bridge roadway is open for traffic.
26.4.10.1 Elastomeric Concrete
a. Elastomeric Concrete Material

Elastomeric concrete material includes two-component elastomer and prebagged fillers. The
Contractor shall mix elastomeric concrete material and use it according to its Manufacturer’s
recommendations. For such mixing and use, the Contractor may need to apply heat to accelerate
curing and to ensure a quality bond between concrete and steel. Elastomeric concrete shall have
the following features:
1. Compatibility with all allowable joint seal materials and with all concrete or steel to which it is
bonded
2. Provision of a smooth riding surface across the joint
3. Capability of being mixed by normal equipment
4. Capability of being mixed and placed when temperatures range from 7º C to 38º C
b. Elastomeric Concrete Cured Binder Material

The Contractor shall ensure elastomeric concrete cured binder material (without filler) has the
physical properties shown in Table 26-8.
Table 26-8: Physical properties for elastomeric concrete cured binder material (without
filler)

Before oven aging:
Tensile strength (minimum) 5.2 MPa ASTM D638 - 10
Elongation at break (minimum) 200% ASTM D638 - 10
Hardness (Type D durometer) 39 - 58 ASTM D2240 - 05(2010)
Compression set, 22 hrs at maximum 70° ASTM D395 - 03(2008) Method
80%
C B
ASTM D624 - 00(2012)
Tear resistance (minimum) 2.7 kg/mm
50 mm/min
Water absorption (maximum) 1.2% ASTM D570 - 98(2010)e1
Heat shrinkage (maximum) 1.6% ASTM D1299-55(1979)E01
Impact strength (minimum) 9.5 N m Article d of Subsection 26.4.10.1
Properties after oven aging at 70° C for 72 hours
Hardness (Type D durometer) 90, ± 3 ASTM D2240 - 05(2010)
Impact strength (minimum) 9.5 N m Sub-article d of Article 26.4.10.1
Page 26-17
c. Elastomeric Concrete Binder Material

The Contractor shall ensure that the elastomeric concrete binder material (with filler) has the physical
requirements shown in Table 26-9.
Table 26-9: Physical requirements for elastomeric concrete binder material (with filler)
Resilience at 5% deflection (minimum) 70% Sub-article d of Article 26.4.10.1

Bond strength to concrete (minimum*) 2.6 MPa Sub-article d of Article 26.4.10.1
Wet bond strength to concrete (minimum*) 1.7 MPa Sub-article d of Article 26.4.10.1
Pot life (minimum) 5 minutes Sub-article d of Article 26.4.10.1

*greater than concrete failure strength (tensile strength)
d. Testing Method for Elastomeric Concrete

The Contractor shall use this test method to determine pot life, bond strength to concrete, wet bond
strength to concrete, resilience at 5 percent deflection, and impact strength of elastomeric concrete
material covered under Article 26.4.10.1 of these Specifications.
1. Apparatus
The apparatus shall consist of the following:
i. Containers: Use containers big enough to weigh each component to the proper ratio.
Also, use a container big enough to hold all components during mixing.
ii. Paper Cups: Use unwaxed paper cups, 480 ml, 75 mm diameter base.
iii. Wooden Tongue Depressors
iv. Large Spoon or Spatula
v. Balance: Use a balance capable of weighing the components; accurate to 1 g.
vi. Stopwatch: Use a watch with one-second divisions.
vii. Molds: Use briquet molds as specified in AASHTO T 132:1987 (R2013).
viii. Riehle Briquet Tester: Use the tester or equivalent that meets the requirements of
AASHTO T 132:1987 (R2013).
ix. Saw: Use a diamond-tooth saw or other cutting tool capable of producing clean, smooth
faces.
x. Testing Machine: Use the machine specified in ASTM D638 - 10, equipped with a drive
mechanism to allow a testing speed of 5 mm/min.
xi. Molds: Use cylinder molds (75 x 150 mm)
xii. Steel Ball: Use a 414 g ± 23 g steel ball.
2. Sample Size and Preparation

i. Prior to testing, condition the components to a room temperature of 24oC ± 2o C.
ii. After conditioning, stir each component to redisperse any settled material. Be careful not
to contaminate one component with the other.
3. Procedures
I. Pot Life (with filler)
i. Use the proper size containers to measure each component in proper ratio.
Page 26-18
ii. Follow the manufacturer's recommendation, if applicable, to add the resin and catalyst
to be mixed before adding the fillers.
iii. Mix the components together with a large spoon or a spatula in the large mixing
container.
iv. Start the timer as soon as the resin and catalyst are combined.
v. Ensure that all measured material is added and that the components are mixed
thoroughly.
vi. Weigh out 100 g of the mixed material into a 480 ml cup. Place the material in the bottom
of the cup so that the 100 g will be one mass.
vii. Place the sample on a wooden surface that is free of excessive drafts.
viii. Use a wooden tongue depressor to occasionally probe and lightly stir the material to
determine the pot life. The time it takes the material to become unworkable will be
considered the pot life.
II. Bond Strength to Concrete (with filler)
i. Prepare cement mortar briquets according to AASHTO T 132:1987 (R2013). Use Type
I or III cement meeting the requirements of AASHTO M 85-12, and 20-30 standard sand
meeting the requirements of ASTM C190-85.
ii. Allow the briquets to cure for at least 7 days.
iii. Saw the briquets in half at the centerline perpendicular to the long axis.
iv. Abrasive blast the cut faces lightly and blow clean with compressed air.
v. Place three briquet halves back in the molds and cast elastomeric concrete into the
remaining mold spaces. This creates specimens that are half mortar and half elastomeric
concrete.
vi. Cure the specimens for 7 days at 24oC ± 2o C, in 50 percent, ± 10 percent relative
humidity.
vii. After the required curing time, tensile-load the specimens in the briquet tester at a loading
rate of 2669, ± 110 N/minute.
viii. Report the average bond strength to concrete obtained on the specimens.
III. Wet Bond Strength to Concrete (with filler)
i. Prepare the specimens in accordance with Procedures, Step II, i through vi.
ii. After the required curing time, submerge the specimens in water at 24oC ± 2o C for 7
days.
iii. At the end of 7 days, remove the specimens from the water and immediately tensile-load
them in the briquet tester at a loading rate of 2669, ± 110 N/minute.
iv. Report the average wet bond to concrete obtained on the specimens.
IV. Resilience at 5 Percent Deflection (with filler)
i. Mix enough material according to the manufacturer's instructions to make three, 75 x
150 mm cylinders.
ii. Make the cylinders in three layers and rod them 25 times per layer. Trowel the tops
smooth.
iii. Cure the cylinders 7 days at 24oC ± 2o C, in 50 percent, ± 10 percent relative humidity.
iv. At the end of 7 days, remove the cylinders from the molds. Make sure the ends of the
cylinders are relatively perpendicular to the axis. If not, square them with a saw.
Page 26-19
v. Make four measurements at the quarter points around the circumference of the cylinders.
Measure to the nearest 0.025 mm the height of the cylinders. Mark these points on the
side of the cylinders.
vi. Determine the average height of each cylinder.
vii. Compression-load the cylinder at 5 mm/minute, to 95 percent of its original height.
Measure deflection with a micrometer to the nearest 0.025 mm.
viii. Remove the load and let recover for 5 minutes.
ix. Measure the average height again to the nearest 0.025 mm, using the same measuring
points from Procedures, Step IV. v.
x. Calculate resilience after 5 percent deflection as follows:
Height after recovery − Compressed height
% Resilience = x 100
Deflection
Equation 26-1: Resilience after 5 percent deflection
V. Impact Strength (without filler)
i. Cast six specimens with diameters of 69 mm, ± 6 mm and thicknesses of 10, ± 0.6 mm.
ii. Allow the specimens to cure for 7 days at 24o C ± 2o C and 50 percent, ± 10 percent
relative humidity.
iii. Mill the cured specimens plane on both faces to the required thickness.
iv. Place three of the specimens in a freezer at (- 18o C) for at least 30 minutes.
v. Remove the specimens one at the time from the freezer. Place them on a smooth
concrete slab, on a smooth steel plate at least 13 mm thick.
vi. Drop a 4.45 kg steel ball onto the center of each specimen from an initial height of 2.1
m. Perform the drop within 10 seconds of removing the specimen from the freezer. Two
out of three specimens shall pass using the following criteria:
• If the specimen shatters or cracks, it fails.
• If the specimen does not shatter or crack, it passes.
vii. Report the final results as either “less than 9.5 metre-N” or “greater than 9.5 metre-N”
viii. Age the remaining three specimens in the oven at 70o C ± 2o C for 72 hours.
ix. Test the specimens according to Procedures, Step V, iv through vii.
26.4.10.2 Epoxy Concrete

In accordance with the Contract plans, epoxy concrete material shall meet the following minimum
requirements:
• Compatibility with all allowable joint seal materials and with all concrete or steel to which it is
bonded
• Able to provide a smooth riding surface across a joint
• Able to be mixed using normal equipment
• Able to be mixed and placed when temperatures are 13º C or higher.
The Contractor shall use header material that is a two-component rapid curing epoxy with aggregate
that cures to a dense semi-flexible, weather, abrasion, and impact-resistant epoxy concrete. Such
material shall have the physical properties shown in Table 26-10.
Page 26-20
Table 26-10: Physical properties of epoxy concrete material

Mixed epoxy without aggregate (before and after oven aging at 70° C for 72 hours)
Shore D hardness 45-75 ASTM D2240 - 05(2010)
Pot life (maximum) 45 minutes Sub-article d of Article 26.4.10.1
Mixed epoxy with aggregate
Compressive strength at 24 hours ASTM C39 / C39M - 12 (76 mm
75 MPa
(minimum) cylinders)
Resilience at 5% deflection (minimum) 75% Sub-article d of Article 26.4.10.1
Bond strength to concrete (minimum*) 34 MPa Sub-article d of Article 26.4.10.1
Wet bond strength to concrete
1.7 MPa Sub-article d of Article 26.4.10.1
(minimum*)
No
Thermal compatibility ASTM C884 / C884M - 98(2010)
delamination
**greater than concrete failure strength (tensile strength)
The qualified Manufacturer shall furnish the aggregate used in epoxy concrete. The Contractor shall
use well-graded, clean, and dry aggregate that meets the gradation requirement shown in Table
26-11. Care shall be taken to avoid air entrapment upon placement of epoxy concrete around anchor
bolts.
Table 26-11: Gradation requirement for aggregate used in epoxy concrete
Size Percent passing by weight

No. 4 Sieve 100%
No. 80 Sieve 0-5%
Note: Test according to AASHTO T 27-11
a. Temporary Joint Filler

The Contractor shall use temporary joint filler when using epoxy concrete material. Temporary joint
filler shall be an extruded rigid cellular polystyrene with enough compressive strength to maintain
correct joint widths and to obtain relatively smooth and straight faces upon removal of the material.
26.5 Manufacturing and Fabrication of Bridge Deck Joint Systems

The Contractor shall have a joint fabricated to match a bridge deck’s full width, unless construction
is staged (one lane at a time) or when joint lengths prohibit shipment.
26.5.1 Manufacturing Joint Sealing Systems

Compression Seal Expansion Joints: The Contractor shall not splice preformed elastomeric joint
seals in the field, unless the Engineer specifically permits such splicing.
Expansion joint assemblies shall be fabricated by their Manufacturers and delivered to the bridge
site completely assembled, unless the Contract documents specify otherwise.
Preformed Elastomeric Neoprene Profile Seal Expansion Joints: The Contractor shall have the
joint fabricated full width of the bridge deck, except in stage construction (one lane at a time) or when
joint length prohibits shipment.
Page 26-21
Low-Density, Closed Cell, Cross-linked, Nitrogen-blown Seal Expansion Joints: The

Contractor shall have the joint fabricated full width of the bridge deck, except in stage construction
(one lane at a time) or when joint length prohibits shipment.
26.5.2 Manufacturing Strip Seal Type Expansion Joints

The seal gland shall be fabricated in one continuous strip. The Contractor shall not splice gland
material in the field.
The Owner shall not permit welding pieces together in any manner to obtain the final shape of steel
channels. When directional changes is required, the Owner may permit shop welding for this purpose
only using a complete penetration weld within the steel channels in accordance with the
Manufacturer’s recommendations.
The geometry of the steel channels shall not allow the accumulation of water and moisture.
26.5.3 Manufacturing Finger Type Expansion Joints

The finger type expansion joint units shall be shop fabricated as indicated on the Contract plans, as
specified herein and approved by the Engineer on the shop drawings. All metal surfaces shall be
given the corrosion protection after welding and prior to bolting the assembly together.
The adequacy of the joint design and installation details shall meet with the approval of the Engineer.
All welding shall comply with the requirements of Sections 23.4.11 and 23.6.10 of Chapter 23, Steel
Structures, of these Standard Specifications. The surface of the finished joint shall have an applied
welded pattern or other textured non-skid surface approved by the Engineer.
The complete unit shall be fabricated with a minimum of joints and splices. All joints and splices shall
be subject to approval of the Engineer. Joints and splices shall be designed by the Manufacturer to
prevent movement or displacement between abutting sections.
The drainage collector shall have adequate slope of at least 8% to ensure that sand accumulation
in the collector is washed away during rain storms.
26.5.4 Manufacturing Elastomeric Expansion Joints

The size selection of elastomeric expansion joints is predicated on movement of the concrete
superstructures due to shrinkage and creep of concrete and temperature change.
26.5.5 Manufacturing Modular Bridge Joint Systems

A modular bridge joint system (MBJS) shall be fabricated in accordance with the dimensions,
shapes, details, material specifications, and procedures shown in approved shop drawings. Fillet
welds shall be welded continuously. An MBJS shall not have intermittent fillet welds.
The Contractor shall avoid field splices if at all possible. An entire MBJS shall be shipped and
installed as one unit. If field splicing cannot be avoided, the Owner recommends that such splices
be located away from potential wheel paths or under the median traffic barrier. For an MBJS, the
Contractor shall use only field-splice details that have been fatigue-tested in accordance with the
prequalification tests outlined in Section 26.4.7. Typically, fatigue design will dictate that the span of
a centrebeam with the splice must be smaller than the continuous spans; generally, the smallest
span possible works best.
A full-penetration field weld can sometimes be made from a deck when there is only one centrebeam
and it can be lifted out enough to access the bottom of the centrebeam. The Contractor shall be
careful to prevent weld metal from getting into seal retainer grooves, which can lead to seal pullout
and leaking. The Contractor shall not use fillet or partial penetration welds. If there is more than one
centrebeam, the Contractor shall not use welded splices. The Contractor may use field splices for
edgebeam profiles, but only when fillet welds cross only part of the profile.
The Contractor shall provide lifting devices. In addition, at least three devices along each segment
of the length of an MBJS shall be provided to maintain the preset opening of a joint; such devices
shall have uniform spacing that does not exceed 4.5 metres.
Page 26-22
When the fabrication is completed, the Manufacturer shall perform the pre-installation inspection as
described in Article 26.6.2.426.6.7.2 to ensure that the MBJS passes inspection.
26.5.5.1 Edgebeam Profile and Anchorage

The edgebeams shall be fabricated from structural steel. The web of the edgebeam cross section
shall be at least 9.5mm in thickness. The same cross section used in the prequalification test shall
be used. Shop splices in the edgebeam profile shall be two sided, complete joint penetration groove
welds. The edgebeam shall be continuously fillet welded to the support boxes.
Anchorage shall comply with Article 14.5.6.9, “Modular Bridge Joint Systems (MBJS),” of the
AASHTO LRFD Bridge Design Specifications. If an edgebeam cross-section includes a horizontal
element, such element shall also be anchored to resist the full force of the wheel-load and upward
impact (from rebound).
26.5.5.2 Centerbeam and Support Bar

Centrebeams, support bars, and connection details shall be the same type as those used in
prequalification tests. Shop splices in a centrebeam’s profile shall be two-sided, complete-joint-
penetration groove welds. In a welded multiple support bar MBJS, a weld joint between the
centrebeam and support bar shall be a full-penetration groove weld.
After welding, the Contractor shall place the centrebeam (support) bar assembly on a flat surface
and verify that the support bars lie in a single plane, with no part of the bottom of any support bars
more than 6.5 mm off the surface. The Contractor may make as many as three attempts to heat-
straighten the subassembly.
26.5.5.3 Seals
The seal Manufacturer shall install seals in an MBJS before shipment, unless its centrebeam
requires field splices. In such cases, the Contractor shall install continuous seals (without splices) in
the field after construction is complete. In either case, seal installers shall use the same lubricant-
adhesive that was used in prequalification tests. Seals shall extend out from the ends of the
edgebeams and centrebeams by at least 50mm.
26.5.5.4 Support Boxes

To construct support boxes, the Manufacturer shall continuously weld steel plates or tubes that are
at least 9.5 mm thick. If support boxes are more than 400 mm wide, the thickness of the top plate
shall increase so that the width-to-thickness ratio does not exceed 45; otherwise, the Contractor
must apply stiffening. If the Contractor assembles a support box from nested tubes, the diameter or
width-to-thickness ratio of each tube shall not exceed 45.
26.5.5.5 PTFE Sliding Surface

PTFE for sliding surfaces shall be bonded under controlled conditions and in accordance with the
instructions of either the PTFE Manufacturer or the adhesive Manufacturer. After installers complete
the bonding operation, a PTFE surface shall be smooth and free from underlying bubbles.
26.5.5.6 Stainless Steel Sliding Surfaces

The Contractor shall polish an MBJS’s stainless steel surfaces to an 0.20 µm mirror finish.
26.5.5.7 Corrosion Protection

All of an MBJS’s steel surfaces, except surfaces under stainless steel or those to be bonded to
PTFE, shall be protected against corrosion.
Anchors and exposed sections shall be hot dip galvanized in accordance with ASTM A123 / A123M
- 12.
Page 26-23
26.5.6 Manufacturing Fixed Joint Seal

The sealer shall be so shaped that when installed, at minimum joint opening, it shall be so completely
compressed as to be substantially solid and have a minimum of air spaces. It shall also be so shaped
that in its compressed condition the top center of the exposed surface shall be depressed below the
surface of the sealer edges. The sealer shall be furnished in a sufficient width to accomplish this kind
of closure. The shape to be used and the width and depth to be furnished shall have prior approval
of the Engineer. It shall be flexible and pliable and retain its elasticity at temperatures from 54 to -
28o C and shall not develop appreciable permanent set after full compression of the approved joint
shape for the full effective life of the material. It shall be compatible with the material of which the
joint surfaces are composed and be relatively unaffected by the normal moisture in the material. The
joint sealer shall not be field spliced except when specifically permitted by the Engineer.
Each lot of the joint filler shall be identified with the Manufacturer's name or trade mark and shall be
accompanied by the Manufacturer's certification attesting compliance with this specification.
Each lot of the adhesive shall be delivered in containers plainly marked with the Manufacturer's
certification attesting compliance with this specification.
26.5.7 Manufacturing Asphaltic Plug Type Joint

Asphaltic plug joints shall provide a homogenous expansion medium and smooth running surface.
26.6 Construction of Bridge Deck Joint Systems

All joint materials and assemblies, when stored at a job site, shall be protected from damage.
Assemblies shall be supported to maintain their true shape and alignment. Deck joint seals shall
provide a smooth ride. Bridge deck joints shall be covered by protective material after installation
until final cleanup of the bridge deck.
After installation and before final acceptance, the Contractor shall test deck joint seals in the
presence of the Engineer for leakage. Any leakage of the joint seal shall be a cause for rejection.
26.6.1 Construction of Compression Seal Expansion Joints

Joints in a bridge deck’s roadway areas that are to be sealed with compression seals shall be cast
to a narrower width than required for the preformed material. Such joints in curbs and sidewalks may
be cast to full width. Before installation of compression seals in joints that are narrower than needed,
the Contractor shall saw cut a groove of proper width and depth to receive the preformed material
along the top of the joint.
When making saw cuts into a bridge deck, the Contractor shall minimise spalling. Both sides of a
groove shall be cut simultaneously to the proper depth and alignment as shown in the Contract
documents. A rigid guide shall control a saw’s alignment at all times. A groove’s width shall depend
on the temperature and age of the concrete and shall comply with directions from the Engineer. Lip
of saw cut should be bevelled to avoid later breakage. After saw cutting, any spalls, popouts, or
cracks shall be repaired before installation of a lubricant sealant. Saw cuts are not required where a
bridge deck joint includes armour plates.
During installation, a joint shall be clean, dry, and free from spalls and irregularities that might impair
a proper joint seal. Concrete and metal surfaces shall be clean and free of rust, laitance, oils, dirt,
dust, or other deleterious materials. Using suitable hand methods or machine tools, the Contractor
shall install premoulded elastomeric compression joint seals without damaging them. The Contractor
shall apply lubricant adhesive to both faces of a joint before installation and in accordance with the
Manufacturer's instructions. Preformed elastomeric seal shall be compressed to the thickness
specified in the Contract documents or in accordance with directions from the Engineer in a manner
that is appropriate for the rated opening and ambient temperature at the time of installation. The
Owner shall not permit loose-fitting or open points between a seal and a bridge deck.
Construction of expansion joint seal assemblies shall provide absolute freedom of movement
through the range shown in the Contract documents or as prescribed by the Engineer. Final settings
of a deck joint seal assembly at the time of casting in the anchorages of the unit depend on the
relationship between the current temperature of the superstructure and its expected mean
Page 26-24
temperature. Final settings shall comply with the Contract documents, direction from the Engineer,
or the recommendations of the deck joint seal assembly’s Manufacturer.
26.6.2 Construction of Preformed Elastomeric Neoprene Profile Seal Expansion Joints
26.6.2.1 Preparing Surfaces

The Contractor shall ensure that compressed air used to sandblast and to blow debris is free of
moisture and oil. For cleaning joints, the Contractor shall use air compressors that have suitable
traps for removing surplus water and oil from the compressed air. The Contractor shall check the
compressed air daily for contamination and shall not use contaminated air. The compressor for
preparation of a bridge deck seal assembly’s surface shall be able to deliver compressed air at a
continuous pressure of at least 0.620 MPa.
26.6.2.2 Preparing Headers

Where indicated in the Contract plans or specified in the particular specifications, the Contractor
shall prepare the headers in accordance with the joint manufacturer’s recommendations and the
following:
1. Remove loose, eroded, and unsound concrete from the surface within the joint area.
2. Provide horizontal bonding areas by cutting all angular areas of concrete blockouts.
3. Immediately before placing the header material, sandblast the concrete surfaces or
abrade free of oil, dust, dirt, traces of asphaltic concrete, or other contaminants.
26.6.2.3 Preparing to Seal Joints

To make preparations to seal joints, the Contractor shall do the following:
1. Remove loose, eroded, and unsound concrete from the surface within the joint area.
2. Immediately before placing the seal, sandblast the concrete surfaces or abrade free of
oil, dust, dirt, traces of asphaltic concrete, or other contaminants.
3. As necessary, saw-cut the concrete deck to provide an acceptable attachment surface
for the joint seal.
26.6.2.4 Installing Expansion Joint Seal Assembly

Installation of the expansion joint seal assembly shall comply with the Manufacturer's
recommendations. The Contractor shall use an installer who has been trained by the Manufacturer
to install the bridge deck joint sealing system. The Manufacturer’s representative shall be present
during the installation of the approved header material if any. In addition to the Manufacturer’s
recommendations, the Contractor shall comply with the specifications in this section.
26.6.2.5 Blockouts
Blockouts shall comply with relevant details of the Contract plans.
26.6.2.6 Weather Limitations

The Contractor shall not perform any part of an installation in rainy weather or when rain is expected
within one hour of an installation, and shall ensure that an assembly’s surface is completely dry
before applying adhesive or primer. Ambient temperature shall not be less than 13º C during the
installation of preformed elastomeric neoprene profile seal.
26.6.2.7 General Safety, Handling, Mixing, Finishing, and Curing

While complying with the instructions of the joint system’s Manufacturer, the Contractor shall adhere
to the following procedure to handle, place, finish, and cure the system.
a. Fill the blockout, as shown in the Contract Plans, to the correct grade.
Page 26-25
b. After filling the blockouts on both sides, cure the material according to the Manufacturer’s
instructions.
c. Mix and place the epoxy mortar according to the Manufacturer’s recommendations and as
follows:
1. Before adding the aggregate, thoroughly mix the two components (resin and
hardener) of the epoxy mortar.
2. Mix the epoxy mortar in a mechanical mortar mixer by combining one volume of mixed
epoxy (resin plus hardener in the required proportions) with three volumes of
aggregate, meeting the requirements of these specifications.
3. Prime the surface of the concrete in accordance with the manufacture's
recommendations before applying the epoxy concrete.
4. Place and finish the epoxy concrete within one half hour of mixing.
Cure times for epoxy mortar are directly related to temperature. Table 26-12 provides general
guidelines for cure times at various temperatures.
Table 26-12: Cure time for epoxy mortar
Air and Deck Temperature Approximate Cure Time
o
4 C 5 hours
o
10 C 4 hours
16 oC 3 hours
o
21 C 2.5 hours
o
27 C 1.5 hours
o
32 C 1 hours
38 oC 0.75 hours
The Contractor shall postpone the installation process if the ambient temperature is 13º C and rising.
If the Contractor cannot postpone the operation, they shall use supplemental heat to complete the
operation and reopen the lane in a reasonable time. When using supplemental heat, the Contractor
shall ensure that curing has progressed throughout a header’s mass.
26.6.2.8 Mixing and Placing Elastomeric Concrete Material

The Contractor shall handle, place, finish, and cure the elastomeric concrete material according to
the Manufacturer’s instructions, and shall allow the elastomeric concrete to cool and solidify for at
least one hour before opening to traffic.
26.6.2.9 Preformed Elastomeric Neoprene Profile Joint Seal Application

The Contractor shall do the following to seal joints:
1. After the header material has developed enough strength to be ready for traffic, remove the
temporary joint filler (when called for) and thoroughly clean the joint faces of all joint filler.
2. Lightly sandblast the joint to remove all residue.
3. Apply the adhesive according to the Manufacturer’s recommendations.
4. Install the preformed elastomeric neoprene profile seal so that it is recessed approximately 6
mm below the riding surface.
5. After sealing a joint, promptly remove all surplus residue on the bridge deck.
26.6.2.10 Acceptance of Joint Seal Assemblies

The Contractor shall provide evidence from the joint seal assembly’s Manufacturer that the joint
system has been used successfully in installations with similar environmental and project conditions.
The Owner shall reject a joint seal assembly that fails to perform adequately in actual use.
Page 26-26
26.6.2.11 Correction of Defects in Joint Seal Assemblies

At no expense to the Owner, the Contractor shall either repair or remove and replace any completed
joint seals that leak, have adhesive or cohesive failure, or have damage before final acceptance.
26.6.3 Construction of Low-density, Closed Cell, Cross-linked, Nitrogen-blown Seal

Expansion Joints
The construction of Low-density, closed cell, cross-linked, nitrogen-blown seal expansion joints shall
conform to the requirements of Section 26.6.2.
By consulting the most reliable forecasts, the Contractor shall ensure that ambient and surface
temperatures will remain between 7º C and 24º C throughout the installation of a low-density, closed-
cell, cross-linked, ethylene vinyl acetate, polyethylene copolymer, nitrogen blown seal.
26.6.3.1 Low-density, Closed-cell, Cross-linked, Nitrogen-blown Seal Application

The Contractor shall do the following to complete joint seals:
1. After the header material (if required) has developed enough strength to be ready for traffic,
remove the temporary joint filler (when called for) and thoroughly clean the joint faces of all
joint filler.
2. Lightly sandblast the joint to remove all residue.
3. Apply the epoxy adhesive to both sides of the joint opening and into the grooves of the joint
seal material.
4. Splice the seal using the heat welding method, placing the joint seal material ends against a
Teflon heating iron of 177° C for 7 to 10 seconds and pressing the ends together tightly.
5. Install the joint seal material in one piece.
6. Begin installation at the joint’s low end. Install the joint seal material by compressing the
material and pushing it down into the joint opening until it has recessed approximately 6 mm
below the deck surface. Do not push the joint seal material into the joint at an angle that will
stretch the seal material.
7. After starting to install the joint seal material, do not stop until installation is done.
8. Immediately and thoroughly clean off excess epoxy from the surface of the joint material. Do
not use solvents to clean the top surface of the joint seal material.
26.6.4 Construction of Strip Seal Expansion Joints

Strip seal expansion joints shall seal a deck’s surface to prevent moisture and other contaminants
from descending onto pier and abutment caps. Strip joints shall securely anchor the joint assembly
to the bridge deck, preventing any appreciable changes in the deck surface caused by bridge
expansion and contraction. Deformation of the joint’s elastomeric gland shall take all of the bridge
deck’s expansion and contraction movements.
The Contractor shall obtain installation instructions from the supplier of the strip seal expansion joint
material and comply with specified procedures to install such joints. The Engineer shall approve the
design and installation procedure for any strip seal expansion joints before the Contractor installs
them. When the Contractor installs the strip seal expansion joint, a field representative for the joint’s
Manufacturer shall be on hand to provide technical assistance. During joint installation, the
Contractor shall make proper adjustments, as indicated on the Contract drawings, for temperature.
Installation of strip seal type expansion joint assemblies shall comply with the Contract plans. After
paving the bridge deck, the Contractor shall make saw cuts across the asphaltic pavement for an
approved side headers (if required) and break out the asphaltic concrete between these cuts. After
removing a strip of asphaltic pavement from between saw cuts, the Contractor shall prevent
construction traffic from crossing the joint until installation of headers is complete.
The elastomeric strip seal’s gland may be installed in the field. The Contractor shall mechanically
lock the gland component into place.
Page 26-27
The strip seal joint shall conform to the finished grade of the bridge deck. Its elastomeric component
shall be recessed sufficiently from the finished grade of the bridge deck under all combinations of
motion and skew angles to prevent protrusion above the deck when the joint is closed. The
Contractor shall consider the effects of horizontal curvature, vertical curvature, and skew angles to
properly size and install a joint.
Installed joints shall be watertight.
The Contractor shall not start any work or install any joint seals for the Project until a trained factory
representative is on the job site to provide direction and assistance throughout the installation work.
The Contractor shall notify the joint Manufacturer of the scheduled installation at least two weeks in
advance. This factory representative shall be present for the installation of the first joint seal and any
number of succeeding joint seals until they are satisfied that the Contractor is proficient in this work.
Curb-parapet sections of strip seals or sealing systems shall be pre-engineered and approved by
the Engineer.
The Contractor shall warn all personnel against breathing adhesive and solvent vapours. They shall
also warn personnel to avoid letting such adhesive and solvent contact their skin or eyes. Application
of adhesive and solvents shall take place only in well-ventilated areas. The Contractor shall keep all
adhesives and solvents away from heat, sparks, and open flames. The Contractor shall follow all the
Manufacturer's safety precautions as shown on container labels. Misplaced adhesive shall be
immediately removed and seals shall be cleaned of all foreign matter.
26.6.5 Construction of Finger Type Expansion Joint

The Contractor shall obtain installation instructions from the supplier of the finger type expansion
joint and shall comply with the procedures specified in the installation of the joint. The Contractor
shall obtain the technical assistance of a field representative from the Manufacturer of the joint during
its installation. Proper adjustment shall be made for temperature at the time of installation as
indicated on the Contract plans.
The superstructure shall be in place and all post-tensioning shall be completed before the installation
of the finger type expansion joint. Further, the joint shall be installed before the installation of the
asphaltic concrete wearing surface.
Finger type joint assemblies shall be installed in concrete blockouts as indicated on the Contract
plans and as approved by the Engineer. All assemblies shall be set in concrete with a bonded
construction joint as specified in Article 21.3.4.4 of Chapter 21, Concrete Structures, of these
Standard Specifications. The Contractor shall prevent traffic from crossing the joint until such time
as he has installed the joint assembly, as recommended by the joint Manufacturer, and the curing of
all concrete has been completed.
26.6.6 Construction of Elastomeric Expansion Joints

The Contractor shall obtain installation instructions from the supplier of the expansion joint material
and comply with the procedures specified in the installation of the joint. Shop drawings shall be
submitted to the Engineer for approval. The adequacy of the joint design and installation details shall
meet with the approval of the Engineer. The Contractor shall obtain the technical assistance of a
field representative from the Manufacturer of the joint during its installation. Proper adjustment shall
be made for temperature at the time of installation as indicated on the Contract plans.
Joint assemblies shall be installed after the asphaltic pavement has been laid. Before the asphaltic
pavement is laid the Contractor shall cover the joint opening with a strip of thin rigid material and a
strip of strong paper or plastic equal in width to the joint assembly plus the header (if required) on
each side. After the paving is finished, saw cuts shall be made by the Contractor across the asphaltic
pavement either side of the joint plus side headers, and the asphaltic concrete between these cuts
shall be broken out. The protective strips shall then be removed and the concrete surfaces
thoroughly cleaned prior to installation of the joint assembly. Once the strip of asphaltic pavement is
removed from between the saw cuts, the Contractor shall prevent construction traffic from crossing
the joint until such time as he has installed the joint assembly and the headers have been completed.
Page 26-28
For the expansion joints specified, installation shall in no case be permitted until at least forty (40)
days have elapsed after completion of the concrete post-tensioning operation. Permanent fixing of
the joints to the structure shall only be carried out after the superstructure has been jacked to relieve
the bearing shear and when the ambient temperature is within the range of the joint Manufacturer's
recommendations and as approved by the Engineer.
Concrete or metal surfaces on which the neoprene expansion joints are to be set shall be dry; clean
and free from dirt, grease, latency, and contaninants; level; and sound with no broken or spalled
concrete. No joint shall be placed until the Engineer has inspected and approved the seat conditions.
After coating the seat area with the specified sealant adhesive, the joint shall be positioned over the
anchor bolts and the nuts securely tightened. All loose or long anchor bolts shall be corrected in a
manner approved by the Engineer.
All joints between units, around connecting bolts, and cavity plugs shall be carefully sealed with
sealant in a neat workmanlike manner to seal out water and protect against corrosion. Neoprene
surfaces to be in contact with sealant shall be buffed at the plant or wire brushed prior to installation
to provide a bonding surface for the sealant.
Prior to filling the space in the bolt wells, the Engineer will inspect the anchor bolts and tightening of
the nuts to the Manufacturer's specified torque. Any wells sealed without the Engineer's approval
shall be opened and redone at the Contractor's expense.
The finished joint shall present a smooth, neat appearance with no protruding bolts or rough joints.
Excess sealant shall be wiped or scraped away before it becomes hard. Upon completion of an
entire joint, the Contractor shall grind any uneven end butt connections flush. Any openings between
butt ends not showing mastic to the top shall be cleaned and filled with mastic. The end of the joint
at the curb faces shall be caulked with mastic.
26.6.7 Construction of Modular Bridge Joint Systems

When constructing a modular bridge joint system (MBJS), the Contractor shall follow the
Manufacturer’s written installation guidelines and the guidelines outlined in this section.
26.6.7.1 Shipping and Handling Modular Bridge Joint Systems

Delivery of an MBJS to a job site and its storage at that site shall comply with the Manufacturer’s
written recommendations and directions from the Engineer. The Contractor shall ensure that all
materials delivered to site is in original unopened containers bearing the following information:
• Name of the Manufacturer
• Name of product
• Batch number, lot, etc.
The Contractor shall repair any damage to the corrosion protection system to the satisfaction of the
Engineer. Seals shall not be damaged or cut.
26.6.7.2 Pre-installation Inspection for Modular Bridge Joint Systems

Immediately before the installation of an MBJS, the Engineer shall inspect the MBJS and the
blockout for the following conditions:
a. Proper alignment
b. Complete bond between the seals and the steel
c. Proper placement and effectiveness of studs or other anchorage devices
d. Proper placement of elastomeric springs and bearings
e. Proper placement of waterproofing membranes, if included
f. Clearance between the bottoms of the MBJS’s support boxes and the surface of the blockout;
clearance shall be at least 75mm
Page 26-29
Cutting a bridge deck’s reinforcing steel can compromise the structural integrity of the blockout; the
Contractor shall obtain approval from the Engineer before performing such cutting. The Engineer
shall verify that reinforcing mesh or bars are at least 50mm from the edgebeam or anchorages and
do not prevent the flow of concrete around the MBJS.
No bends or kinks in the MBJS steel shall be allowed (except as required to follow the roadway
crown and grades or to accommodate sidewalks and traffic barriers). At no expense to the Owner,
the Contractor shall repair or replace any MBJS that exhibits bends or kinks to the Engineer’s
satisfaction.
Seals that are not fully connected to an assembly’s steel shall be fully connected at the expense of
the Contractor. Headed concrete anchors shall be inspected visually and shall be given a light tap
with a hammer. Any headed concrete anchor that does not have a complete end weld or that does
not emit a ringing sound when struck with a light hammer tap shall be replaced. The Contractor shall
carefully remove any headed concrete anchors along the length of the edgebeam that are more than
25 mm from their intended locations, as shown on shop drawings, and any headed concrete anchors
that are more than 6 mm too high (reducing cover); after removing an incorrectly placed anchor, the
Contractor shall then weld a new anchor in the proper location. The Contractor shall bear the
expense for all such anchor replacement.
26.6.7.3 Installation of Modular Bridge Joint Systems

Before installing an MBJS, the Contractor shall protect the blockout and supporting system from
damage and construction traffic.
a. Setting a Gap Opening

An MBJS shall be installed at the proper gap opening, corresponding to the installation temperature,
as shown on approved shop drawings. The Contractor shall immediately remove opening devices
after placing concrete.
b. Formwork
The Contractor shall ensure that formwork prevents concrete from entering support boxes or from in
any way impeding free movement of the MBJS.
c. Supporting a Modular Bridge Joint System during Concrete Placement

An MBJS shall have full support throughout the placement of the concrete. Welds for temporary
attachments to the centrebeams or support bars that are used to erect the assembly must be
removed and the surface ground shall be smooth. If necessary, the Contractor shall repair the
corrosion protection system for an MBJS to the satisfaction of the Engineer using a method that the
Engineer has approved. To reduce corrosion, an MBJS shall be electrically isolated by preventing
contact between the MBJS and the bridge deck’s steel reinforcement.
d. Placing Concrete for a Modular Bridge Joint System

Concrete shall be controlled, mixed, and handled as specified in Chapter 4, Concrete Works, and
Chapter 21, Concrete Structures. The blockout shall not include very-high-slump concrete. The
Contractor shall not deposit concrete in forms until the Engineer has inspected and approved the
placement of the reinforcement, conduits, anchorages, and pre-stressing steel.
If an installation site has a vertical grade, the Contractor shall first place concrete on the downhill
side of the blockout. Concrete shall be vibrated thoroughly to adequately consolidate concrete
beneath the support boxes and edgebeams. The Contractor shall be careful not to displace forms
and reinforcing steel. Concrete shall not be placed during heavy rain.
e. Finished Tolerances for a Modular Bridge Joint System

An MBJS shall be inspected after installation and again after at least one year of traffic (or longer if
there is a warranty period) to verify the following conditions:
Page 26-30
• The MBJS’s top surfaces shall be recessed from the finished roadway profile from 0 mm to
6 mm.
• Elevations between the tops of centrebeams and edgebeams shall not differ by more than 3
mm. Such variations shall be measured vertically from a straight line connecting the top of
the deck profile on each side of the MBJS.
• Gaps at either end of a seal or among the multiple gaps of an MBJS shall not differ by more
than 12.5 mm.
f. Bridging a Modular Bridge Joint System after Installation

Construction loads shall not be allowed on the MBJS for at least 72 hours after installation is
completed. If it is necessary to cross the MBJS, the Contractor shall bridge over the MBJS in a
manner approved by the Engineer.
g. Removal of Forms and Debris from a Modular Bridge Joint System

After installing a MBJS, the Contractor shall remove all forms and debris.
h. Watertightness Test for a Modular Bridge Joint System

If the Contract documents require such testing, the Contractor shall test an installed MBJS for
watertightness. After an MBJS has been installed and completed, the Contractor shall flood it for a
at least one hour to a minimum depth of 76 mm. If a MBJS leaks, the Contractor shall repair it to the
Engineer’s satisfaction and retest it at no expense to the Owner. Such repair shall comply with a
procedure recommended by the assembly’s Manufacturer that has been approved by the Engineer.
i. Acceptance of Modular Bridge Joint System Installation

An MBJS that fails inspection or testing shall be replaced or repaired to the satisfaction of the
Engineer at the Contractor’s expense. Any proposed corrective procedure shall be submitted to the
Engineer for approval before corrective work is begun.
26.6.8 Construction of Fixed Joint Seal

The sealer shall be installed by suitable hand or machine tools and thoroughly secured in place with
an approved adhesive which shall cover both sides of the sealer over the full area in contact with the
sides of the joint. The adhesive may be applied to the sides of the joint or the sealer or both. The
sealer shall be installed in a compressed condition and shall at all times be below the level of the
surface by approximately the amount shown on the Contract plans. The sealer shall be in one
continuous piece for the full width of transverse joint prior to being installed in the joint. The
continuous piece for installation shall not have more than one (1) butt splice within its length. The
butt splice shall be a Manufacturer's splice. If this splice is torn or damaged it shall be repaired, prior
to installation, using the Manufacturer's recommended adhesive. In longitudinal joints the sealer shall
be in practical lengths. Any joints in the sealer material shall be adequately sealed with additional
adhesive.
After installation and prior to final acceptance, deck joint seals shall be tested, in the presence of the
Engineer, for leakage of water through the joint. Any leakage of the joint shall be cause for rejection.
The sealer shall be installed immediately after the removal of the curing cover, using an adhesive
that is compatible with the sealer and the material of which the joint surfaces are composed.
Temperature limitations of the adhesive as guaranteed by the Manufacturer shall be observed. Joints
shall be clean and free of foreign material immediately prior to the installation of the sealer.
No shipment of materials shall be accepted for use unless the material complies with the
requirements of these standard specifications.
The materials shall not be used until the Contractor has been notified by the Engineer that they meet
the requirements of these standard specifications.
Page 26-31
26.6.9 Construction of Asphaltic Plug Joint

1. Joints shall be finished nominally flush with the road surface within the tolerance of the
asphaltic surfacing specification.
2. Joint material shall be consolidated during installation in accordance with the
manufacturer’s method statement.
3. Joints shall be installed between inside faces of opposing bridge railing on the deck
structure to ensure continuity of waterproofing.
4. When completed the joint shall prevent the passage of water into the joint gap.
26.7 Warranty and Maintenance for Bridge Deck Joint Systems

The Contractor shall obtain the warranty period from the Manufacturer for all types of bridge deck
joint systems that are installed for the Project. Such warranties shall cover all elements of the bridge
deck joint system. During this period, warranties cover any defective workmanship and product
failure in accordance with the loading criteria of the structure, which should be certified before the
recommendation of the specific joint system.
The required warranty periods for each category of bridge deck joint system shall be as follows:
- 15 years for modular, strip, compression and finger type
- 10 years for elastomeric, fixed and asphaltic plug type
The Contractor shall provide certification from the Manufacturer of bridge deck joint systems that
shows that the joint system materials conform to the requirements outlined in Section 26.4. The
Contractor shall transfer to the Owner the Manufacturer’s ten years warranty on each installation. A
warranty claim may be filed for the cohesive or adhesive failure of the materials supplied or material
failure due to weathering, and surface crazing, abrasion or tear failure resulting from normal traffic
use.
The Contractor shall inspect any bridge deck joint system that are installed on the Project within one
year of opening to traffic and perform any required maintenance to ensure the joint system’s
functionality and durability.
For the rest of the warranty period, if deficiencies are found, the Owner may inform the Manufacturer
through the Contractor in writing of any defects and specify a required completion date for repairs.
The joint system Manufacturer shall provide guidelines and manuals to support routine maintenance
and replacement of the joint system and to support resolution of any concerns during the warranty
period.
26.8 Documentation for Bridge Deck Joint Systems

The Contractor shall provide all necessary documentation for approval of the design, manufacture,
and installation of a bridge desk joint system and for the long term inspection, maintenance, and
potential replacement of such system. Such documentation shall include the following:
• Designs
• Working drawings
• Inspection and test plans
• A certificate of compliance from the Manufacturer
• Certified documentation of the structure’s loading criteria and load tests
• Quality records
• As-installed details, including tabulated benchmark measurements that will allow the
movement of the structure to be monitored during operation
• Procedures for the inspection of the joint system
Page 26-32
• Procedures for maintenance

• A fully detailed method statement for the replacement of the bridge deck joint system
• Risk assessments and appropriate safety information.
Page 26-33
INDEX
adhesives, 5, 14, 30 Welding, 7, 12, 19

anchor bolts, 5, 18, 23, 30 wheel loads, 5, 16
Anchorage, 25
Blockouts, 27
brochures, 11
centerbeams, 5, 6
certification, 10, 11, 12, 26, 33
Compatibility, 8, 13, 19, 23
compression seal expansion joints, 5
concrete headers, 27
Corrosion Protection, 16, 26
deck surfaces, 5
Department of Transport, 26-3
Design calculations, 12
documentation, 10, 33, 34
Documentation, 12, 33
Drainage Collector, 15
edgebeams, 5, 25, 32
elastomeric expansion joints, 5, 16, 17, 24
epoxies, 5, 18
Epoxy mortar, 18
extruded steel channels, 5
finger type expansion joints, 5, 15
fixed joint seals, 5
formwork, 32
Hardness, 8, 15, 16, 20
installation, 6, 9, 10, 11, 12, 13, 14, 15, 19, 24,
25, 26, 27, 28, 29, 30, 31, 32, 33
Lifting locations, 12
modular bridge joint systems, 5
molded units, 5, 16
movement ranges, 5
movements, 5, 6, 9, 11, 13, 16, 29
Oil Deterioration, 16
recesses, 5
riding surface, 14, 19, 23, 28
Risk assessments, 34
saw cuts, 26, 29, 30
sealants, 5
sealed joints, 5, 19
smooth ride, 26
springs, 5, 6, 12, 18, 31
stainless, 6, 18, 25, 26
steel components, 13, 15, 16, 18
strip seal, 5, 11, 14, 15, 16, 17, 29
structural steel angles, 5
studs, 5, 31
support boxes, 5, 6, 25, 31, 32
temporary, 12, 24, 28, 29, 32
traffic, 10, 12, 19, 25, 28, 29, 30, 31, 32, 33
two-component, 13, 14, 19, 23
warranty, 32, 33
water tightness, 5
Page 26-34
PART 2
ROAD STRUCTURES
CHAPTER 27 - RAILINGS
DOCUMENT NO: TR-

FIRST EDITION
JANUARY 2018
Chapter 27: Railings

TABLE OF CONTENTS
List of Figures ................................................................................................................................. ii
List of Tables .................................................................................................................................. ii
27 Railings ........................................................................................................................... 27-1
27.2 Working Drawings Submission .................................................................................... 27-4
27.3 Materials for Railings ................................................................................................... 27-4
27.3.1 Aluminium Railing ................................................................................................. 27-5
27.3.2 Steel Railing ......................................................................................................... 27-7
27.3.3 Metal Beam Railing ............................................................................................... 27-8
27.3.4 Stainless Steel Railing .......................................................................................... 27-8
27.3.5 Copper Alloys Railing............................................................................................ 27-8
27.3.6 Concrete Railing ................................................................................................... 27-8
27.3.7 Screening for Railings ........................................................................................... 27-8
27.4 Construction Requirements for Railings ....................................................................... 27-8
27.4.1 General................................................................................................................. 27-8
27.4.2 Constructing Aluminium Railing ............................................................................ 27-9
27.4.3 Constructing Steel Railings ................................................................................. 27-10
27.4.4 Constructing Stainless Steel Railing ................................................................... 27-12
27.4.5 Constructing Copper Alloys Railing ..................................................................... 27-12
27.4.6 Constructing Concrete Railing ............................................................................ 27-13
27.4.7 Constructing Screening for Railings .................................................................... 27-13
27.4.8 Welding for Railings ............................................................................................ 27-13
27.4.9 Storing Construction Materials for Railings ......................................................... 27-14
27.4.10 Constructing Temporary Railings ........................................................................ 27-14
27.5 Testing and Acceptance of Railings ........................................................................... 27-14
27.5.1 General............................................................................................................... 27-14
27.5.2 Bridge Railing Test ............................................................................................. 27-14
27.5.3 Crash Testing Policy ........................................................................................... 27-14
27.6 Spares for Railings .................................................................................................... 27-15
27.6.1 Constructing Spares for Railings ......................................................................... 27-15
Index ...................................................................................................................................... 27-15
Page i
CHAPTER 27: RAILINGS First Edition -January 2018
LIST OF FIGURES
Figure 27-1: Types of railing system Joint construction ............................................................ 27-11
LIST OF TABLES
Table 27-1: Designations and titles for AASHTO and ASTM standards that apply to railing
construction works ..................................................................................................................... 27-2
Table 27-2: Types of anodic coatings......................................................................................... 27-9
Page ii
27 RAILINGS
This chapter outlines standards and requirements for furnishing materials and constructing railing of
concrete, steel, aluminium, or a combination of these materials for the Project.
This chapter’s specifications apply to all work and materials related to railing construction, including
necessary anchorage for the railing on bridges, culverts, walls, or other structures as shown on the
Contract plans. These specifications apply to hand and pedestrian railings, bridge railings (which are
sometimes called bridge or traffic barriers), and railings for similar purposes. Railings shall conform
to the type and details specified in the Contract documents for the location where they are
constructed.

Standards and codes for railings shall be as specified in these specifications, in the Contract
AA Aluminum Association;
AA ADM-1 Aluminum Association - Aluminum Design Manual, 2010
Edition;
AASHTO LRFD American Association of State Highway and Transportation
Officials - Load and Resistance Factor Design, Bridge
Construction Specifications;
AASHTO LRFD American Association of State Highway and Transportation
Officials - Load and Resistance Factor Design, Bridge Design
Specifications;
AASHTO Standard Specifications for Transportation Materials and
Methods of Sampling and Testing;
AASHTO GSH-9 Guide Specifications for Highway Construction, 9th Edition;
D1.5M/D1.5:2010
AASHTO MASH AASHTO Manual for Assessing Safety Hardware;
ANSI/AWS D1.2/ Structural Welding Code—Aluminum;
D1.2M:2003
AWS D 1.6/ Structural Welding Code - Stainless Steel;
D 1.6M: 2007
NCHRP350 National Cooperative Highway Research Program Report 350
- Recommended Procedures for the Safety Performance
Evaluation of Highway Features;
NOMMA National Ornamental & Miscellaneous Metals Association;
NOMMA Voluntary Joint Finish Guidelines;
Guideline 1
Page 27-1
SSPC Society for Protective Coatings;

SSPC-SP 6/ Society for Protective Coatings, Commercial Blast Cleaning.
NACE No. 3
Table 27-1 presents American Association of State Highway and Transportation Officials (AASHTO)
and American Society for Testing and Materials (ASTM) standards that are related to materials for
railings. It also includes designations and titles.
Table 27-1: Designations and titles for AASHTO and ASTM standards that apply to railing
construction works
AASHTO ASTM
Title

ASTM A307 - 10

ASTM A500 /
Seamless Carbon Steel Structural Tubing in Rounds and
A500M - 10a
Shapes
AASHTO M
Standard Specification for Chain-Link Fence
181-10
Standard Specification for Structural Bolts, Steel, Heat

ASTM A325 - 10
Treated, 120/105 ksi Minimum Tensile Strength
ASTM A53 / Standard Specification for Pipe, Steel, Black and Hot-
A53M - 12 Dipped, Zinc-Coated, Welded and Seamless
AASHTO M ASTM A123 / Standard Specification for Zinc (Hot-Dip Galvanized)

111M/M 111-11 A123M - 12 Coatings on Iron and Steel Products
AASHTO M ASTM A153 / Standard Specification for Zinc Coating (Hot-Dip) on Iron
232M/M 232-10 A153M - 09 and Steel Hardware
Standard Specification for General Requirements for Flat-

ASTM A480 /
Rolled Stainless and Heat-Resisting Steel Plate, Sheet,
A480M - 12
and Strip
ASTM A575 - Standard Specification for Steel Bars, Carbon, Merchant

96(2007) Quality, M-Grades
Standard Specification for Aluminum and Aluminum-Alloy

ASTM B221 - 12
Extruded Bars, Rods, Wire, Profiles, and Tubes
Standard Specification for Steel Bar, Carbon and Alloy,

ASTM A108 - 07
Cold-Finished

ASTM B210 - 12
Drawn Seamless Tubes
ASTM B108 / Standard Specification for Aluminum-Alloy Permanent

B108M - 12e1 Mold Castings
Page 27-2
AASHTO ASTM
Title
ASTM B429 / Standard Specification for Aluminum-Alloy Extruded

B429M - 10e1 Structural Pipe and Tube

ASTM
Drawn Tube and Pipe for General Purpose Applications
B483/B483M-03
(Withdrawn 2012)
AASHTO M193- Standard Specification for Cast Aluminum Alloy Railing

1980 Posts

ASTM B209 - 10
Sheet and Plate
ASTM F594 -
Standard Specification for Stainless Steel Nuts
09e1
ASTM F593 - Standard Specification for Stainless Steel Bolts, Hex Cap
02(2008)e1 Screws, and Studs

ASTM A240 /
Nickel Stainless Steel Plate, Sheet, and Strip for Pressure
A240M - 12
Vessels and for General Applications
Standard Specification for Quenched and Tempered Alloy

ASTM A354 - 11 Steel Bolts, Studs, and Other Externally Threaded
Fasteners

ASTM A1011 / Rolled, Carbon, Structural, High-Strength Low-Alloy, High-
A1011M - 12a Strength Low-Alloy with Improved Formability, and Ultra-
High Strength
ASTM B766 - Standard Specification for Electrodeposited Coatings of

86(2008) Cadmium
Standard Specification for Stainless Steel Bars and

ASTM A276 - 10
Shapes
ASTM B211 - Standard Specification for Aluminum and Aluminum-Alloy

12e1 Rolled or Cold Finished Bar, Rod, and Wire
ASTM B26 /
Standard Specification for Aluminum-Alloy Sand Castings
B26M - 12
Standard Specification for Seamless Red Brass Pipe,

ASTM B43 - 09
Standard Sizes
Standard Specification for Composition Bronze or Ounce

ASTM B62 - 09
Metal Castings
ASTM B308 / Standard Specification for Aluminum-Alloy 6061-T6

B308M - 10 Standard Structural Profiles
Page 27-3
AASHTO ASTM
Title
Standard Specification for Copper-Zinc-Lead Alloy

ASTM B455 - 10
(Leaded-Brass) Extruded Shapes
ASTM B584 - Standard Specification for Copper Alloy Sand Castings for
12a General Applications
Standard Specification for Zinc Coating, Hot-Dip,

ASTM F2329 - Requirements for Application to Carbon and Alloy Steel
11 Bolts, Screws, Washers, Nuts, and Special Threaded
Fasteners
27.2 Working Drawings Submission

Designs for all types of railings shall comply with the latest version of the AASHTO Load and
Resistance Factor Design LRFD Bridge Design Specifications, and Abu Dhabi Road Structures
Design Manual (AD-D-06). Unless railing details are shown in the Contract drawings or if required in
the Contract documents, the Contractor shall submit for the Engineer’s approval design calculations
that verify that railings provide the necessary rigidity, support all required loads, and satisfy specified
levels of testing as defined in Section 27.5.2, the Contract documents, the AASHTO LRFD Bridge
Design Specifications, and Road Structures Design Manual (ADQCC TR-516), as applicable.
The Contractor shall submit working drawings to the Engineer that cover the installation procedure
and assembly for the railing using proprietary railing systems. The Contractor shall submit shop
drawings for the Engineer’s approval for all railings.
The Contractor shall not perform any work on the railing before receiving approval for working
drawings from the Engineer. Such approval shall not relieve the Contractor of any responsibility
under the Contract documents for successful completion of the work.
In general appearance, railings shall be as shown on the Contract drawings and shall have the
A professional structural design engineer shall design, sign, and seal the Contractor’s calculations
and working drawings. The Contractor shall submit three sets of railing drawings and one set of
design calculations to the Engineer for approval.
The Contractor shall test each bridge railing in accordance with Section 27.5, and submit the test
results to the Owner for review and issuing acceptance letter.
The Contractor shall assume responsibility for conforming to these specifications and the Contract
plans, and shall include the following items in the submission to the Engineer:
a. The Manufacturer’s brochure on the proposed railing, showing physical dimensions for
components, installation procedures, material certifications
b. Design calculations
c. Presetting details
d. Drawings that detail the railing’s installation and indicate the lengths of component members.
e. Samples and test results.
27.3 Materials for Railings

All railing materials for which the Contract documents do not define specific requirements shall
comply with the requirements for applicable materials that are outlined in this section and the
• Chapter 4, Concrete Works, in these Standard Specifications.
Page 27-4
• Chapter 5, Reinforcing Steel, in these Standard Specifications.

• Chapter 23, Steel Structures, in these Standard Specifications.
• Chapter 24, Painting, in these Standard Specifications.
• Chapter 30, Miscellaneous Metal, in these Standard Specifications.
27.3.1 Aluminium Railing

For all parts of aluminium railings, except for anchor bolts, toggle bolts, and other miscellaneous
hardware, the Contractor shall use aluminium alloy that conforms to the requirements specified in
this section.
The Contractor shall furnish a certified report of test or analysis to the Engineer for the railing tubes,
cast and extruded shapes for posts, and anchor bolts. For miscellaneous hardware required to
complete installation of railing, such as (toggle bolts, washers, nuts, bolts, screws, pins, clamps, and
shims), the Contractor shall provide a certificate of compliance to the Engineer.
Dimensional tolerances for aluminium products shall conform to the requirements defined in the
ASTM’s Standard Specification for Aluminum and Aluminum-Alloy Drawn Seamless Tubes (ASTM
B210 - 12).
27.3.1.1 Cast Aluminium Railing Posts

Materials for aluminium railing posts shall conform to the requirements defined in AASHTO’s
Standard Specification for Cast Aluminum Alloy Railing Posts (AASHTO M193-1980) or
requirements for alloy A 444.0 as defined in ASTM’s Standard Specification for Aluminum-Alloy
Permanent Mold Castings (ASTM B108 / B108M - 12e1).
27.3.1.2 Extruded Pipe and Extruded or Drawn Tube for Aluminium

Railing
Extruded pipe or tube shall meet the requirements outlined in either ASTM’s Standard Specification
for Aluminum-Alloy Extruded Structural Pipe and Tube (ASTM B429 / B429M - 10e1), or ASTM’s
Standard Specification for Aluminum and Aluminum-Alloy Extruded Bars, Rods, Wires, Profiles, and
Tubes (ASTM B221 - 12).
The Contractor shall ensure that the extruded finish of such tubing is free from nicks, blemishes, and
discoloration marks.
Drawn tube shall meet the requirements outlined in either ASTM’s Standard Specification for
Aluminum and Aluminum-Alloy Drawn Tube and Pipe for General Purpose Applications (ASTM
B483/B483M-03), or ASTM’s Standard Specification for Aluminum and Aluminum- Alloy Drawn
Seamless Tubes (ASTM B210 - 12).
The Contractor shall use one of the following alloys for the aluminium railing system:
1. Alloy 6063-T52 shall be used where bending without heating is specified.
2. Alloy 6063-T832 shall be used for clear anodizing without discoloration or where very smooth
surface and high dimensional accuracy is required.
3. Alloy 6061-T6 shall be used where bending is not required and a yellowish tint when anodized
is acceptable by the Contract documents.
27.3.1.3 Shims for Aluminium Railing

Shim sizes shall match those shown in the Contract plans and shall be alloy 1100 that conforms to
the requirements outlined in ASTM’s Standard Specification for Aluminum and Aluminum-Alloy
Sheet and Plate (ASTM B209 – 10).
Page 27-5
27.3.1.4 Stainless Steel Nuts, Bolts, and Washers for Aluminium

Railing
Sizes for nuts, bolts, and washers shall be as shown on the Contract plans. Such materials shall
also conform to the following requirements:
a. Hex nuts shall comply with the requirements outlined in ASTM’s Standard Specification for
Stainless Steel Nuts (ASTM F594 - 09e1).
b. Hex bolts and anchor bolts shall comply with the requirements for alloy groups 1, 2, or 3, as
outlined in ASTM’s Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and
Studs (ASTM F593 - 02(2008)e1).
c. Washers shall be Type 304 that complies with the requirements outlined in ASTM’s Standard
Specification for Chromium and Chromium-Nickel Stainless Steel Plate, Sheet, and Strip for
Pressure Vessels and for General Applications (ASTM A240 / A240M - 12).
27.3.1.5 Plates for Aluminium Railing

Plates for aluminium railing shall by alloy 6061-T6 that conforms to the requirements outlined in
ASTM’s Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate (ASTM B209 -
10).
27.3.1.6 Standard Structural Shapes for Aluminium Railing

Materials for standard aluminium structural shapes shall conform to the requirements outlined in
ASTM’s Standard Specification for Aluminum-Alloy 6061-T6 Standard Structural Profiles (ASTM
B308 / B308M - 10).
27.3.1.7 Toggle Bolts for Aluminium Railing

Toggle bolts shall be steel that meets the requirements outlined in the Contract plans. Materials for
toggle bolts shall comply with the requirements of the following specifications:
a. Toggle bolts and pins shall be cold finished steel, heat-treated to Brinell hardness 311-363,
that complies with ASTM’s Standard Specification for Quenched and Tempered Alloy Steel
Bolts, Studs, and Other Externally Threaded Fasteners (ASTM A354 - 11).
b. Toggle washers shall be a manufacturer’s standard washers of hot rolled steel that conforms
to the requirements outlined in ASTM’s Standard Specification for Steel, Sheet and Strip,
Hot-Rolled, Carbon, Structural, High-Strength Low-Alloy, High-Strength Low-Alloy with
Improved Formability, and Ultra-High Strength (ASTM A1011 / A1011M - 12a).
c. Spacer nut shall be Grade 1213 steel that conforms with the requirements outlined in ASTM
A108 - 07. Spacer nuts shall also be cold finished steel that has been heat-treated as outlined
in ASTM’s Standard Specification for Structural Bolts, Steel, Heat Treated, 120/105 ksi
Minimum Tensile Strength (ASTM A325 - 10).
The Contractor shall plate the complete assembly of toggle bolts in type III, class 12 cadmium that
meets the requirements outlined in ASTM’s Standard Specification for Electrodeposited Coatings of
Cadmium (ASTM B766 - 86(2008)).
27.3.1.8 Miscellaneous Hardware for Aluminium Railing

Additional hardware for aluminium railing shall comply with the following specifications:
a. Stainless steel clamping bars shall be any type in the 300 series as described in the Standard
Specification for Stainless Steel Bars and Shapes (ASTM A276 - 10).
b. Stainless steel cap screws shall comply with the requirements for alloy groups 1, 2, or 3 as
outlined in ASTM’s Standard Specification for Stainless Steel Bolts, Hex Cap Screws, and
Studs (ASTM F593 - 02(2008)e1).
c. Aluminium clamping bars shall be alloy 6061-T6 that conforms to the requirements outlined
in ASTM’s Standard Specification for Aluminum and Aluminum-Alloy Rolled or Cold Finished
Bar, Rod, and Wire (ASTM B211 - 12e1).
Page 27-6
d. Cast aluminium washers shall be alloy 356.0 that conforms to the requirements outlined in
ASTM’s Standard Specification for Aluminum-Alloy Sand Castings (ASTM B26 / B26M - 12).
e. Aluminium pins shall be alloy 6061-T6 that conforms to the requirements outlined in ASTM’s
Standard Specification for Aluminum and Aluminum-Alloy Rolled or Cold Finished Bar, Rod,
and Wire (ASTM B211 - 12e1).
27.3.2 Steel Railing

Materials and fabrication of steel railings shall conform to the applicable requirements of Chapter 23,
Steel Structures, except that formed sections may be fabricated from mild steel and pipe sections
shall be of standard steel pipe. Nuts and bolts not designated as high strength shall conform to the
requirements outlined in ASTM’s Standard Specification for Carbon Steel Bolts and Studs, 60 000
PSI Tensile Strength (ASTM A307 - 10). Steel tubing shall conform to the requirements for grade B
steel outlined in ASTM’s Standard Specification for Cold-Formed Welded and Seamless Carbon
Steel Structural Tubing in Rounds and Shapes (ASTM A500 / A500M - 10a).
The Contractor shall furnish a certified report of test or analysis to the Engineer for the railing pipe,
plate beam and tubing, and the component parts of the posts and anchor bolts. For miscellaneous
hardware and objects required for completing the installation, the Contractor shall submit a certificate
of compliance to the Engineer.
27.3.2.1 Steel Pipe Railing

As specified in the Contract documents, rails and posts for pipe railing shall be galvanized or black,
round, steel pipe. Connections in architectural railing systems shall be made by welding unless
designated otherwise in the Contract documents.
a. Galvanized Steel Pipe and Fittings

Galvanized steel pipe and fittings shall be standard weight pipes that meet the requirements of
ASTM’s Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and
Seamless (ASTM A53 / A53M - 12). The Owner waives the requirement for hydrostatic testing for
such pipe.
b. Black Steel Pipe and Fittings

Black steel pipe and fittings shall be standard weight pipes that meet the requirements of ASTM’s
Standard Specification for Pipe, Steel, Black and Hot-Dipped, Zinc-Coated, Welded and Seamless
(ASTM A53 / A53M - 12). Class of pipe shall be as per the specified use required in the Contract
documents. The Owner waives the requirement for hydrostatic testing for such pipe.
27.3.2.2 Anchor Bolts for Steel Railing

Anchor bolts for anchoring steel railing to structures shall match the materials, sizes, and styles
shown on the Contract plans. The Contractor shall take the following actions regarding anchor bolts:
a. Provide regular hexagon nuts and standard flat washers.
b. Hot-dip zinc coat the upper 89 mm of anchor bolts, nuts, and washers as specified for class
C coating in ASTM’s Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel
Hardware (ASTM A153 / A153M - 09) and supplemented by ASTM’s Standard Specification
for Zinc Coating, Hot-Dip, Requirements for Application to Carbon and Alloy Steel Bolts,
Screws, Washers, Nuts, and Special Threaded Fasteners (ASTM F2329 - 11).
c. Use only nuts and anchor bolts that have been manufactured with sufficient clearance to
allow nuts to run freely on the bolts after coating.
d. Apply a good grade of heavy grease to bolt threads before applying nuts.
Page 27-7
27.3.3 Metal Beam Railing

Metal beam rails, posts, and hardware shall conform to the requirements of Section 7.2 of Chapter
7, Incidental Construction, of these standard specifications, and in Section 606 of the AASHTO’s
Guide Specifications for Highway Construction, 9th Edition, AASHTO GSH-9.
27.3.4 Stainless Steel Railing

Stainless steel pipe rails and posts shall be as indicated on the Contract drawings and shall be of
AISI type 316 stainless steel tubing that complies with ASTM’s Standard Specification for Steel Bars,
Carbon, Merchant Quality, M-Grades (ASTM A575 - 96(2007)). The Contractor may use Type 312
stainless steel, however, for curved corners.
27.3.5 Copper Alloys Railing

"Bronze" pipe railing systems shall be fabricated from drawn, seamless red brass (Alloy C23000)
pipe. This alloy shall nominally contain 85% copper, 15% zinc, and shall conform to ASTM B43 - 09.
For architectural applications it shall be supplied in special untrademarked 6 m lengths with markings
of size, weight and manufacturer along each length.
Architectural bronze (Alloy C38500) conforming to ASTM B455 - 10 shall be used for bars, standard
shapes and special shapes such as handrail moldings.
Alloy C23000 pipe in the standard light annealed temper shall be bent to the radii specified in the
Contract documents. Returns and offsets shall be provided by mitering and welding or by the use of
flush fittings. The standard pipe sizes, Alloy C23000 pipe shall be compatible with standard cast
fittings. Leaded red brass (Alloy C83600) shall be specified for sand castings. This alloy, also
identified as ingot No. 115, shall conform to ASTM B62 - 09 and ASTM B584 - 12a, and shall have
nominal composition of 85% copper, 5% lead, 5% tin and 5% zinc.
27.3.6 Concrete Railing

All concrete railing and parapet materials shall conform to the applicable requirements of Chapter 4,
Concrete Works, Chapter 21, Concrete Structures, and Chapter 5, Reinforcing Steel.
Unless specified otherwise in the Contract documents or Contract drawings, the concrete at railings
shall be of the class C40/20.
27.3.7 Screening for Railings

For railing tubular screening, the Contractor shall provide the following materials:
a. Type IV, class B chain link fence fabric with a bonded polyvinyl chloride (PVC) coating that
conforms to AASHTO’s Standard Specification for Chain-Link Fence (AASHTO M 181-10).
b. Fabric woven of 9-gauge wire in 25 mm diamond pattern mesh with both the top and bottom
selvages knuckled.
c. PVC-coated ties and tension bars that conform to AASHTO M 181-10.
The Contractor shall ensure that all fencing components match the colour of the railing framework
materials in accordance with the Contract plans.
27.4 Construction Requirements for Railings

27.4.1 General
Before ordering or fabricating material for railing construction, the Contractor shall submit working
drawings including shop drawings for the Engineer’s approval in accordance with Section 27.2. The
shop drawings shall show all splice locations and details. Railings shall be spliced only as provided
on the Contract plans, and specified in this chapter.
Page 27-8
Before erecting railing, the Contractor shall swing the bridge spans free from falsework or formwork.
During construction, the Contractor shall ensure that expansion joints in the railing will function
properly after the railing is installed.
The Contractor shall make the railings line and grade true, with no any unevenness such as may
exist in a sidewalk or wall that supports the railing. Unless the Contract plans require otherwise, the
Contractor shall construct the railing with the posts normal to the grade of the structure.
The Contractor shall fabricate all aluminium and steel railings and post panels in sections that
conform to the details shown in the Contract plans. They shall field-verify lines and grades. Adjacent
sections shall be fabricated so that they will accurately engage each other in the field. The Contractor
shall match mark each pair of sections so they can be erected in the same position in which they
were fabricated.
The Contractor shall fabricate all aluminium and steel rail elements that are included as part of the
railing system to the dimensions and cross-sections shown on the Contract plans and within a
tolerance of 6 mm per 3 metres in the straightness of either edge. The Contractor shall joint and
connect rail elements to the rail posts as shown on the Contract plans, lapping rail elements in the
direction of traffic in the adjacent lane.
Before fixing aluminium and steel railings in place, the Contractor shall carefully adjust them to
ensure proper matching at abutting joints, correct alignment, and accurate camber throughout each
railing’s entire length.
Unless the Contract plans specify otherwise, the Contractor shall set anchor bolts in the supporting
concrete during concrete placement. The Contractor shall place the anchor bolts in a way that
provides correct and true railing alignment. Anchor bolt depths shall ensure that bolts do not project
through the completed work more than 10 mm beyond nuts.
If required to set anchor bolts in holes drilled in concrete, the Contractor shall use bolts with
expansion sleeves of a type that has been approved by the Engineer. The Contractor shall place
bolts and expansion sleeves in drilled holes and the firmly anchor bolts before tightening nuts to their
final positions.
The Contractor shall place any shims that the Contract plans require under each railing post, each
end base plate of pipe, and each structural steel railing.
27.4.2 Constructing Aluminium Railing

Aluminium railing system connections shall be made by bending, by mitering and welding, or by
using standard fittings.
When systems are assembled by welding, the Contractor shall weld railings in compliance with
ANSI/AWS D1.2/D1.2M:2003, Structural Welding Code – Aluminum. Alloy 5356 filler wire shall be
used to minimize discoloration if anodizing the assembly is specified in the Contract documents.
Either Alloy 4043 or Alloy 5356 filler wire shall be used for mill finish or organic coatings but Alloy
4043 shall not be used for anodizing. Welds shall be ground, polished and blended. It must be
remembered that welding removes temper and reduces strength within 25.4 mm of the weld.
If mill finish is specified in the Contract documents for the aluminium railing, the mill finish shall be
followed by anodizing with bronze being the colour used.
Architectural Class I finish, which has a minimum anodic coating thickness of 0.7 mills shall be used
for the railing systems. The types of anodic coatings to be used are listed below in Table 27-2.
Table 27-2: Types of anodic coatings
AA - Aluminum Association’s
Type of Anodic Coating
Designations for Class I
Clear (Natural) Anodized A41
Page 27-9
AA - Aluminum Association’s
Type of Anodic Coating
Designations for Class I
Integral Colour Anodized A42
Electrolytically Deposited Color Anodized A44
All exposed welds shall be finished by grinding or filing to give a smooth surface. Welding of
aluminium materials shall be done by an inert gas shielded, electric arc welding process using no
welding flux. The Contractor shall not torch-cut or flame-cut aluminium. Fabrication of aluminium
railing shall comply with requirements outlined in Section 27.4.1 and the specifications of the
Aluminum Association’s Aluminum Design Manual, Latest Edition, (AA ADM-1).
The Contractor shall blast clean or polish and burnish cast posts to ensure that finished castings
have surfaces of consistent texture and a smooth, uniform appearance.
Before laying out or working on aluminium materials, the Contractor shall ensure that they are
straight. If straightening is necessary, the Contractor shall not mar the rails appearance or weaken
the strength of the metal. To facilitate bending or straightening, the Contractor may heat aluminium
materials other than castings to a temperature up to 204° C for no more than 30 minutes. The
Engineer shall reject material with sharp kinks and bends.
The Contractor shall store aluminium railing above the ground on platforms, skids, or other suitable
supports. Materials shall be protected from moisture and kept free from oil, grease, dirt, and contact
with dissimilar metals until the railing is complete.
The Contractor shall neatly finish those portions of the railing that are exposed to view. When
handling, shipping, and erecting railing material, the Contractor shall not scratch, dent, or otherwise
degrade a railing’s durability or appearance.
Where aluminium alloys come in contact with other metals or concrete, the Contractor shall either
thoroughly coat contacting surfaces with a dielectric aluminium-impregnated caulking compound or
place a synthetic rubber gasket between the two surfaces.
27.4.3 Constructing Steel Railings

Steel railing construction shall comply with the applicable requirements outlined in Chapter 23, Steel
Structures, except as specified otherwise in this section.
Connections in steel railing systems shall be made by welding unless designated otherwise in the
Contract documents or Contract plans.
The Contractor shall weld railings in compliance with AASHTO/AWS D1.5M/D1.5:2010, Bridge
Welding Code, and the specifications in Sections 23.4.11 and 23.6.10 of Chapter 23, Steel
Structures.
27.4.3.1 Type of Joint Construction

Depending upon the usage of the railing system, the desired appearance of the joints varies
considerably. Figure 27-1 presents four types of joint construction that are described as follows:
• Type 1: Ornamental quality - used where appearance is a critical factor
• Type 2: Weld of good appearance used in areas of traffic - where highly ornamental quality
is not required
• Type 3: Used in areas where it is not subject to view - as in service stairs
• Type 4: Acceptable when appearance is not a factor - used in industrial and non public areas.
Page 27-10
Figure 27-1: Types of railing system Joint construction

Unless designated otherwise in the Contract documents or Contract plans, the Contractor shall
furnish Type 2 of joint construction complying with NOMMA Guideline 1, Voluntary Joint Finish
Guidelines, developed by the National Ornamental & Miscellaneous Metals Association (NOMMA).
27.4.3.2 Fabrication
Pipe rails and pipe posts shall conform to the Contract plan details The Contractor shall saw the
vertical members of the railing to length, without shearing them. Pipe and tubular steel railing shall
be fabricated according to the Contract plan details.
The Contractor shall use screw fittings or welds to join the posts and rails together, as shown on the
Contract plans. The Contractor shall grind welded joints to a smooth finish. Pipe rails shall not be
spliced with screw fittings between the posts.
27.4.3.3 Casting
The Contractor shall provide permanent mould castings of the materials specified. Such castings
shall be true to pattern in form and dimension and of uniform quality and condition. Castings shall
be free from cracks and defects, such as blowholes, porosity, hard-spots, or shrinkage, that could
affect their suitability for use. The Contractor shall repair minor defects in aluminium castings by an
approved inert gas-welding process. They shall ensure that finished castings are free of burrs, fins,
discoloration, and mould marks, with a uniform appearance and texture.
The Contractor shall produce castings under radiographic control that is sufficient to establish and
verify that the product is free from harmful internal defects. When heat-treating is required, the
Contractor shall heat-treat the entire lot of castings to the specified temper.
The Contractor shall permanently mark the heat or lot number on the web or top of the base of all
castings. The Contractor shall furnish mill test reports that indicate the heat or lot number, chemical
composition, tensile strength, elongation, and number of pieces for each casting heat or lot. For
aluminium castings, the heat or lot should consist of no more than 4.45 kN of trimmed castings when
produced from batch type furnaces, or 8.90 kN when produced from a continuous furnace within 8
or fewer consecutive hours. The Contractor shall furnish the entire number of acceptable posts cast
from each heat or lot, except when a portion is required to complete the Project.
27.4.3.4 Finish
As specified in the Contract documents, the steel pipe and tabular railing system shall be either
finished by painting in the field, over a shop applied prime coat, or galvanized after completing its
fabrication.
Unless the Contract documents specify otherwise, the Contractor shall zinc coat the pipe and tubular
steel railings as specified in AASHTO’s Standard Specification for Zinc (Hot-Dip Galvanized)
Coatings on Iron and Steel Products (AASHTO M 111M/M 111-11) or (ASTM A123 / A123M - 12).
Galvanizing of nuts and bolts shall conform to the requirements of AASHTO’s Standard Specification
Page 27-11
for Zinc Coating (Hot-Dip) on Iron and Steel Hardware (AASHTO M 232M/M 232-10) or (ASTM A153
/ A153M - 09). Before applying zinc coating, the Contractor shall blast clean the steel railing
according to Society for Protective Coatings (SSPC) requirements for SSPC-SP 6 sand blasting, as
outlined in SSPC-SP 6/NACE No. 3, Commercial Blast Cleaning. Minor abrasions to galvanized
surfaces shall be repaired with zinc-rich paint. After erection, all sharp protrusions shall be removed
and the railing cleaned of discolouring foreign materials.
Damaged galvanized surfaces may be repaired, only if so approved by the Engineer. Such surfaces
shall be repaired by thoroughly wire brushing and then by applying 2 coats of an approved zinc-dust
zinc-oxide primer.
When painting is specified in the Contract documents, the type and coating shall conform to the
requirements of Section 24.3 of Chapter 24, Painting, or requirements specified in the Contract
documents.
27.4.3.5 Shipping and Handling

When shipping, handling, and erecting the zinc-coated pipe and tubular steel railing, the Contractor
shall avoid scratching or marring the spelter coating. The Contractor shall repair damaged zinc
coating in accordance with the specifications in Article 24.3.10.7 of Chapter 24, Painting.
Rail elements to be erected within a radius of 45 metres or less shall be shaped in the shop. The
Contractor shall stencil the radius of curvature on the back of each section of rail. Rail elements shall
be designed to be spliced in the direction of traffic flow at intervals of 4 or 8 metres. Such splices
shall be made at posts, unless the Contract documents show otherwise.
27.4.4 Constructing Stainless Steel Railing

Care must be taken in fabricating, finishing and maintaining stainless steel to avoid contamination
and rust stains. Grease, dirt, and other foreign matter are some of the sources of discoloration under
the effects of weathering.
The completed hand rail shall have a No. 2B surface finish that complies with the requirements
outlined in ASTM’s Standard Specification for General Requirements for Flat-Rolled Stainless and
Heat-Resisting Steel Plate, Sheet, and Strip (ASTM A480 / A480M - 12). Unless the Contract
drawings indicate otherwise, all posts and railings shall be 38 mm nominal (48 mm outside diameter)
stainless steel with 16 gauge wall thickness. Where possible, the handrail shall have a shop-
fabricated length of at least 6 metres.
Welding stainless steel railings shall comply with AWS D 1.6/D 1.6M: 2007, Structural Welding Code
- Stainless Steel.
27.4.5 Constructing Copper Alloys Railing

The railing pipe shall be pre-finished before fabricating. Finishes shall be either satin or brushed
(directional textured) and shall be achieved through the use, either singly or progressively, of No.
80, 180 and 220 grit abrasive. Following pre-finishing, the pipe shall be covered with strippable tape,
a spray-applied strippable coating, or other suitable means, for protection during fabricating
operations. After assembly, the protective covering shall be removed, and the completed railing
system shall be given its final finish.
The natural golden colour of Alloy C23000 normally darkens by oxidation upon exposure to the
atmosphere. To protect the natural color, immediately following mechanical finishing the completed
railing system sections shall be coated with acrylic or clear lacquer. The Contractor shall use
"Incralac" as a clear lacquer that has been developed by the International Copper Research
Association specifically for use on copper alloys. The Copper Development Association has
additional information on this type of coating. The Contractor shall use wax to protect the natural
colour. The natural weathering process shall be accelerated by chemical conversion treatments. Of
these treatments, the aqueous sulfide solutions, which produce the "statuary bronze" finishes, shall
be required for the copper railing systems.
Page 27-12
27.4.6 Constructing Concrete Railing

Concrete railing (barrier) and parapet construction shall comply with the requirements outlined in the
following chapters of these standard specifications:
• Chapter 1, General Requirements
• Chapter 4, Concrete Works
• Chapter 5, Reinforcing Steel
• Chapter 21, Concrete Structures
Reinforced concrete traffic barriers on structures shall be cast-in-place, as indicated on the Contract
drawings, as specified in this section, and as directed by the Engineer.
To construct other concrete railings, depending on their design, the Contractor may apply either the
cast-in-place method, the precast method, or (when approved by the Engineer) the slip form method.
When using slip forms, the Contractor shall provide sensor control for both line and grade.
Barrier contraction joints shall reside at intervals not more than 6.0 metres, except as directed by the
Engineer.
In addition to meeting the requirements indicated on the Contract drawings and specified in this
section, the Contractor shall construct all concrete barriers and parapets on the bridge deck after
completing post-tensioning operations. All concrete barriers and parapets shall be constructed in
agreement with the lines, shapes, dimensions, profiles, and details indicated on the Contract
drawings.
Forms shall be smooth and tight fitting. Their design shall enable the Contractor to hold them rigidly
to line and grade during concrete placement and to move them readily without damaging green
concrete. The Contractor shall not remove forms until adequate measures to protect and cure the
concrete are in place and the concrete has sufficient strength to prevent surface or other damage
that removal of a form may cause.
All form detail work shall comply with the requirements specified in Section 1.20.8 of Chapter 1,
General Requirements.
The Contractor shall construct forms so that the railing’s line and grade can be checked after
concrete has been placed but before it has reached initial set. The Contractor shall not disturb the
form’s alignment during finish floating of the railing tops. When performing other construction
activities, the Contractor shall avoid disturbing or vibrating a span that has newly placed railing.
Finish for railings constructed with fixed forms shall be Class 2 - Rubbed Finish. Finish for railings
constructed with slip forms and for temporary railings shall be Class 1 - Ordinary Finish.
Junction boxes and electrical conduit shall be embedded in the concrete barriers as indicated on the
Contract plans. The Contractor shall coordinate the placement of the junction boxes and the
electrical conduit in the concrete barriers with precast facing panels, and bollards and in the box
girders and walls.
27.4.7 Constructing Screening for Railings

The screen fencing component’s colour shall match the colour of railing framework materials before
framework has been painted. The Contractor shall install chain link screening fence fabric that
conforms to the Contract plan details. The Contractor shall touch up any painted framework surfaces
that have been marred during the installation of fencing.
27.4.8 Welding for Railings

The Contractor shall visually inspect and certify the quality of field welds. The Contractor's inspector
shall be either an AWS certified welding inspector (CWI) or an individual that the Owner approves
as competent to perform such inspections. The Contractor's inspector shall complete a standard
inspection form for each structure and submit these forms to the Engineer for inclusion in the
permanent Project record.
Page 27-13
27.4.9 Storing Construction Materials for Railings

The Contractor shall store railing materials above the ground on platforms, skids, or other supports,
and keep them free from grease, dirt, and contact with dissimilar metals. The Contractor shall avoid
scratching, marring, denting, discolouring, or otherwise damaging rails and railing materials.
27.4.10 Constructing Temporary Railings

Temporary railings shall be constructed of materials and to the details specified in the Contract
documents. Railings shall be properly joined and aligned at the required locations. Temporary
precast barriers shall be installed on a solid base. The temporary railing shall be maintained in first-
class condition and shall not be removed until all work requiring the railing has been completed.
Previously used units may be employed if they are clean and undamaged. After removal, temporary
railing shall continue to be the Contractor’s property.
27.5 Testing and Acceptance of Railings

27.5.1 General
All materials incorporated into railings shall be sampled, tested, and evaluated to verify the material
requirements.
The Contractor shall use only components that comply with the manufacturer's specifications, and
the requirement of these specifications.
Copies of certificates of guarantee and test reports shall be provided for the components of each
railing system that is manufactured off site.
27.5.2 Bridge Railing Test

Bridge railings are very important components of the roadway safety and play an important role in
preventing and mitigating crashes. Since the primary purpose of the bridge railing is to prevent
penetration, it must be strong enough to redirect an impacting vehicle.
The Owner requires all bridge railings used on the Project to meet full-scale crash criteria as per
AASHTO Manual for Assessing Safety Hardware (MASH) or National Cooperative Highway
Research Program Report 350 - Recommended Procedures for the Safety Performance Evaluation
of Highway Features (NCHRP350). The test criteria are documented in MASH and NCHRP350.
The Contractor is required to test each bridge railing according to the evaluation criteria, and submit
the test results to the Owner for review and issuing acceptance letter.
The test criteria describe six levels of testing and crashworthiness ratings. Test Levels 1-3 are based
on impacts from light vehicles such as passenger cars and light trucks. Test Levels 4-6 contain
additional tests for bridge railings designed to contain and redirect heavy vehicles such as buses
and larger trucks. All new or replacement bridge railing on the Project shall meet the crash-test
criteria for the test level designated in the Contract documents as a minimum.
Standards for design of bridge railings are presented in Chapter 13 of the AASHTO Load and
Resistance Factor Design (LRFD) Bridge Design Specifications, and Road Structures Design
Manual (ADQCC TR-516). Railings on newly constructed bridges and replacement railing should be
constructed to these standards. However, repair or retrofit of an existing railing system that has
previously been found acceptable does not require further testing.
27.5.3 Crash Testing Policy

To be acceptable bridge railing must be crash tested and comply with the acceptance criteria as set
out in Section 27.5.2. The Owner may also accept bridge railings if they can be evaluated as being
both geometrically and structurally equal to a compliant crash-tested system certified to have meet
the Evaluation Criteria in Section 27.5.2.
Page 27-14
27.6 Spares for Railings

The Contractor shall provide spares for railings in accordance with the quantities indicated in the
Contract plans or specified in the particular specifications or Contract documents. All spare railing
units shall comply with all applicable Contract document requirements and the specifications outlined
in this chapter.
The Contractor shall suitably box and crate all spare units and place them in storage locations
designated by the Owner. All spare units shall be identical to and by the same manufacturer as units
approved by the Engineer for the Project.
The Contractor shall provide all labour, tools, equipment, and appurtenances needed to carefully
transport, unload, and store all spares. No materials, boxes, or crates shall be stored directly on the
ground or any similar horizontal surface. The Contractor shall provide all wood, concrete, or other
materials that have been approved as blocking by the Engineer under all materials, boxes, or crates.
All materials, crates, and boxes shall be suitably identified in accordance with the Contract
requirements.
27.6.1 Constructing Spares for Railings

All spare metal railing units shall be constructed in accordance with the details indicated on the
Contract drawings, shop drawings (that have been approved by the Engineer), and specifications in
this chapter.
Page 27-15
INDEX
aluminium, 27-1, 27-5, 27-6, 27-7, 27-9, 27- equipment, 27-15

10, 27-11 Evaluation Criteria, 27-14
anchorage, 27-1 extruded shapes, 27-5
appearance, 27-4, 27-10, 27-11 fittings, 27-7, 27-8, 27-9, 27-11
appurtenances, 27-15 full-scale crash criteria, 27-14
bridges, 27-1, 27-14 initial set, 27-13
clamps, 27-5 Junction boxes, 27-13
concrete, 27-1, 27-8, 27-9, 27-10, 27-13, 27- labour, 27-15
15 miscellaneous hardware, 27-5, 27-7
concrete barriers, 27-13 nuts, 27-5, 27-6, 27-7, 27-9, 27-11
crashworthiness ratings, 27-14 painting, 27-11, 27-12
culverts, 27-1 pedestrian railings, 27-1
Damaged galvanized surfaces, 27-12 permanent mould castings, 27-11
Department of Transport, ii pins, 27-5, 27-6, 27-7
Design calculations, 27-4 Plates, 27-6
Dimensional tolerances, 27-5 posts, 27-5, 27-7, 27-8, 27-9, 27-10, 27-11,
discoloration marks, 27-5 27-12
electrical conduit, 27-13
Presetting details, 27-4

railing tubes, 27-5
railings line and grade, 27-9
roadway safety, 27-14
screening, 27-8, 27-13
screws, 27-5, 27-6
Seamless, 27-2, 27-3, 27-5, 27-7
shims, 27-5, 27-9
spare railing units, 27-15
Stainless, 27-1, 27-2, 27-3, 27-6, 27-8, 27-12
steel, 27-1, 27-6, 27-7, 27-8, 27-9, 27-10, 27-
11, 27-12
Steel tubing, 27-7
structural shapes, 27-6
Temporary railings, 27-14
toggle bolts, 27-5, 27-6
traffic barriers, 27-1, 27-13
types of joint construction, 27-10
vertical members, 27-11
walls, 27-1, 27-13
washers, 27-5, 27-6, 27-7
welded joints, 27-11
Page 27-16
PART 2
ROAD STRUCTURES
CHAPTER 28 - WATERPROOFING
DOCUMENT NO: TR-

FIRST EDITION
JANUARY 2018
Chapter 28: Waterproofing

TABLE OF CONTENTS
List of Tables .................................................................................................................................. ii
28 Waterproofing .................................................................................................................. 28-1
28.2 Type A Waterproofing Membranes .............................................................................. 28-5
28.2.1 Submittals for Type A Membranes ........................................................................ 28-5
28.2.2 Delivery, Storage, and Handling of Type A Membranes ........................................ 28-5
28.2.3 Type A Waterproofing Materials ............................................................................ 28-6
28.2.3.1 Waterproof Membrane ................................................................................... 28-6
28.2.3.2 Bituminous Mastic.......................................................................................... 28-7
28.2.3.3 Primer ............................................................................................................ 28-7
28.2.3.4 Protection Board ............................................................................................ 28-7
28.2.4 Application of Type A Waterproofing Membrane ................................................... 28-7
28.2.4.1 Application of Type A Membrane to Concrete ................................................ 28-7
28.2.4.2 Installation of Asphalt Protection Board Courses ........................................... 28-8
28.2.4.3 Repairs to Type A Waterproofing Membranes ............................................... 28-8
28.3 Type B Waterproofing Membranes .............................................................................. 28-8
28.3.1 Submittals for Type B Waterproofing Membranes ................................................. 28-9
28.3.2 Delivery, Storage, and Handling of Type B Membranes ........................................ 28-9
28.3.3 Type B Sheet Applied Waterproofing Materials ................................................... 28-10
28.3.3.1 Application of Type B Sheet Applied Waterproofing Membranes ................. 28-11
28.3.3.2 Surface Preparation for Type B Sheet Applied Waterproofing Membranes .. 28-11
28.3.3.3 Compartmented Loosely Laid Sheet Installation .......................................... 28-12
28.3.3.4 Mechanical Bonded System Installation....................................................... 28-12
28.3.3.5 Field Quality Control for Type B Sheet Applied ............................................ 28-13
28.3.3.6 Protection and Cleaning for Type B Sheet Applied ...................................... 28-14
28.3.4 Type B Liquid Sprayed Applied Waterproofing Materials .................................... 28-14
28.3.4.1 Submittals for Type B Liquid Sprayed Applied Membranes .......................... 28-15
28.3.4.2 Application of Type B Liquid Sprayed Applied Membranes .......................... 28-16
28.3.4.3 Field Quality Control for Type B Liquid Sprayed Applied Membranes .......... 28-16
28.4 Type C Waterproofing Membranes ............................................................................ 28-17
28.4.1 Type C Waterproofing Materials ......................................................................... 28-17
28.4.2 Application of Type C Waterproofing ................................................................... 28-17
28.4.3 Storage of Type C Membranes ........................................................................... 28-18
28.5 Type D Waterproofing Membranes ............................................................................ 28-18
28.5.1 Type D Liquid Spray Applied Waterproofing Systems ......................................... 28-18
28.5.1.1 Materials and Submittals for Liquid Spray Applied Systems ......................... 28-18
28.5.1.2 Materials for Additional Bituminous Protection ............................................. 28-19
28.5.1.3 Surface Preparation for Liquid Spray Applied Systems ................................ 28-20
28.5.1.4 Installation of Liquid Spray Applied Systems................................................ 28-20
28.5.1.5 Installation of Additional Bituminous Protection ............................................ 28-20
28.5.2 Water Seepage Relief Channels ......................................................................... 28-20
28.5.3 Protection of Bridge Deck Waterproofing System during Construction ................ 28-20
28.5.4 Integrity Testing of Type D Waterproofing ........................................................... 28-21
28.6 Integral Waterproofing ............................................................................................... 28-21
28.6.1 Submittals for Integral Waterproofing .................................................................. 28-22
28.6.2 Quality Assurance for Integral Waterproofing ...................................................... 28-22
28.6.3 Delivery, Storage and Handling of Integral Waterproofing ................................... 28-23
28.6.4 Warranty ............................................................................................................. 28-23
28.6.5 Concrete Batching, Mixing, Placing & Curing ...................................................... 28-24
Page i
CHAPTER 28: W ATERPROOFING First Edition -January 2018
28.6.6 Field Quality Control ........................................................................................... 28-24

Index ........................................................................................................................................ 28-25
LIST OF TABLES
Table 28-2Table 28-1: Designations and titles for AASHTO, and ASTM standards that apply to
waterproofing works ................................................................................................................... 28-2
Table 28-2: Designations and titles for BS, and BS EN, and DIN standards that apply to waterproofing
works ......................................................................................................................................... 28-4
Table 28-3: Physical properties of Type A, self-adhering sheet membranes .............................. 28-6
Table 28-4: Physical properties of Type B, PVC loosely laid membranes ................................ 28-10
Table 28-5: Physical properties of Type B, PVC mechanical bonded membranes ................... 28-10
Table 28-6: Physical properties of Type B, liquid sprayed applied membranes ........................ 28-14
Table 28-7: Physical properties of Type C membranes ............................................................ 28-17
Table 28-8: Physical properties of bridge Deck liquid spray applied system ............................. 28-19
Page ii
28 WATERPROOFING
This chapter outlines standards and requirements that apply to the preparation, installation, and
maintenance of waterproofing systems, including four different types of waterproofing membranes.
When performing such work, the Contractor shall comply with this chapter, the Contract documents,
and any directions from the Engineer.
The Contractor shall furnish and install the following types of waterproofing membranes on all
structures as applicable and as specified in the Contract plans or indicated in the Particular
Specifications, and as specified in these Standard Specifications.
• Type A: For use, as concrete protection, on all concrete and block masonry surfaces in
contact with soil. Surfaces to be protected by Type A waterproofing include, all
foundations, all bridge substructure elements in contact with soil such as
abutments, wing walls, retaining walls, and piers, backfilled back-side surfaces of
contingency utility ducts end walls and base slab, exterior surfaces and concrete
base of all storm water drainage structures, external faces of all pullboxes
(manholes) for traffic control system, and any surfaces that the Engineer identifies
for such work.
• Type B: For use, as waterproofing, on all concrete structures that require water-tightness
(e.g. tunnels and similar structures).
• Type C: For use, as concrete protection, on all concrete and block masonry surfaces in
contact with soil where Type A waterproofing application is declared by the
Engineer to be impractical.
• Type D: For use on roadway surfaces of concrete bridge decks and tunnels.
This chapter outlines standards and requirements of Type A, Type B, Type C, and Type D of
waterproofing membranes.
It also outlines standards and requirements for integral waterproofing to concrete structures as
indicated on the Contract plans and as specified herein.
All exposed concrete surfaces for structures indicated on the Contract plans not to be painted or
waterproofed, and all internal concrete surfaces (e.g. inside box girder type of bridges) shall be
sealed as per the requirements of Section 29.6 of Chapter 29, Miscellaneous Items for Structures,

Standards and codes for waterproofing shall be as specified in these specifications, in the Contract
AASHTO LRFD American Association of State Highway and Transportation Officials - Load and
Resistance Factor Design, Bridge Construction Specifications;
Resistance Factor Design, Bridge Design Specifications;
and Testing;
ADQCC (TR-516) Roads Structures Design Manual
ACI 212.3R-10 Report on Chemical Admixtures for Concrete;
BBA British Board of Agreement (BBA);
Page 28-1
BD 47/99 Design Manual for Roads and Bridges – Volume 2, Section 3, Part 4,
Waterproofing and Surfacing of Concrete Bridge Decks;
CAN/CSA Canadian Standards Association;
CRD-C48-92 U.S. Army Corps of Engineers “Standard Test Method for Water Permeability of
Concrete;
ICC International Code Council (ICC);
UK BE27 UK Department Transport Tech. Memo BE27 90°C.
EN), and German (DIN) Standards that are related to materials for waterproofing works. It also
Table 28-1: Designations and titles for AASHTO, and ASTM standards that apply to waterproofing
works
AASHTO ASTM
Title
ASTM D449 - Standard Specification for Asphalt Used in Dampproofing
03(2008) and Waterproofing
ASTM D638 -
10
ASTM D746 - Standard Test Method for Brittleness Temperature of
07 Plastics and Elastomers by Impact
ASTM D41 / Standard Specification for Asphalt Primer Used in Roofing,
D41M - 11 Dampproofing, and Waterproofing
Standard Specification for Coal-Tar Pitch Used in Roofing,
ASTM D450-07
Dampproofing, and Waterproofing
ASTM D43 /
Standard Specification for Coal Tar Primer Used in
D43M -
Roofing, Dampproofing, and Waterproofing
00(2012)e1
ASTM D173 /
Standard Specification for Bitumen-Saturated Cotton
D173M -
Fabrics Used in Roofing and Waterproofing
03(2011)e1
ASTM D542 - Standard Test Method for Index of Refraction of
00(2006) Transparent Organic Plastics
ASTM D490 -
Standard Specification for Road Tar
92(2011)
ASTM D1004 - Standard Test Method for Tear Resistance (Graves Tear)
13 of Plastic Film and Sheeting
ASTM D2939- Standard Test Methods for Emulsified Bitumens Used as
03 Protective Coatings
ASTM D792 - Standard Test Methods for Density and Specific Gravity
08 (Relative Density) of Plastics by Displacement
Page 28-2
AASHTO ASTM
Title
05(2010) Hardness
ASTM D4541 - Standard Test Method for Pull-Off Strength of Coatings
09e1 Using Portable Adhesion Testers
ASTM B117 - Standard Practice for Operating Salt Spray (Fog)
11 Apparatus
Standard Practice for Operating Fluorescent Ultraviolet
ASTM G154 -
(UV) Lamp Apparatus for Exposure of Nonmetallic
12a
Materials
AASHTO M ASTM D994 / Standard Specification for Preformed Expansion Joint Filler
33-99 (2012) D994M - 11 for Concrete (Bituminous Type)
ASTM D1505 - Standard Test Method for Density of Plastics by the
10 Density-Gradient Technique
ASTM D570 -
98(2010)e1
06a(2013) Thermoplastic Elastomers—Tension
ASTM C309 - Standard Specification for Liquid Membrane-Forming
11 Compounds for Curing Concrete
ASTM E329 - Standard Specification for Agencies Engaged in
13a Construction Inspection, Testing, or Special Inspection
ASTM C39 / Standard Test Method for Compressive Strength of
C39M - 12a Cylindrical Concrete Specimens
ASTM C157 / Standard Test Method for Length Change of Hardened
C157M - 08 Hydraulic-Cement Mortar and Concrete
ASTM C494 / Standard Specification for Chemical Admixtures for
C494M - 13 Concrete
ASTM D5385 - Standard Test Method for Hydrostatic Pressure Resistance
93(2006) of Waterproofing Membranes
ASTM E154 / Standard Test Methods for Water Vapor Retarders Used in
E154M - Contact with Earth Under Concrete Slabs, on Walls, or as
08a(2013)e1 Ground Cover
ASTM E96 / Standard Test Methods for Water Vapor Transmission of
E96M - 13 Materials
Page 28-3
Table 28-2: Designations and titles for BS, and BS EN, and DIN standards that apply to
waterproofing works
BS BS EN DIN
Designation Designation Title
Designation
DIN
16726:2011- Plastic sheets - Testing
01
Cold processable plastic jointing materials
DIN
for sewer drains - Jointing materials for
4062:1978-
prefabricated parts of concrete,
09
requirements, testing and processing
Testing of rubber - Shore A and Shore D
DIN 53505
hardness test
BS EN ISO Quality management systems.
9001:2015 Requirements
BS EN ISO 527- Plastics. Determination of tensile properties.
1:2012 General principles
BS EN ISO 527- Plastics. Determination of tensile properties.
3:1996 Test conditions for films and sheets
Plastics. Determination of tensile properties.
BS EN ISO 527-
Test conditions for unidirectional fibre-
5:2009
reinforced plastic composites
UNI EN ISO Geosynthetics - Static puncture test (CBR
12236 test)
Rubber, vulcanized or thermoplastic.
BS ISO 34-
Determination of tear strengthTrouser,
1:2010
angle and crescent test pieces
Flexible sheets for waterproofing. Bitumen,
BS EN plastic and rubber sheets for roof
1928:2000 waterproofing. Determination of
watertightness
BS EN ISO Paints and varnishes. Pull-off test for
4624:2003 adhesion
Sampling and examination of bituminous
mixtures for roads and other paved areas
BS 598-
Method of test for the determination of the
107:2004
composition of design surface course rolled
asphalt
BS EN Bitumen and bituminous binders.
12591:2009 Specifications for paving grade bitumens
Bitumen and bituminous binders.
BS EN
Specifications for hard paving grade
13924:2006
bitumens
BS EN 13108- Bituminous mixtures. Material specifications
4:2006 Hot Rolled Asphalt
Code of practice for protection of below
BS 8102:2009 ground structures against water from the
ground
Page 28-4
BS BS EN DIN
Designation Designation Title
Designation
Testing concrete - Recommendations for
BS 1881-
the assessment of concrete strength by
207:1992
near-to-surface tests
BS EN 12390- Testing hardened concrete - Depth of
8:2009 penetration of water under pressure
Admixtures for concrete, mortar and grout
BS EN 934- Concrete admixtures. Definitions,
2:2009+A1:2012 requirements, conformity, marking and
labelling
28.2 Type A Waterproofing Membranes

The Contractor shall provide and install Type A waterproofing membranes on surfaces in accordance
with the specifications outlined in this section and as indicated in the Contract plans. The Contractor
shall provide and apply a self-adhering, waterproof, and protective membrane and shall install
asphalt protection board courses on all surfaces that are selected to receive Type A waterproofing
membranes.
The Contractor shall provide to the Engineer affidavits from the Manufacturer that confirm that the
proposed Type A waterproofing membrane system to be used for the Project has a ten years history
of successful use in similar applications in the Gulf Region. The Contractor shall also provide
evidence that the material applicator is qualified and approved by the membrane Manufacturer.
28.2.1 Submittals for Type A Membranes

The Contractor shall submit a material submittal as per Section 1.15, Submittal Procedures, outlined
in Chapter 1, General Requirements, of these standard specifications, including three samples of
each type of the following materials to the Engineer for review and approval in accordance with the
Contract documents:
a. Self-adhering waterproofing membrane sheet: 500 mm x 500 mm.
b. Bituminous mastic: 500 millilitres containers
c. Primer: 500 millilitres containers
d. Protection board: 500 x 500 mm
The membrane shall provide long term protection to reinforced concrete and block masonry in the
Gulf Region. All waterproofing materials, including membranes, protection boards, bituminous
mastics, and primers etc shall be compatible with each other and shall be from a manufacturer
operating the BS EN ISO 9001:2015 quality management scheme. All materials shall have a valid
Agreement Certificate for Roads and Bridge Structures issued by a member of the European Union
of Agreement (UEAtc.) verifying that the materials furnished comply with the requirements of system
manufacturer.
28.2.2 Delivery, Storage, and Handling of Type A Membranes

Products shall be delivered to the jobsite in their original, unopened containers, which shall be clearly
labelled with the Manufacturer’s name, brand designation, type, and class, as applicable.
After products are delivered, the Contractor shall store them in an approved, dry area with roll goods
laid flat, one pallet high. Products shall be protected from contact with soil and from exposure to the
elements. They shall remain dry at all times.
When handling products, the Contractor shall not break containers or damage products. Surfaces to
which waterproofing materials will be applied shall be dry, smooth, and free of dirt, grease, or oil.
Page 28-5
28.2.3 Type A Waterproofing Materials

The Contractor shall comply with the specifications outlined in this section for Type A waterproofing
materials.
28.2.3.1 Waterproof Membrane

Waterproof membranes shall consist of self-adhering sheet membranes consisting of a rubberised
asphalt compound or polymer modified bitumen, with integral fabric reinforcement such as, but not
limited to, polyester, glass fiber, etc. coated to one side of a polyethylene film. The membrane shall
have a minimum overall thickness of 2.0 mm, and shall incorporate a selvedge to provide a bitumen
to bitumen seal.
The properties of the waterproofing membrane shall not significantly diminish with age. The provision
of test data and/or evidence of successful performance of the membrane in climatic conditions similar
to the UAE shall be a condition of acceptance of any waterproofing system. Type A membranes shall
meet the following physical properties as shown in Table 28-3.
Table 28-3: Physical properties of Type A, self-adhering sheet membranes
Test Method Requirement

Property
Tensile Strength (polyethylene ASTM D638-10 15 N/mm2 minimum

film)
Elongation (polyethylene film) ASTM D638-10 150 % minimum
Tensile Strength (full membrane) ASTM D638-10 5 N/mm2 minimum
Elongation (full membrane) ASTM D638-10 30% minimum
Tear Strength ASTM D5147 300 N minimum
Water Resistance ASTM D2939-03 (A & B) Excellent

United Kingdom Department of
Transport (DoT) test for the >1.00 mm
Crack Bridging Capability approval of Waterproofing Systems
for Concrete Decks Method C IV.
Water Absorption (%) ASTM D570 - 98(2010)e1 < 0.15
Puncher Resistance ASTM E154 / E154M - 08a(2013)e1 > 300 N
Moisture Vapour Transmission 0.6 g/m2/24 Hrs

ASTM E96 / E96M - 13
Rate maximum
Chemical Resistance to dilute

acids, to dilute alkalis, to
sulphates, and to chlorides (to the ASTM D543 Resistant
levels expected in the most
aggressive areas of the Gulf
Region)
ASTM D4541 - 09e1or
Adhesion to concrete BS EN ISO 4624 :2003 (minimum 3 ≥ 1.0 MPa
per 500 m2)
Water penetration BD 47/99 Zero
Resistance to high temperature BD 47/99 Yes

from concrete surface (60°C)
Page 28-6
28.2.3.2 Bituminous Mastic

Bituminous mastic material shall consist of special compounds provided by the self-adhering
membrane Manufacturer and formulated for its intended use. Physical properties of the bituminous
mastic, its application conditions and application equipment shall be in accordance with the self-
adhering membrane Manufacturer’s recommendations.
28.2.3.3 Primer
Primers shall consist of a special compound provided by the self-adhering membrane Manufacturer
and formulated for its intended use.
28.2.3.4 Protection Board

Protection boards are multi-ply, semi-rigid boards composed of a mineral-filled asphaltic core
between a layer of asphalt-saturated felt or kraft liner and a glass fibre mat liner that is weather-
coated and has a polyethylene film facing.
Protection Boards shall be approximately 120 cm wide, 240 cm long, and 4.0 mm thick with at least
75% asphalt content, by weight. The softening point of the protection boards shall not be less than
140o C.
The puncture resistance shall be such that no effect is noted on the underside of the protection board
following a drop test. (68o tip angle of chisel, weight 0.619 kg, drop height 0.46 m, average puncture
depth 1.1 mm).
28.2.4 Application of Type A Waterproofing Membrane

When applying a waterproofing membrane, the Contractor shall comply with the specifications
outlined in this section and shall comply with the following general procedural requirements:
a. Technical backup services and supervision on site during application of the water proofing
system must be provided by the manufacturer.
b. Self-adhering waterproofing membrane work shall be coordinated by the Contractor so that
the placement of the protection boards will follow the waterproofing membrane application
by not more than five days.
c. Application of primer materials may be by brush or roller.
d. Membrane sheets shall be applied with minimum 12-cm overlaps or as specified by the
manufacturer at edges and ends and rolled down firmly and completely.
e. For specific procedures, details, and materials not specified herein, the Contractor shall
follow the self-adhering membrane Manufacturer's approved, written recommendations.
f. If the work must be left partially complete, the Contractor shall finish the exposed edges on
outside strips of membrane with a trowelled bead of mastic.
28.2.4.1 Application of Type A Membrane to Concrete

When applying a Type A waterproofing membrane to concrete, the Contractor shall comply with the
following procedural requirements:
a. Over the cleaned concrete surface, to the extent shown in the Contract plans, the Contractor
shall apply primer in a manner and using quantities in accordance with the membrane
Manufacturer's printed instructions. The Contractor shall allow these surfaces to dry before
proceeding and shall prime the surface again if it not covered with a membrane within 36
hours.
b. After the primer has dried, the Contractor shall apply the self-adhering membrane to the
concrete without stretching it and with the polyethylene face out. Membranes shall be
smoothed down with heavy hand pressure or a small roller. Edges and ends shall be lapped
as specified.
Page 28-7
c. Inside and outside corners shall be doubled by using an initial strip of 30 cm wide membrane,
centered along the axis of the corner. This strip shall be covered by the regular application
of self-adhering membrane. Exposed edges shall have a trowelled bead of mastic over these
edges.
d. Membranes on horizontal slabs shall extend to the outer edges and shall be protected until
subsequent overhead work is complete. Sidewall membrane shall extend down and out to
the edge of the previously applied horizontal slab membrane. Where the top of the membrane
terminates at a reglet, the Contractor shall extend the membrane therein and fill the reglet
with rubberised mastic.
e. Areas around piping and protrusions shall be double covered with an additional layer of
self-adhering membranes for a minimum of 300 mm in each direction. Membrane edges shall
be coated, the gaps between the membranes shall be filled, and protrusions shall be filled
with bituminous mastic.
f. Apply two coats of silane / siloxane clear sealant to the exposed surfaces of retaining walls,
abutments, wing walls, piers, and other similar structures from top of waterproofing to a line
1.00 m above the finished grade. The minimum performance test requirements for the clear
sealant shall be as shown in Table 24.13 of Chapter 24, Painting, of these standard
specifications.
28.2.4.2 Installation of Asphalt Protection Board Courses

Within five days after membrane application, the Contractor shall install asphalt protection board to
vertical and horizontal membrane-on-concrete surfaces. These boards shall be installed with the
polyethylene face out, in two (2) layers, and with butted edges and ends adhered to the membrane
by means of mastic or other approved compound. Joints in the second layer shall be staggered in
relation to the joints in the first layer. Exposed edges and gaps between penetrations and edges of
the protection board shall be pointed up with mastic. Protection board on horizontal slabs shall
terminate at the outer comers of the concrete structure above. Sidewall protection board shall extend
down and out to cover the horizontal slab membrane.
28.2.4.3 Repairs to Type A Waterproofing Membranes

Gouges and other damage to the completed membrane shall be repaired by the Contractor by
means of membrane patches applied prior to placement of the protection courses.
28.3 Type B Waterproofing Membranes

Type B waterproofing shall be either sheet applied or liquid applied as specified in the Contract plans
or indicated in the Particular Specifications. The Contractor shall comply with the specifications
outlined in this section for Type B waterproofing materials.
The Contractor may use a firm that has been approved by the waterproofing Manufacturer for the
installation of Type B waterproofing membranes.
Before beginning installation, the Contractor shall prepare a mock-up by installing a sample of the
Type B waterproofing membrane to the concrete element to demonstrate surface preparation, crack
and joint treatment, corner treatment, and execution quality. If the Engineer determines mock-ups
do not comply with requirements, the Contractor shall reapply the Type B waterproofing membrane
until the mock-ups are approved. Approved mock-ups may become part of the completed work, if
undisturbed at the time of substantial completion.
The Contractor shall provide to the Engineer affidavits from the Manufacturer that confirm that the
proposed Type B waterproofing membrane system to be used for the Project has a ten years history
of successful use in similar applications in the Gulf Region. The Contractor shall also provide
evidence that the material applicator is qualified and approved by the membrane Manufacturer.
If the Contract plans or particular specifications indicate the use of sheet applied waterproofing, for
the base slab of the structure, and liquid applied waterproofing, on vertical and roof surfaces for
example, to achieve the water-tightness of the structure, the Manufacturer/Applicator shall provide
Page 28-8
for the Engineer’s approval the required lapping detail at corners including the prerequisite bond
formation between the sheet and liquid applied waterproofing to ensure the complete system to work
as intended.
28.3.1 Submittals for Type B Waterproofing Membranes

For Type B waterproofing, the Contractor shall submit the materials outlined in this section to the
Engineer for review and approval.
a. Product Data: Include the Manufacturer's written instructions for evaluating, preparing, and
treating substrate, technical data, and tested physical and performance properties of
waterproofing.
b. Shop Drawings: Show locations and extent of waterproofing, including details for substrate
joints and cracks, sheet flashings, penetrations, inside and outside corners, tie-ins with
adjoining waterproofing membranes, and other termination conditions. This shall also include
setting drawings showing layout, sizes, sections, profiles, and joint details of pedestal-
supported concrete pavers.
c. Samples: For 500-mm x 500-mm square of Type B waterproofing membrane.
d. Applicator Certificates: Signed by the Manufacturer certifying that applicators comply with
requirements.
e. Qualification Data: For applicator.
f. Product Test Reports: Based on evaluation of comprehensive tests performed by a
qualified testing agency, for waterproofing as per the Engineer’s directive.
g. Warranties: The special warranty specified in this section shall not deprive the Owner of
other rights the Owner may have under other provisions of the Contract Documents, and
shall be in addition to, and run concurrent with, other warranties made by the Contractor
under requirements of the Contract Documents.
Special Warranty and Maintenance: The Contractor shall submit a written warranty signed
by waterproofing manufacturer and applicator agreeing to repair or replace waterproofing
that does not meet requirements or that does not remain watertight within the warranty period
specified herein.
The Contractor shall obtain a ten year warranty period from the waterproofing membrane
Manufacturer and Applicator after date of substantial completion for all Type B waterproofing
membranes that are installed for the Project. Such warranty shall cover any defective
workmanship, damp patches observed on internal surfaces, and any product failure.
The Contractor shall transfer to the Owner the Manufacturer/Applicator’s ten years warranty
on each waterproofing installation of the Project.
The Contractor shall inspect the water-tightness and waterproofing membranes installed on
the Project within one year of handing over the Project. The Contractor shall be responsible
for any required maintenance to ensure such waterproofing functionality and durability.
For the rest of the warranty period, if deficiencies are found, the Owner may inform the
Manufacturer/Applicator through the Contractor in writing of any defects and specify a
required completion date for repairs.
28.3.2 Delivery, Storage, and Handling of Type B Membranes

Products shall be delivered to the jobsite in their original, unopened containers, which shall be clearly
labelled with the Manufacturer’s name, brand designation, type, and class, as applicable. Additional
delivery, storage, and handling procedures are as follows:
a. Delivered materials shall be in original packages with seals unbroken, labelled with the
Manufacturer's name, product brand name and type, date of manufacture, and directions for
storing and mixing with other components.
Page 28-9
b. Liquid materials shall be stored in their original, undamaged packages in a clean, dry, and
protected location that is within the temperature range required by the waterproofing
Manufacturer.
c. Liquid materials that cannot be applied within their stated shelf life shall be removed and
replaced.
d. Rolls shall be stored according to the Manufacturer's written instructions.
e. Stored materials shall be protected from direct sunlight.
28.3.3 Type B Sheet Applied Waterproofing Materials

Type B sheet applied waterproofing membrane shall be one layer of compartmented loosely laid or
mechanical bonded, 2-mm thick, synthetic PVC manufactured in a UNI EN ISO 9001-certified plant.
It shall in all respects comply with the requirements of British Code of practice for protection of below
ground structures against water from the ground (BS 8102:2009).The type of sheet applied
waterproofing and extension shall be as per the Contract documents. Substitution of this
specification shall be subject to the approval of the Owner.
Compartmented loosely laid PVC membranes shall meet the following physical properties as shown
in Table 28-4:
Table 28-4: Physical properties of Type B, PVC loosely laid membranes
Physical Property Value Method
- Transverse minimum 16.7 N/mm²

Tensile strength BS EN ISO 527-1/3/5
- Machine direction mini.16.4 N/mm²
- Transverse minimum 300%
Elongation at break BS EN ISO 527–1/3/5
- Machine direction minimum 300%
Impact strength > 750 mm DIN 16726:2011-01 – 5.12
Seam strength 90 percent minimum of tensile strength ASTM D638 – 10
Tear resistance > 45 N/mm BS ISO 34-1:2010 Specimen
Cold bending < -25° C UNI EN 495 – 5 or

ASTM D746 - 07
Puncture resistance 1,100 N minimum DIN 16726:2011-01 - 5.12
Resistance to static > 2,300 N UNI EN ISO 12236

punching (CBR)
Hydrostatic pressure 6 hours at 5 bars BS EN 1928: 2000 Method B
resistance
Moisture Vapour 0.6 g/m2/24 Hrs maximum ASTM E96 / E96M – 13
Transmission Rate
Root resistance No penetration DIN 4062:1978-09
Shore A Hardness Not less than 50 DIN 53505
Chemicals Unaffected by Chemicals ASTM D542 - 00(2006) – 112 Day

Immersion
The mechanical bonded PVC membranes shall meet the following physical properties as shown in
Table 28-5:
Table 28-5: Physical properties of Type B, PVC mechanical bonded membranes
Page 28-10
Physical Property Value Method
Key spacing 65 mm
Tensile strength 16.3 N/mm² BS EN ISO 527-1/3/5
Elongation at break 270% BS EN ISO 527-1/3/5
Shore A Hardness Not less than 50 DIN 53505
Cold bending < -30° C ASTM D746 - 07
Specific gravity 1.3 ASTM D1505 - 10
Water absorption Not less than 0.15% ASTM D570 - 98(2010)e1
Moisture Vapour 0.6 g/m2/24 Hrs maximum ASTM E96 / E96M - 13

Transmission Rate
Tear resistance ≥ 80 N/mm ASTM D1004 - 13
Chemicals Unaffected by Chemicals ASTM D542 - 00(2006) – 112

Day Immersion
28.3.3.1 Application of Type B Sheet Applied Waterproofing

Membranes
When applying Type B sheet applied waterproofing membrane, the Contractor shall comply with the
standard specifications outlined in this section, the Contract documents, and the following general
procedural requirements:
a. In presence of the Manufacturer’s representative and /or applicator, the Contractor shall
examine substrates and areas to ensure compliance with requirements and to identify any
conditions that could affect performance.
b. When waterproofing a substrate, the Contractor shall verify that they are clean, sound, and
smooth. Substrates shall be free of fins, sharp edges, loose and foreign matter, oil and
grease, and anything detrimental to the waterproofing membrane. The Contractor shall repair
any pitted surfaces before installing a membrane.
c. If the Contractor anticipates any problems with using Type B waterproofing membranes over
substrates, they shall notify the Engineer in writing.
d. After correcting all unsatisfactory conditions and approved by the Engineer, the Contractor
may proceed with the installation.
28.3.3.2 Surface Preparation for Type B Sheet Applied Waterproofing

Membranes
When preparing a surface for a Type B sheet applied waterproofing membrane, the Contractor shall
comply with the following specifications:
a. Before commencing with the application of Type B waterproofing membranes— and as this
work proceeds — the Contractor shall sweep surfaces clean and remove debris,
irregularities, standing water, and any adhering materials that will impair the works.
b. The Contractor shall remove fins, ridges, mortar, and other projections, then fill any
honeycomb, aggregate pockets, holes, and other voids.
Page 28-11
c. Substrate joints shall be prepared, filled, primed, and treated in accordance with the
d. Vertical and horizontal surfaces shall be prepared, treated, and sealed at terminations and
penetrations through waterproofing and at drains and protrusions, in accordance with the
28.3.3.3 Compartmented Loosely Laid Sheet Installation

When installing compartmented, loosely laid sheet for a Type B membrane, the Contractor shall
comply with the following specifications:
a. General
1. This installation shall comply with that shown in the Contract plans. Membrane shall be
extended under trenches, pits, and depressions. Sheets shall be accurately aligned and shall
maintain uniform side and end laps of the minimum dimensions required. End laps shall be
staggered.
2. Membrane sheets shall be applied with minimum 80 mm overlaps or as specified by the
manufacturer at lap joints. All sheet lap joints and all joints between the membrane and
external waterstops to form the compartmentalization shall be double-seam welded and
pressure tested. Completed membranes shall be thoroughly inspected at the end of each
day’s work as well as before the placement of concrete.
3. The Manufacturer’s technical representative shall thoroughly check all seams. Any seams
deemed faulty shall be repaired.
4. For all details of corners, membrane termination, pipe penetration, pile head treatment, and
the like, the Contractor shall refer to the technical documents and approved shop drawings
and provide reinforcing strips, collars, metal clamps, and sealants.
5. To prevent any water penetration, seals shall be watertight to all items, such as ties, anchors,
and pipes that pass through the membrane. Sealing details shall comply with the
6. Full coverage shall be applied and geotextile overlapped, where necessary.
7. Geotextiles shall be spot-adhered to the membrane with an approved adhesive by the
membrane Manufacturer.
b. Horizontal Application
1. Application of membranes on horizontal surfaces shall be as directed by the Manufacturer.
A 370 g/m2, nonwoven, needle-punched, polypropylene geotextile shall be laid over blinding
concrete. Membranes shall be loosely laid over geotextile and compartmentalised by welding
a PVC waterstop at predetermined locations.
2. The Contractor shall apply a 50-mm uniform thickness of protection screed over the
waterproofing membrane, which is placed horizontally on the concrete blinding. Screeds shall
not extend over concrete pile.
c. Vertical Application
1. As a protection layer, the Contractor shall apply a 370 g/m 2, nonwoven, needle-punched
polypropylene geotextile on all vertical and sloping surfaces to protect the waterproofing
membrane from damages due to placing and vibrating concrete and to reduce drag-down on
the membrane by the placing action of the concrete.
28.3.3.4 Mechanical Bonded System Installation

When installing mechanical bonded sheet waterproofing for a Type B membrane, the Contractor
shall comply with the following specifications:
Page 28-12
a. The sheet membrane shall be locked into the structure by ribs when concrete is poured
directly against it.
b. For horizontal applications, the membrane shall be applied to smooth monolithic concrete
blinding with a wood float finish.
c. Blinding shall be free from loose aggregate and sharp protrusions that could damage the
membrane during re-bar and concrete placement. Protrusions greater than 3mm shall be
removed by mechanical means.
d. Proper 60 mm diameter concrete spacers shall be used for the placement of steel
reinforcement to hold the bars securely in place. Spacers shall be placed flat against the
sheet membrane. The Contractor shall provide for the Engineer’s approval calculations to
demonstrate that the membrane will not subject to a load more than 10 MPa at any point of
the membrane.
e. Prior to welding on both horizontal and vertical surfaces, the sheets shall be rolled and
accurately positioned to overlap the previous sheet by 80mm at both sides and end laps with
the ribs facing upwards to have double seam continuous machine weld.
f. The Contractor shall ensure that both surfaces to be welded together are dry and free from
dirt and contamination.
g. Welding shall be carried out by robotic hot air welding equipment and trained approved
operatives.
h. Joints shall be tested for integrity by the manufacturer recommended method approved by
the Engineer.
i. For application to vertical substrates, the membrane should be mechanically fastened using
appropriate fixings such as G-clamps or wooden battens as approved by the Engineer.
j. Fixings can be made through the bottom layer of the weld seam so that the membrane can
be securely welded.
k. The Contractor shall comply with the manufacturer recommendations.
28.3.3.5 Field Quality Control for Type B Sheet Applied

To control quality in the field, the Contractor shall comply with the following specifications.
a. A visual inspection of the membrane shall be made prior to covering it with the protection
layer. This inspection shall check for damages indicated by breaches in a light-coloured
signal layer.
b. Air pressure tests will be carried out on all double-seam welds. Acceptable pressure drop in
the channel between the two welds shall be according to the Manufacturer’s
recommendations.
c. Spark test is an electronic integrity test, as frequently called up on Architects specifications.
However, for existing structures, a spark test will accurately identify any holes (from almost
invisible pinholes, right up to larger holes). As an alternative to penetration testing of weld
seams, a spark testing method may used instead. During welding, a continuous length of thin
copper wire is inserted into the centre of the weld seam before it is closed. In the case of
application using weld tape, the wire can be stuck onto the weld tape before closing the joint.
d. After all weld seams are closed, the seams are tested by running a CK200 Mk.5 High
Frequency Spark Tester or similar along the weld seam.
e. Where sparks are detected, this indicates that the weld seam is not fully sealed and should
be repaired accordingly.
f. Once spark testing is completed successfully the weld seam is deemed to be fully water-
tight.
Page 28-13
g. Applicators must be approved by the Manufacturer and be able to demonstrate their

participation in the Manufacturer’s locally based training scheme.
28.3.3.6 Protection and Cleaning for Type B Sheet Applied

To protect and clean a type B waterproofing membrane, the Contractor shall comply with the
a. Excessive foot or vehicular traffic shall not be permitted on an unprotected membrane.
b. Type B sheet applied waterproofing membrane shall be protected from damage and wear
during the remainder of the construction phase.
c. Spillage and soiling shall be cleaned from adjacent construction using cleaning agents and
procedures recommended by the Manufacturer.
28.3.4 Type B Liquid Sprayed Applied Waterproofing Materials

Waterproofing membrane shall be a rapid curing, two-component cold, liquid spray-applied 100%
polymer based material meeting the following performance criteria as shown in Table 28-6:
Table 28-6: Physical properties of Type B, liquid sprayed applied membranes
Properties Unit Tested to Range
Density g/cc ASTM D792 - 08 ≥ 1.0
Shore A hardness # ASTM D2240 - 05(2010) ≥ 60
Tensile strength MPa ASTM D638 - 10 ≥ 6.00
Elongation at break % ASTM D638 - 10 ≥ 300%
Tear resistance kN/m ASTM D624 - 00(2012) ≥ 7.50
Adhesion to concrete MPa ASTM D4541 - 09e1or ≥ 2.0 on concrete with

BS EN ISO 4624 :2003 90% failure of concrete
(minimum 1 per 150 m2) surface (no debonding)
Crack bridging ability mm BD 47/99 ≥ 3.0 (static)

≥ 0.3 (dynamic)
Moisture Vapour g/m2/ 24 Hrs ASTM E96 / E96M - 13 0.6 maximum

transmission rate
Water penetration BD 47/99 Zero
Transport Research
Chemical resistance Laboratory (TRL) Resistant
Research Report 248
Chloride penetration BD 47/99 Negligible
Resistance to SNCF Taber Method High abrasion resistance

abrasion
Holidays (pinholes) Electronic detection None
Resisting hydrostatic m ASTM D5385 - 93(2006) In excess of 20 m

head
Page 28-14
Properties shall not degrade by more than 10% after exposure according to ASTM B117-11 (salt
spray) and ASTM G154 - 12a (UV resistance).
The proposed system shall have a valid British Board of Agreement (BBA) Certificate (or equally
recognized certification).
The waterproofing material shall not be sensitive to and/or affected by atmospheric moisture during
application. Over coating and lapping at joints shall not be dependent on critical over coating
windows. Over coating shall be possible without needing any special surface preparation.
Penetration of the waterproofing membrane for dewatering, temporary construction or any
permanent construction (unless specifically indicated on the Contract plans, i.e., pipes at manholes)
shall not be permitted by the Engineer.
a. Thickness Application
1. For horizontal surfaces: total thickness of ≥ 3.0 mm (DFT) shall be applied in two or more
coats as approved by the Engineer.
2. For vertical surfaces: total thickness of ≥ 2.0 mm (DFT) shall be applied in two or more
coats as approved by the Engineer
Multiple coats shall be colour-coded to ensure proper coverage. First coat should be checked and
repaired before application of subsequent coat(s).
b. Expansion, Construction and Contraction Joints

At expansion, construction, and contraction joints, a minimum of 175 mm wide polyester
reinforcement scrim shall be provided directly over the joint and embedded into first coat of
waterproofing membrane.
c. Protection Boards
Protection for the waterproofing membrane shall be 4 mm thick non-absorbent board in compliance
with performance properties stipulated by AASHTO M 33-99 (2012). The board shall be used at all
locations, and as directed by the Engineer and as recommended and endorsed by the waterproofing
material supplier and applicator. For horizontal application, one layer of 4mm protection shall be
used. For vertical application, two (2) layers of 4mm protection board shall be used.
d. Screed Protection
The Contractor shall furnish and install 75 mm thick screed concrete in accordance with Section
21.7.8 of Chapter 21, Concrete Structures, for additional protection of waterproofing on all buried
roof concrete slabs and other horizontal surfaces as specified in the Contract plans and as directed
by the Engineer.
28.3.4.1 Submittals for Type B Liquid Sprayed Applied Membranes

In addition to the requirements of Section 28.3.1, the Contractor shall submit a material submittal as
per Section 1.15, Submittal Procedures, outlined in Chapter 1, General Requirements, of these
standard specifications including the following for all materials for the Engineer’s approval:
1. Material samples and technical brochures.
2. Recent test data of physical and mechanical properties from certified laboratories.
3. Qualifications of proposed sub-contractors, for application of materials. The subcontractor
should be endorsed by the waterproofing manufacturer.
4. Method statement for application of materials which shall be endorsed by the applicator and
supplier and include the following as a minimum.
a) QC testing of thickness, adhesion and holidays during application.
b) Details of sequencing and temporary and permanent protection.
Page 28-15
c) Provisions for repair of any incidental damage.

d) Provisions for substrate preparation and sealing of any pre-existing cracks. Primer
should be as recommended by the waterproofing manufacturer.
5. A mock-up sample of size 2 m x 2 m to the specified and approved details.
6. Shop drawings with detailing at joints, corners, edges, etc.
The Engineer may perform in-house testing of the materials to determine suitability. Final approval
of materials will be given after analysis of such test results. The decision of the Engineer shall be
final. Provisions for in-house and/or independent testing of the materials prior and during application
shall be included by the Contractor/manufacturer/supplier.
28.3.4.2 Application of Type B Liquid Sprayed Applied Membranes

1. Surface preparation, including use of primers, mixing, application and protection of all
materials shall strictly conform to manufacturer’s printed instructions, as specified in these
specifications and as instructed by the Engineer.
2. Protection board shall be installed using adhesives or similar methods so as not to damage
the waterproofing membrane.
3. The material shall be applied by a licensed subcontractor specialized in waterproofing
material application.
28.3.4.3 Field Quality Control for Type B Liquid Sprayed Applied

Membranes
a. Inspection
Prior to priming of the surface, the Engineer, Applicator and Manufacturer’s representative shall
inspect and approve the prepared substrate.
Random tests for adequate tensile bond strength shall be conducted on the substrate by the
Applicator at the job site using an Elcometer Adhesion Tester in accordance with the requirements
of ASTM D4541 - 09e1. The minimum test frequency shall be three per 500 m2.
Adequate surface preparation shall be indicated by tensile bond strengths of primer to the substrate
greater than or equal to 2.0 MPa or 90% failure in the concrete.
If the tensile bond strength is lower than the minimum specified, the Engineer shall request additional
substrate preparation. Any primer not adequately applied shall be removed and a new application
effected at the Contractor’s expense as directed by Engineer.
Cracks and joints shall be treated in accordance with the Manufacturer’s recommendations as
approved or directed by the Engineer.
b. Field Quality Control

The following tests shall be conducted by the Applicator or Manufacturer’s representative and
recorded on a form to be submitted to the Engineer. The testing equipment shall be furnished by the
Contractor.
• Temperature: Air, substrate temperatures and dew point.
• Adhesion Tests: Adhesion tests of the cured membrane to the substrate shall be checked
as per Item 1 above.
• Membrane Thickness: Wet film thickness shall be checked every 9 m2 using a gauge pin or
standard comb type thickness gauge during application where membrane gel time permits.
Ultrasonic testing, calibrated point-penetrating (destructive) testing, or other methods
approved by the Engineer, shall be employed for determination of dry film thickness in the
event that rapid set time of the membrane does not allow for the use of wet film thickness
Page 28-16
testing methods. Repair of the membrane system following destructive testing shall be in
accordance with the manufacturer’s recommendations.
• Coverage Rates: Rates for all layers shall be monitored by checking quantity of material
used against the area covered.
• Holidays (pinholes): All horizontal and vertical surfaces shall be scanned by the applicator for
holidays (pinholes) by using the proper equipment followed by local touch up spraying at
these pinhole locations. No pinholes will be accepted in the completed waterproofing system.
Detailed shop drawings shall be submitted for the Engineer’s approval.
28.4 Type C Waterproofing Membranes

Type C waterproofing membranes shall be furnished and supplied by the Contractor as specified
herein to all concrete and block masonry surfaces where Type A waterproofing is impractical, as
indicated in the Contract plans, the particular specifications, or directed by the Engineer.
28.4.1 Type C Waterproofing Materials

Type C waterproofing shall be cold applied, single component, water based, emulsified rubber
modified bitumen coating that can be applied on damp substrates of closed or confined areas. The
membrane shall have a minimum overall thickness of 2.0 mm.
The properties of the waterproofing membrane shall not significantly diminish with age. The provision
of test data and/or evidence of successful performance of the membrane in climatic conditions similar
to the UAE shall be a condition of acceptance. Type C membranes shall meet the following physical
properties as shown in Table 28-7.
Table 28-7: Physical properties of Type C membranes
Test Method Requirement

Property
- > 10 %
Rubber Content
ASTM D638-10 5 N/mm2 minimum
Tensile Strength
ASTM D412 - 06a(2013) 30% minimum
Elongation
ASTM D4541 - 09e1, and > 0.75 MPa
Adhesion Strength BS 1881-207:1992
- Non flammable
Flammability
- < 90 minutes
Drying Time
ASTM C309 - 11 < 0.50 kg/m3
Curing Efficiency (water loss)
28.4.2 Application of Type C Waterproofing

a. The application temperature shall be between 4o C to 45o C.
b. Surfaces shall be cleaned thoroughly of all contaminants like dust, traces of curing
compound, oil and grease by light mechanical grinding, grit blasting, or high pressure water
jet as needed and as directed by the Engineer. All surface imperfections or protrusions shall
be removed and repaired. Structurally unsound concrete and friable concrete shall be
removed and repaired with a suitable concrete repair mortar as approved by the Engineer.
c. Priming coating shall be applied in two coats on the surface prior to the application of the
bitumen coating. The second coat shall be applied only after the first coat dries of completely.
In case of delay in application of the second coat for more than 24 hours, a fresh coat of
primer shall be reapplied.
Page 28-17
d. Depending on the dry film thickness required, the rubberized bitumen coating shall be applied
at a rate recommended by the manufacturer and approved by the Engineer.
e. On vertical surfaces, the coating shall be applied in multiple layers. Subsequent coats shall
be applied only after the previous coat dries off completely and shall be applied at right angles
for the previous coat. Clean dry sand shall be broadcasted onto the wet coating.
f. The coating shall be cured for a minimum period of 48 hours before applying any protection
board or backfilling.
g. The Contractor shall ensure that the first coat is not punctured during the application of the
second coat. If the coating is damaged, the damaged area shall be over coated provided the
surface preparation is done properly.
h. Type C membrane shall be protected by protection boards as per Section 28.2.3. On vertical
surfaces, protection boards shall be fixed on the membrane by a double sided bitumen
adhesive tape as per the manufacturer recommendations.
28.4.3 Storage of Type C Membranes

Products shall be stored in a covered area, away from direct sunlight, UV and other source of heat.
The Contractor shall demonstrate to the Engineer that the shelf life of the stored products has not
exceeded the manufacturer recommended shelf life.
28.5 Type D Waterproofing Membranes

When required by the Contract plans or particular specifications, the waterproofing of roadway
surfaces of concrete bridge decks, tunnels, approach slabs and other areas shall be as described
below. This section applies to proprietary liquid spray applied waterproofing systems.
28.5.1 Type D Liquid Spray Applied Waterproofing Systems

28.5.1.1 Materials and Submittals for Liquid Spray Applied Systems
All materials shall comply with the requirements of Waterproofing and Surfacing of Concrete Bridge
Decks (BD 47/99), and its Appendix B, Certification Test Requirements for Waterproofing Systems
on Concrete Bridge Decks, and the requirements of this section.
The waterproofing system shall provide long term protection to the concrete from the ingress of
water-borne chlorides or other deleterious substances.
Waterproofing for bridge decks shall be rapid curing and liquid spray applied conforming to the
requirements of Section 28.3.4 and this section. A total thickness of ≥ 4.0 mm (DFT) including peaks
and arises shall be applied in two coats in accordance with the manufacturer’s recommendations
and as approved by the Engineer. Sufficient time shall be allowed for the first coat to adequately
cure prior to the application of the second coat. The waterproofing shall incorporate an anti-slip
aggregate under traffic areas, as per the manufacturer’s recommendations, in the final coat. The
finished membrane shall be free of pinholes.
Good adhesion shall be provided between the membrane and the concrete and between the
membrane and the asphalt by the use of compatible, purpose made primer and tack coats. Adhesion
between the membrane and the concrete shall be at least 2.0 MPa average. The membrane shall
have good flexibility and be able to bridge live cracks of up to 3mm.
The waterproofing membrane, primer and bonding agents including tack coat shall be compatible
with each other.
The use of ventilating layers, partial bonding or bond breakers with the waterproofing system shall
not be permitted.
The membrane shall be resistant to water and chloride ion penetration, embrittlement, abrasion, UV
degradations, pedestrian traffic, indentation by hot or cold aggregates and the effect of placing
asphalt.
Page 28-18
The membrane shall easily accommodate the need for day joints and patch repairs as a result of
testing for adhesion or coating thickness, if required by the Engineer.
In addition to the requirements of Article 28.3.4.1, the following information shall be submitted for the
Engineer's approval:
1. Full details of previous bridge deck waterproofing contracts performed in climatic conditions
similar to the UAE including details of contract, contractor, Consultant/ Engineer,
Client/Employer, location, size (m²), temperature and brief description.
2. Curricula Vitae of technical representatives and skilled operatives.
3. Full technical literature with test results etc. relevant to UAE climatic conditions and proof
of compliance with this specification including the requirements of Table 28-6 and additional
physical property requirements shown in Table 28-8.
Table 28-8: Physical properties of bridge Deck liquid spray applied system

As approved by the 2 mm
Minimum Thickness (for each layer) Engineer
Shear adhesion to sand asphalt BD 47/99 0.15 Mpa minimum (at 40°C)
and hot rolled asphalt
Tensile adhesion to sand asphalt BD 47/99 0.15 Mpa minimum
and hot rolled asphalt
Indentation by hot or cold
aggregate during asphalt placing or BD 47/99 Negligible
pedestrian traffic prior to any
protection
Resistance to high temperature
from concrete surface (80°C) or due BD 47/99 Yes
to asphalt placing (150°C)
Holidays (pinholes) Electronic detection None
Blisters None
UK Department Transport
Resistance to embrittlement Tech. Memo BE27 90°C No cracking
Mandrel Test at 0°C
BAM ZTV BEL-B @ 160° No change
Resistance to hot asphalt or more
Resistance to chisel impact BD 47/99 No indentation
The above properties shall also apply for the small areas of patch repair that may be required. The
above properties shall not significantly diminish with age.
An additional protective layer shall be applied immediately above bridge deck waterproofing to those
areas shown on the Contract plans and shall comply with this section.
28.5.1.2 Materials for Additional Bituminous Protection

Bituminous protection, where shown on the Contract plans as an additional protective layer, shall be
15mm sand asphalt having a Marshall Stability of 5.5 kN ± 2 kN when tested in accordance with BS
598-107:2004 and comply with BS EN 12591:2009, BS EN 13924:2006, and BS EN 13108-4:2006
recipe Type F wearing course mixture Designation 0/3 except that 5% ± 0.5% of the total mix shall
be inorganic red oxide and regarded as part of the filler content.
Page 28-19
28.5.1.3 Surface Preparation for Liquid Spray Applied Systems

The Contractor shall prepare all concrete surfaces prior to the application of waterproofing system,
and ensure they are free of cracks, voids, and blowholes.
Immediately before the application of the primer or laying of the waterproofing system or protective
layer, the concrete surface or primed surface shall be clean, dry and free from moisture, laitance,
loose aggregate, sand, dust and other debris. The Contractor shall use mechanical surface
preparation such as vacuum blasting as directed by the Engineer to provide lattice free substrate.
Where the adhesion to the concrete would be impaired, the surface shall be free from curing liquids,
compounds and membranes.
28.5.1.4 Installation of Liquid Spray Applied Systems

Proprietary waterproofing systems shall be installed only by applicators approved by the
manufacturers and the Engineer and in accordance with the approved installation procedures.
The formation of defects affecting the integrity of the membrane including pin/blow holes and blisters
in the waterproofing shall:
1. be made good by repair in accordance with the manufacturer's procedure before any
subsequent layers are applied; or
2. require the system to be replaced where directed by the Engineer.
Proprietary waterproofing systems shall be laid to follow the contours of the concrete surface and
shall be incapable of flow and slump.
28.5.1.5 Installation of Additional Bituminous Protection

Additional bituminous protection complying with Article 28.5.1.2 shall be laid on the clean and dry
substrate and compacted to the areas and thickness shown on the Contract plans.
The additional protective layer or surfacing laid on the waterproofing system shall be firmly bonded
to the waterproofing system. Where a tack coat for the additional protective layer or surfacing is not
provided as part of the waterproofing system a satisfactory bond to the membrane shall be obtained
from:
1. A separate compatible tack coat or
2. The binder within the directly applied additional protective layer or surfacing.
Where the tack coat is of the type activated by the heat of the succeeding bituminous layer, the
rolling temperature of this layer shall be sufficient to ensure adhesion.
Tack coats between the waterproofing membrane and overlying asphalt shall have a minimum
softening point of 80o C.
28.5.2 Water Seepage Relief Channels

Water seepage relieve channels shall be provided where specified on the Contract plans. In general
the seepage relief channels shall be located adjacent to the lower kerb line and at bridge deck
expansion joints or as directed by the Engineer. The waterproofing membrane shall be lapped onto
the interior of any seepage relief wells or drainage fittings to form a lap of 100mm. Outlets shall be
spaced in accordance with the manufacturer’s requirements.
28.5.3 Protection of Bridge Deck Waterproofing System during

Construction
On any structure, providing no damage results, only plant and equipment fitted with rubber tyres may
stand or travel on proprietary waterproofing systems with the prior approval of the Engineer solely
for the purposes of laying an additional protective layer or surfacing course on that structure.
Rollers shall not be permitted to stand or travel directly on the waterproofing system.
Page 28-20
Where it is necessary for plant, equipment or traffic to stand or travel on a bridge deck that has been
waterproofed with a proprietary system before the laying of an additional protective layer, suitable
temporary protection shall be provided to the satisfaction of the Engineer. All such plant and
equipment shall have its tyre treads regularly inspected and any embedded stones removed.
Temporary protection shall be provided where damage to the waterproofing, protective layer or
additional protective layer could result from particular site traffic.
The protective layer of a two layer waterproofing system, or any protective layer additional to that
included as part of a waterproofing system, shall be laid immediately after the waterproofing layer's
bonding agent has set or cured.
Where a waterproofing membrane also serves as an adhesive for the protective layer, any additional
protective layer shall not be laid until the liquid waterproofing membrane/adhesive has set or cured.
28.5.4 Integrity Testing of Type D Waterproofing

The Contractor shall submit for the approval of the Engineer a regime of compatible tests to check
the integrity of the waterproofing system that he proposes to use in order to substantiate fitness of
purpose. The test methods shall be those which have been assessed by the British Board of
Agreement (BBA) for use with waterproofing system.
28.6 Integral Waterproofing

This section Includes furnishing of all labor, materials, services, and equipment necessary for the
supply and installation of integral waterproofing admixture to concrete structures as indicated on the
Contract plans and as specified herein. The integral waterproofing material shall be added to
concrete during the mixing cycle.
Integral waterproofing admixture shall be a specially formulated product, usually in the form of a dry
powder, liquid or other suitable form which can be added to the concrete mix at the batch plant or
the jobsite in order to make the hardened concrete practically impervious to moisture penetration.
Such admixtures may be water repellent, hydrophobic/hydrophilic, concrete densifiers, pore blockers
or crystalline types.
The integral waterproofing admixture must meet the classification of a Permeability Reducing
Admixture for Hydrostatic Conditions (PRAH) as indicated by ACI 212.3R-10, Report on Chemical
Admixtures for Concrete and meet the requirements of ASTM C494, Type S admixtures, as
applicable. The effect of the admixture must remain available within the hardened concrete and must
be able to pore blocking or self-sealing of minor cracking that may occur in the future. It shall protect
the concrete from deterioration due to harsh environmental conditions.
Dosage of the integral waterproofing admixture shall be as recommended by the manufacturer
technical literature. System Requirements for Integral Waterproofing
a. Testing Requirements: Integral waterproofing system shall be tested in accordance with the
following standards and conditions, and the testing results shall meet or exceed the
requirements as specified herein.
b. Independent Laboratory: Testing shall be performed by an independent laboratory meeting
the requirements of ASTM E329 - 13a and approved by the Owner. The testing laboratory
shall obtain all concrete samples and waterproofing product samples.
c. Crystalline or Pore blocking Formation: Crystallizing or pore blocking capability of
waterproofing system shall be evidenced by independent SEM (Scanning Electron
Microscope) photographs showing crystalline or pore blocking formations within the concrete
matrix.
d. Permeability: Independent testing shall be performed according to U.S. Army Corps of
Engineers CRD-C48-92 “Standard Test Method for Water Permeability of Concrete”. No
passage of water shall be exhibited through treated samples when exposed to a vertical
water head equal to minimum 140 meters (1.38 MPa).
Page 28-21
e. Permeability: The coefficient of permeability for admixture treated concrete shall be reduced
by a minimum of 90% compared to untreated concrete when tested using BS EN 12390-
8:2009 at 1.035 MPa of pressure for 96 hours (Taywood- Valenta Method, ACI 212.3R-10,
Report on Chemical Admixtures for Concrete).
f. Chemical Resistance: Independent testing shall be performed to determine “Sulfuric Acid
Resistance of Concrete Specimens”. Treated concrete samples (at the full range of dosage
rates required for the concrete mix design) shall be tested against untreated control samples.
All samples shall be immersed in sulfuric acid and weighed daily until a control sample
reaches a weight loss of 50% or over. On final weighing the percentage weight loss of the
treated samples shall test significantly lower than the control samples.
g. Compressive Strength: Independent testing shall be performed according to applicable
ASTM or BS standards. Concrete samples containing the integral waterproofing admixture
shall be tested against untreated control sample. At 28 days and at one year, the treated
samples shall exhibit the same or better compressive strength over the control.
h. Drying Shrinkage: Minimum 20% reduced drying shrinkage for treated concrete compared to
untreated concrete when tested according to ASTM C157 / C157M – 08 or equivalent.
i. Admixtures with Self-Sealing Properties: Autogenous crack sealing of treated concrete for
cracks with width of up to 0.5mm or greater; verified by independent testing.
j. Carbonation Resistance: No increase in rate of carbonation compared to untreated concrete
when exposed to a 4% carbon dioxide atmosphere for 28 days. Test method according to
BS 1881-210:2013 or ISO 1920-12:2015 or other similar international standards.
k. Sulfate Resistance: Improved resistance to sulfate attack compared to untreated concrete
when tested to the US Bureau of Reclamation Accelerated Method or other similar
international standards.
l. History: The waterproofing admixture must have demonstrated success in similar
applications that are no less than 15 years old.
28.6.1 Submittals for Integral Waterproofing

a. General: The Contractor shall submit listed submittals in accordance with conditions of the
Contract.
b. Product Data: The Contractor shall submit product data, including manufacturer’s
specifications, installation instructions, and general recommendations for waterproofing
applications. The Contractor shall also include manufacturer’s certification or other data
substantiating that products comply with the requirements of the Contract documents.
c. Test Reports: The Contractor shall submit, for the Engineer’s approval, complete test reports
from approved independent testing laboratories certifying that waterproofing system
conforms to the characteristics and testing requirements specified herein.
d. Manufacturer’s Certification: The Contractor shall provide certificate signed by the
manufacturer certifying that the materials to be installed comply in all respects with the
requirements of this specification.
e. Project References: The Contractor shall provide case study documents demonstrating
successful applications of the waterproofing admixture in similar projects over a period of no
less than 15 years.
28.6.2 Quality Assurance for Integral Waterproofing

a. Manufacturer Qualifications: Manufacturer to be BS EN ISO 9001:2015 registered, and to
have no less than 15 years’ experience in manufacturing the integral waterproofing admixture
for the required work. Manufacturer shall be capable of providing field service representation
during construction phase. Manufacturers that cannot provide the performance test data
specified herein shall not be considered for the Project.
Page 28-22
b. Waterproofing admixture: It shall

• Comply with ASTM C494 / C494M – 13 Type S, admixture.
• Be certified by the International Code Council (ICC), or equivalent, as a Chemical
Admixture used in Concrete (AC198).
• Bear a CE mark or equivalent and conform to the performance and quality
requirements of BS EN 934-2:2009+A1:2012.
• Hold a valid Agreement Certificate from the British Board of Agreement (BBA) or
equally recognized certification.
• Hold a valid Appraisal certificate from BRANZ Limited or equally recognized
certification.
• Be certified to NSF/ANSI Standard 61 – Drinking Water System Components – Health
Effects or equally recognized certification.
c. Applicator (concrete supplier): Installer of integral waterproofing admixture shall be approved
by the manufacturer in writing. Applicator shall conduct laboratory and field trials as
necessary to successfully incorporate the waterproofing admixture into their concrete
mixture, and shall follow the manufacturer’s testing guidelines.
d. Pre-Installation Conference: Prior to installation of waterproofing, the Contractor shall
conduct meeting with the Engineer, the Owner, the Applicator, concrete placer, and
waterproofing manufacture to verify and review the following:
• Project requirements for waterproofing as set out in the Contract documents.
• Manufacturer’s product data including application instructions.
• Procedures, roles and responsibilities among the parties.
e. Technical Consultation: The waterproofing manufacturer’s representative shall provide
technical consultation on waterproofing application.
f. All parties shall follow the manufacturer’s written instructions as contained in the Application
Instructions, published by the manufacturer.
g. All waterproofing system components shall bear a traceable manufacturer’s lot number.
28.6.3 Delivery, Storage and Handling of Integral Waterproofing

a. Ordering: The Contractor shall comply with manufacturer’s ordering instructions and lead
time requirements to avoid construction delays.
b. Delivery: The contractor shall deliver packaged waterproofing materials to project site in
original undamaged containers, with manufacturer’s labels, lot number, and seals intact.
c. Storage: The Contractor shall store waterproofing materials in dry, enclosed location, at
temperature and humidity conditions recommended by the manufacturer.
d. Handling: The Contractor shall observe all occupational health and safety requirements, read
and follow the Material Safety Data Sheet for each product, and conform to all local
regulations.
28.6.4 Warranty
The manufacturer shall provide the following executed by authorized company official:
• 25 years manufacturer’s limited standard material warranty for the waterproofing admixture.
• 10 years manufacturer’s limited labor and material performance warranty for the
waterproofing admixture system from Date of Substantial Completion.
Page 28-23
28.6.5 Concrete Batching, Mixing, Placing & Curing

Concrete batching, mixing, placing, and curing shall comply with the applicable requirements of
Chapter 4, Concrete Works, and Chapter 21, Concrete Structures, of these standard specifications.
Waterproofing admixture shall be added to the concrete mix during batching operations as per the
recommendations of the manufacturer. Waterproofing admixture shall not be mixed with other
admixtures prior to addition. It shall be added separately from other admixtures.
28.6.6 Field Quality Control

The Contractor shall not conceal concrete before it has been observed by the manufacturer’s
representative and the Engineer. Concrete shall be examined for structural defects such as faulty
construction joints, cold joints and cracks. Such defects to be repaired in accordance with the
manufacturer’s repair procedures
Page 28-24
INDEX
abutments, 28-1 mastic, 28-5, 28-7, 28-8

Additional bituminous protection, 28-20 mechanical bonded, 28-10, 28-12
adhesion, 28-4, 28-15, 28-18, 28-19, 28-20 Membrane Thickness, 28-16
affidavits, 28-5, 28-8 mock-up, 28-8, 28-16
Air pressure tests, 28-13 Over coating, 28-15
applicator, 28-5, 28-8, 28-9, 28-11, 28-15, 28- performance properties, 28-9, 28-15
17 Permeability, 28-21, 28-22
approach slabs, 28-18 piers, 28-1
base slab, 28-1 Primer, 28-2, 28-5, 28-7, 28-16
Blinding, 28-13 protection board, 28-5, 28-7, 28-8, 28-15, 28-
block masonry surfaces, 28-1, 28-17 18
box girder, 28-1 protective membrane, 28-5
bridge decks, 28-1, 28-18 pullboxes, 28-1
bridge substructure, 28-1 Random tests, 28-16
channels, 28-20 retaining walls, 28-1
compartmented, 28-10, 28-12 roadway surfaces, 28-1, 28-18
concrete protection, 28-1 self-adhering, 28-5, 28-6, 28-7, 28-8
contact with soil, 28-1, 28-5 self-seal, 28-21
contingency utility ducts, 28-1 sheet applied, 28-8, 28-10, 28-11, 28-14
corner treatment, 28-8 Spark test, 28-13
corners, 28-8, 28-9, 28-12, 28-16 special warranty, 28-9
crystalline waterproofing, 28-21, 28-22, 28-23 storm water drainage structures, 28-1
damp substrates, 28-17 substrate, 28-9, 28-11, 28-16, 28-20
end walls, 28-1 Sulfate Resistance, 28-22
European Union of Agreement, 28-5 sunlight, 28-10, 28-18
execution quality, 28-8 technical data, 28-9
exposed concrete surfaces, 28-1 Temperature, 28-2, 28-16
exterior surfaces, 28-1 Temporary protection, 28-21
fabric reinforcement, 28-6 tensile bond strength, 28-16
Gulf Region, 28-5, 28-6, 28-8 traffic control system, 28-1
horizontal slabs, 28-8 tunnels, 28-1, 28-18
impractical, 28-1, 28-17 unopened containers, 28-5, 28-9
ingress, 28-18 visual inspection, 28-13
integral waterproofing, 28-1 warranty, 28-9
integrity, 28-13, 28-20, 28-21 Water seepage, 28-20
joint treatment, 28-8 water-borne chlorides, 28-18
laid sheet, 28-12 water-tightness, 28-1, 28-8
Liquid materials, 28-10 wearing course, 28-19
liquid spray-applied, 28-14 weld seams, 28-13
Manufacturer, 28-5, 28-7, 28-8, 28-9, 28-10, welding, 28-12, 28-13
28-11, 28-12, 28-13, 28-14, 28-16, 28-22, wing walls, 28-1
28-23 written instructions, 28-9, 28-10, 28-23
Page 28-25
PART 2
ROAD STRUCTURES
CHAPTER 29 - MISCELLANEOUS ITEMS FOR

STRUCTURES
DOCUMENT NO: TR-

FIRST EDITION
JANUARY 2018
Chapter 29: Miscellaneous Items for Structures

TABLE OF CONTENTS
List of Tables ..................................................................................................................................iv
29 Miscellaneous Items for Structures .................................................................................. 29-1
29.2 Removing Existing Bridge Structures ........................................................................... 29-5
29.2.1 Submissions for the Removal of Structures .......................................................... 29-5
29.2.2 Removal Construction........................................................................................... 29-6
29.2.3 Partial Removal of Structures ............................................................................... 29-6
29.2.4 Removal of Structures for Demolition.................................................................... 29-6
29.2.5 Removal of Bridges, Culverts, and Other Existing Structures................................ 29-6
29.2.6 Salvaging Materials after Removal........................................................................ 29-7
29.2.7 Removing Abandoned Structures ......................................................................... 29-7
29.2.8 Disposal of Materials after Removal...................................................................... 29-8
29.3 General Requirements for Structures Foundations ...................................................... 29-8
29.3.1 Protection of Existing Structures ........................................................................... 29-8
29.3.2 Excavation ............................................................................................................ 29-9
29.3.2.1 Abutment (End Bent) Fill .............................................................................. 29-10
29.3.3 Cofferdams ......................................................................................................... 29-10
29.3.4 Vibrations on Freshly Placed Concrete (Drilled Piles and Piers) ......................... 29-11
29.4 Bridge Drainage Systems .......................................................................................... 29-11
29.4.1 Bridge Drainage Terminology ............................................................................. 29-11
29.4.2 Materials for Bridge Drainage Systems ............................................................... 29-11
29.4.2.1 Materials Related to Superstructure ............................................................. 29-11
29.4.2.2 Materials Related to Retaining Systems ...................................................... 29-13
29.4.3 Construction Requirements for Bridge Drainage Systems .................................. 29-13
29.4.3.1 Inlet Frames, Grates, and Scuppers for Bridge Drainage Systems .............. 29-13
29.4.3.2 Steel Alloy Pipe for Bridge Drainage Systems ............................................. 29-13
29.4.3.3 Fibreglass Pipe and Fittings for Bridge Drainage Systems ........................... 29-13
29.4.3.4 Concrete Gutters for Bridge Drainage Systems ........................................... 29-14
29.4.3.5 Weep Holes for Bridge Drainage Systems ................................................... 29-14
29.4.3.6 Drainage Blankets for Bridge Drainage Systems ......................................... 29-14
29.4.3.7 Geocomposite Drainage Systems ................................................................ 29-15
29.5 Resin Injection of Cracks in Concrete Structures ....................................................... 29-15
29.5.1 Materials for Resin Injections .............................................................................. 29-15
29.5.2 Equipment for Resin Injections ........................................................................... 29-15
29.5.3 Qualifications for Resin Injection Personnel ....................................................... 29-15
29.5.4 Cracked Surface Preparation and Cleaning ........................................................ 29-16
29.5.5 Sealing Cracks for Resin Injection ...................................................................... 29-16
29.5.6 Resin Injection .................................................................................................... 29-16
29.5.7 Cleaning after Resin Injection ............................................................................. 29-16
29.5.8 Acceptance of Resin Injection ............................................................................. 29-16
29.6 Sealing Concrete Surfaces and Cracks ..................................................................... 29-17
29.6.1 Penetrant Sealers ............................................................................................... 29-17
29.6.1.1 Materials for Penetrant Sealers.................................................................... 29-17
29.6.1.2 Surface Preparation for Penetrant Sealers................................................... 29-18
29.6.1.3 Application of Penetrant Sealers .................................................................. 29-18
29.6.1.4 Control of Concrete Sealing Materials.......................................................... 29-19
29.6.2 High Molecular Weight Methacrylate Sealers ...................................................... 29-20
29.6.2.1 Materials for a Methacrylate System ............................................................ 29-20
29.6.2.2 Surface Preparation for a Methacrylate System ........................................... 29-22
Page i
CHAPTER 29: MISCELLANEOUS ITEMS FOR STRUCTURES First Edition -January 2018
29.6.2.3 Method for Applying Methacrylate ................................................................ 29-22

29.6.2.4 Opening Roadway Surfaces to Traffic.......................................................... 29-24
29.6.2.5 Cure Test ..................................................................................................... 29-24
29.7 Epoxy Compounds .................................................................................................... 29-24
29.7.1 Types of Epoxy Compounds ............................................................................... 29-24
29.7.2 Epoxy Design Requirements............................................................................... 29-25
29.7.2.1 Certifications for Epoxy Products ................................................................. 29-25
29.7.3 Specific Requirements for Type A and Type B Epoxy Compounds ..................... 29-25
29.7.3.1 Mixing and Applying Type A and Type B Epoxy Compounds ....................... 29-25
29.7.3.2 Performance Tests for type A and type B Epoxy Compounds ...................... 29-26
29.7.4 Specific Requirements for Type E Epoxy Compounds ........................................ 29-26
29.7.5 Specific Requirements for Type F Epoxy Compounds ........................................ 29-26
29.7.6 Specific Requirements for Type G Epoxy Compounds........................................ 29-27
29.7.7 Specific Requirements for Type H Epoxy Compounds ........................................ 29-27
29.7.8 Specific Requirements for Type I Epoxy Compounds ......................................... 29-27
29.7.9 Specific Requirements for Type J Epoxy Compounds......................................... 29-27
29.7.10 Specific Requirements for Type K Epoxy Compounds ........................................ 29-28
29.7.11 Specific Requirements for Type L Epoxy Compounds ........................................ 29-28
29.7.12 Specific Requirements for Type M Epoxy Compounds ....................................... 29-28
29.7.13 Specific Requirements for Type N Epoxy Compounds ........................................ 29-28
29.7.14 Specific Requirements for Type Q Epoxy Compounds........................................ 29-28
29.7.15 Specific Requirements for Type T Tape Compounds .......................................... 29-29
29.7.16 Packaging, Labelling, and Safety for Epoxy ........................................................ 29-29
29.7.17 Storage of Epoxy ................................................................................................ 29-30
29.7.18 Fillers for Mixing Mortars and Grouts .................................................................. 29-30
29.8 Adhesive Bonding Material Systems .......................................................................... 29-30
29.8.1 Certification of Adhesive Bonding Products ........................................................ 29-31
29.8.2 Minimum Performance Requirements for Adhesive Bonding Materials ............... 29-31
29.8.3 Product Identification (Fingerprint) Properties for Adhesive Bonding Materials ... 29-31
29.8.4 Packaging and Marking Adhesive Bonding Materials .......................................... 29-32
29.9 Adhesive-bonded Anchors and Dowels ..................................................................... 29-32
29.9.1 Adhesive-bonded Anchors and Dowels .............................................................. 29-32
29.9.2 Storage of Adhesive-bonded Anchors and Dowels ............................................. 29-32
29.9.3 Equipment for installing Adhesive-bonded Anchors and Dowels ......................... 29-33
29.9.4 Preparing Concrete Members for Adhesive-bonded Anchors and Dowels .......... 29-33
29.9.5 Method of Installing Adhesive-bonded Anchors and Dowels ............................... 29-33
29.9.6 Testing Adhesive-bonded Anchors and Dowels .................................................. 29-33
29.9.6.1 Field Tests for Adhesive-bonded Anchors and Dowels ................................ 29-33
29.9.6.2 Removal and Replacement of Adhesive-bonded Anchors and Dowels that Have
Failed Testing ................................................................................................................ 29-34
29.9.7 Acceptance of Installed Adhesive-bonded Anchors and Dowels ......................... 29-34
29.10 Embedment Anchors ................................................................................................. 29-34
29.10.1 Prequalification for Embedment Anchors ............................................................ 29-34
29.10.2 Materials for Embedment Anchors ...................................................................... 29-35
29.10.3 Construction Methods for Embedment Anchors .................................................. 29-35
29.10.4 Inspection and Testing for Embedment Anchors ................................................. 29-35
29.11 Bridge Deck Wearing Surfaces .................................................................................. 29-36
29.11.1 General Requirements for the Installation of Latex-modified Concrete Type Wearing
Surfaces 29-36
29.11.2 Materials for the Installation of Latex-modified Concrete Wearing Surfaces ........ 29-37
29.11.2.1 Portland Cement .......................................................................................... 29-37
29.11.2.2 Aggregates .................................................................................................. 29-37
29.11.2.3 Water ........................................................................................................... 29-37
29.11.2.4 Latex Emulsion for the Wearing Surfaces .................................................... 29-37
29.11.3 Mix Design of Latex-modified Concrete for Wearing Surfaces ............................ 29-37
29.11.4 Applying Latex-modified Concrete for Wearing Surfaces .................................... 29-38
29.11.4.1 Preparing the Surface .................................................................................. 29-38
Page ii
29.11.4.2 Proportioning and Mixing to Apply the Wearing Surfaces............................. 29-39

29.11.4.3 Installation Procedures for the Wearing Surfaces ........................................ 29-40
29.11.5 Curing Latex-modified Concrete Wearing Surfaces ............................................ 29-41
29.11.6 Testing and Acceptance of Latex-modified Concrete Wearing Surfaces ............. 29-42
29.11.6.1 Compression Strength Test for the Wearing Surfaces ................................. 29-42
29.12 Drip Check Angle ....................................................................................................... 29-42
29.13 Lockable Doors, Access Covers, and Internal Access Walkways .............................. 29-42
29.14 End walls for ducts ..................................................................................................... 29-42
29.14.1 Materials for the Construction of End Walls for Ducts ......................................... 29-43
29.14.2 Construction Methods for End Walls for Ducts .................................................... 29-43
29.15 Scour Protection ........................................................................................................ 29-44
29.15.1 Method Statement .............................................................................................. 29-44
29.15.2 Rock Materials .................................................................................................... 29-45
29.15.2.1 Physical Properties ...................................................................................... 29-45
29.15.2.2 Cracks, Laminations and Other Deficiencies................................................ 29-45
29.15.2.3 Length to Thickness Ratio ........................................................................... 29-45
29.15.2.4 Grading of Rock ........................................................................................... 29-45
29.15.2.5 Quality Control ............................................................................................. 29-46
29.15.3 Placing of Rock Materials ................................................................................... 29-46
29.15.3.1 Transporting and Depositing Rock Materials................................................ 29-46
29.15.3.2 Grading of Armouring to be Maintained ....................................................... 29-46
29.15.3.3 Survey Equipment ....................................................................................... 29-47
29.15.3.4 Construction Survey .................................................................................... 29-47
29.15.3.5 Above Water Survey Technique for Rock Armour ........................................ 29-47
29.15.3.6 Below Water Survey Techniques for Rock Structures .................................. 29-47
29.15.3.7 Presentation of Results ................................................................................ 29-47
29.15.3.8 Tolerances ................................................................................................... 29-47
29.16 Sea Port Authority Works ........................................................................................... 29-48
29.16.1 Navigation beacons ............................................................................................ 29-48
29.16.2 Navigation direction signs ................................................................................... 29-48
Index ...................................................................................................................................... 29-49
Page iii
LIST OF TABLES
Table 29-1: Designations and titles for AASHTO and ASTM standards that apply to miscellaneous
items for structures .................................................................................................................... 29-2
Table 29-2: Designations and titles for BS and BS EN standards that apply to miscellaneous items
for structures .............................................................................................................................. 29-5
Table 29-3: Physical properties of penetrant sealers................................................................ 29-17
Table 29-4: Physical properties of methacrylate resin .............................................................. 29-21
Table 29-5: Types of epoxy compounds .................................................................................. 29-24
Table 29-6: Additional requirements for type E epoxy compounds ........................................... 29-26
Table 29-7: Properties for subtype F-1 compounds.................................................................. 29-26
Table 29-8: Properties for subtype F-2 compounds.................................................................. 29-26
Table 29-9: Requirements for the mix of type G epoxy compounds ......................................... 29-27
Table 29-10: Requirements for the sand epoxy mix of type K compounds ............................... 29-28
Table 29-11: Standard ASTM test methods for epoxy grout plus aggregate mix for type Q epoxy 29-
29
Table 29-12: Gradation requirements for fillers for use with epoxy compounds ........................ 29-30
Table 29-13: Uniform bond stress for adhesive bonding material ............................................. 29-31
Table 29-14: Polymer type stabilizers styrene butadiene ......................................................... 29-37
Table 29-15: Approximate latex-modified concrete mixture proportions ................................... 29-38
Table 29-16: Rock physical properties for scour protection ...................................................... 29-45
Table 29-17: Rock grading(s) ................................................................................................... 29-46
Table 29-18: Rock test requirements for scour protection ........................................................ 29-46
Table 29-19: Rock material tolerances ..................................................................................... 29-47
Page iv
29 MISCELLANEOUS ITEMS FOR STRUCTURES

This chapter outlines standards and requirements that apply to the following work activities and
related miscellaneous structures that are not otherwise covered in these specifications.
1. Removing Existing Bridge Structures
2. General Requirements For Structures Foundations
3. Bridge Drainage Systems
4. Epoxy Injection of Cracks in Concrete Structures
5. Sealing Concrete Surfaces and Cracks
6. Epoxy Compounds
7. Adhesive Bonding Material Systems
8. Adhesive-Bonded Anchors and Dowels
9. Embedment Anchors
10. Bridge Deck Wearing Surfaces
11. Drip Check Angles
12. Lockable Doors, Access Covers, and Internal Access Walkways
13. End Walls for Ducts
14. Scour Protection
15. Sea Port Authority Works
The Contractor shall comply with the specifications in this chapter whenever performing such work
and using such materials for the Project.

Standards and codes for miscellaneous items for structures and related construction works shall be
as specified in this section, in the Contract documents, if any, and the following, in their latest edition:
and Testing;
AASHTO GSH-9 Guide Specifications for Highway Construction, 9th Edition;
ACI 349-06 Code Requirements for Nuclear Safety-Related Concrete Structures and
Commentary;
ADQCC (TR-516) Road Structures Design Manual
ANSI/AWWA AWWA Standard for Ductile-Iron Pipe, Centrifugally Cast;
C151/A21.51-09
ANSI/AWWA AWWA Standard for Coal-Tar Protective Coatings and Linings for Steel
Page 29-1
C203-08 Water Pipelines—Enamel and Tape—Hot Applied;

D1.1/D1.1M:2010
AWWA American Water Works Association;
DIN 8061-8062 Sizes and Description - PVC Pressure Pipes & Fittings
FM 3-C882 Florida Test Method for Performance of Epoxy-Resin Systems with Concrete by
Slant Shear and Compressive Strength;
FM 5-518 Florida Test Method for Wet Bond Strength of Epoxy Mortars to Concrete and
Fiberglass Jacket Surfaces;
FM 5-568 Florida Method of Test for Anchor System Tests for Adhesive-Bonded Anchors
and Dowels;
FM 5-569 Florida Method of Test for Material Properties Identification of Adhesive-bonded
Anchors and Dowels;
FS MMM-A-121 Federal Specification Adhesive, Bonding Vulcanized Synthetic Rubber to Steel
HAP-Free Replacement;
IALA International Association of Marine Aids to Navigation and Lighthouse
Authorities;
NCHRP 244 Condition Evaluation of Concrete Bridges Relative to Reinforcement Corrosion,
Volume 5: Methods of Evaluating the Effectiveness of Penetrating Sealers;
Rock Manual Manual on the Use of Rock in Coastal and Shoreline Engineering,
CIRIA Construction Industry Research and Information Association;
CIRIA-C683 The Rock Manual 2007: The Use of Rock in Hydraulic Engineering;
USACE United States Army Corps of Engineers;
USACE C-200 US Army Corps of Engineers - Guide Specification, Coal Tar Epoxy.
Officials (AASHTO), American Society for Testing and Materials (ASTM), British (BS), and European
(BS EN) Standards that are related to materials for miscellaneous items for structures. It also
miscellaneous items for structures
AASHTO ASTM
TITLE
AASHTO M 105-
Standard Specification for Gray Iron Castings
09
ASTM D3333 - Standard Practice for Sampling Manufactured Staple
07(2012) Fibers, Sliver, or Tow for Testing
Page 29-2
AASHTO ASTM
TITLE
ASTM D2996 - Standard Specification for Filament-Wound "Fiberglass"
01(2007)e1 (Glass-Fiber-Reinforced Thermosetting-Resin) Pipe
ASTM B211 - Standard Specification for Aluminum and Aluminum-
12e1 Alloy Rolled or Cold Finished Bar, Rod, and Wire
ASTM A377 - Standard Index of Specifications for Ductile-Iron
03(2008)e1 Pressure Pipe
ASTM A48 /
Standard Specification for Gray Iron Castings
A48M - 03(2008)
ASTM A183 - Standard Specification for Carbon Steel Track Bolts and
03(2009) Nuts
AASHTO M 306- Standard Specification for Drainage, Sewer, Utility, and
10 Related Castings
AASHTO M ASTM A123 / Standard Specification for Zinc (Hot-Dip Galvanized)
111M/M 111-11 A123M - 12 Coatings on Iron and Steel Products
ASTM A500 /
Seamless Carbon Steel Structural Tubing in Rounds
A500M - 10a
and Shapes
ASTM A536 -
84(2009)
ASTM A780 / Standard Practice for Repair of Damaged and Uncoated
A780M - 09 Areas of Hot-Dip Galvanized Coatings
ASTM D3278 - Standard Test Methods for Flash Point of Liquids by
96(2011) Small Scale Closed-Cup Apparatus
Standard Test Method for Density, Absorption, and
ASTM C642 - 06
Voids in Hardened Concrete
ASTM C672 / Standard Test Method for Scaling Resistance of
C672M - 12 Concrete Surfaces Exposed to Deicing Chemicals
ASTM E274 / Standard Test Method for Skid Resistance of Paved
E274M - 11 Surfaces Using a Full-Scale Tire
Standard Test Method for Density and Relative Density
ASTM D1481 -
(Specific Gravity) of Viscous Materials by Lipkin
02(2007)
Bicapillary Pycnometer
Standard Test Method for Gel Time and Peak
ASTM D2471-99 Exothermic Temperature of Reacting Thermosetting
Resins (Withdrawn 2008)
Page 29-3
AASHTO ASTM
TITLE
ASTM C307 - Standard Test Method for Tensile Strength of Chemical-
03(2012) Resistant Mortar, Grouts, and Monolithic Surfacings
ASTM C882 / Standard Test Method for Bond Strength of Epoxy-
C882M - 12 Resin Systems Used With Concrete By Slant Shear
Test Method for Viscosity of Epoxy Resins and Related
ASTM D2393-86
Components
Standard Test Methods for Compressive Strength of

ASTM C579 -
Chemical-Resistant Mortars, Grouts, Monolithic
01(2012)
Surfacings, and Polymer Concretes
Standard Test Method for Flexural Strength and
ASTM C580 -
Modulus of Elasticity of Chemical-Resistant Mortars,
02(2012)
Grouts, Monolithic Surfacings, and Polymer Concretes
Standard Test Method for Linear Shrinkage and
ASTM C531 - Coefficient of Thermal Expansion of Chemical-Resistant
00(2012) Mortars, Grouts, Monolithic Surfacings, and Polymer
Concretes
ASTM C884 /
Standard Test Method for Thermal Compatibility
C884M -
Between Concrete and an Epoxy-Resin Overlay
98(2010)
ASTM C1339 - Standard Test Method for Flowability and Bearing Area
02(2012) of Chemical-Resistant Polymer Machinery Grouts
ASTM E488 / Standard Test Methods for Strength of Anchors in
E488M - 10 Concrete Elements
ASTM E1512 - Standard Test Methods for Testing Bond Performance
01(2007) of Bonded Anchors
Standard Specification for Fine Aggregate for Hydraulic
AASHTO M 6-08
Cement Concrete
AASHTO M 80- Standard Specification for Coarse Aggregate for
08 Hydraulic Cement Concrete
AASHTO M 43- Standard Classification for Sizes of Aggregate for Road
ASTM D448 - 08
05 (2009) and Bridge Construction
ASTM C31 / Standard Practice for Making and Curing Concrete Test
C31M - 12 Specimens in the Field
Standard Test Method for Resistance to Degradation of
ASTM C131 - 06 Small-Size Coarse Aggregate by Abrasion and Impact in
the Los Angeles Machine
AASHTO T 259- Standard Method of Test for Resistance of Concrete to
2002(R 2006) Chloride Ion Penetration
Page 29-4
AASHTO ASTM
TITLE
AASHTO T 260- Standard Method of Test for Sampling and Testing for
97 (2011) Chloride Ion in Concrete and Concrete Raw Materials
AASHTO T Standard Method of Test for Compressive Strength of
ASTM C 109/C
106M/T 106-12 Hydraulic Cement Mortar (Using 50-mm or 2-in. Cube
109M-11b)
Specimens)
ASTM C403 / Standard Test Method for Time of Setting of Concrete
C403M - 08 Mixtures by Penetration Resistance
Table 29-2: Designations and titles for BS and BS EN standards that apply to miscellaneous
items for structures
BS EN
BS Designation Designation Title
Plastics piping systems for water supply and for buried

BS EN ISO and above-ground drainage and sewerage under
1452-1:2009 pressure. Unplasticized poly(vinyl chloride) (PVC U).
General
BS 812- Testing aggregates. Method for determination of particle
103.1:1985 size distribution. Sieve tests
BS 6349-1:2000 Maritime structures. Code of practice for general criteria
29.2 Removing Existing Bridge Structures

The Contractor shall remove, wholly or in part, all bridges, retaining walls, and other major structures
that are designated to be removed in the Contract documents. Unless the Contract documents
specify otherwise, the Contractor shall also complete any necessary excavation and backfilling of
trenches, holes, or pits that result from such removal. To the satisfaction of the Engineer and Owner,
the Contractor shall also salvage or dispose of materials from such work. The Contractor shall also
bear responsibility for all costs for environmental and health monitoring systems or programs that
the Project requires.
29.2.1 Submissions for the Removal of Structures

The Contractor shall prepare method statement with supporting calculations and working drawings
showing methods and a sequence of removal under the following conditions:
a. When the Contract documents specify that structures or portions of structure are to be
removed and salvaged
b. When removal operations will be performed over or adjacent to public traffic or railroad
property
c. When specified in the Contract documents.
The Contractor shall submit method statement, calculations, and working drawings to the Engineer
for approval at least ten days before 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 responsibility under the Contract documents for the successful completion of the work.
When salvage is required, drawings shall clearly indicate how individual segments of the structure
will be marked to designate them for removal.
Page 29-5
29.2.2 Removal Construction

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 portion of structure designated to be
removed. All concrete and other foundations shall be removed to a depth of at least 600 mm below
ground elevation or 900 mm below the subgrade elevation, whichever is lower. Unless otherwise
specified in the Contract documents, the Contractor has the option to either pull piles or cut them off
at a point not less than 600 mm below ground line. Cavities left after structures are removed shall
be backfilled to the level of the surrounding ground and, if they are within the area of roadway
construction, shall be compacted to meet the requirements of the Contract documents for
embankment.
Explosives 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.
29.2.3 Partial Removal of Structures

When structures are to be widened or modified and only portions of the existing structures are to be
removed, these portions shall be removed in such a manner as to leave the remaining structure
undamaged and in proper condition to fulfil their required purposes. Methods that involve the use of
blasting or wrecking balls shall not be used within any span or pier unless the entire span or pier is
to be removed. Any damage to the portions that remain in service shall be repaired by the Contractor
at the Contractor's expense.
Before beginning concrete removal operations that involve the removal of a portion of a monolithic
concrete element, the Contractor shall make a saw cut approximately 25 mm deep 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. Surfaces that are visible as a result of this removal shall be reasonably
true and even, with sharp, straight corners that permit a neat joint with the new construction or be
satisfactory to fulfil the surfaces’ required purposes. Where existing reinforcing bars will extend from
the existing structure into new construction, the Contractor shall remove the concrete, leaving the
projecting bars clean and undamaged. Where projecting bars will not extend into the new
construction, the Contractor shall cut them off flush with the surface of the old concrete.
During full-depth removal of deck concrete over steel beams or girders that will remain in place, the
Contractor shall be careful not to notch, gouge, or distort the top flanges. The Contractor shall repair
any damage at the direction of the Engineer and at his own expense. Repairs may include grinding,
welding, heat straightening, or member replacement, depending on the location and severity of the
damage.
29.2.4 Removal of Structures for Demolition

If the Contract requires demolition, the Contractor shall remove existing structures and restore the
existing surface in accordance with the Contract documents or as directed by the Engineer.
Before beginning demolition, the Contractor shall coordinate disconnection of utility services with the
appropriate utility owner.
The Contractor shall immediately repair broken or damaged utilities. The Owner shall make no
additional payment to the Contractor for such repair.
29.2.5 Removal of Bridges, Culverts, and Other Existing Structures

Bridges and culverts in use by traffic shall not be removed until alternative arrangements have been
made to accommodate traffic.
When structures are to remain the property of the Owner, the method of dismantling steel
superstructure shall avoid inflecting any damage to the materials. Before dismantling steel members,
the Contractor shall match-marked them in paint and stencils, in accordance with directions from the
Page 29-6
Engineer, to be erected again. Steel members at the original field splices shall be dismantled and
supported on falsework during the operation of dismantling, or in a manner and method that has
been approved by the Engineer.
Without compensation, the Contractor shall replace or satisfactorily repair any damaged steel.
Piers, abutments, and piling shall be cut at the ground line, or in case of channel change, at the
elevation of the channel excavation as shown on the Contract plans.
Salvaged structural steel and other materials shall be stacked on the right-of-way outside of the ditch
line in a neat and workmanlike manner.
Old concrete and other similar materials shall be broken up and placed in the fill as specified for
placing solid rock in fills, or otherwise disposed off as directed by the Engineer.
Where such portions of existing structures lie wholly or in part within the limits of a new structure,
the Contractor shall remove such portions as necessary to accommodate the construction of the
proposed structure.
In no case shall material be left in the channel.
When blasting or other operations that may damage new construction are necessary for the removal
of an existing structure or obstruction, the Contractor shall complete these operations before placing
the new work.
Structures such as piers, abutments, piling, substructures or material in structures shall be removed
and disposed by the Contractor in accordance with the specifications in this chapter.
29.2.6 Salvaging Materials after Removal

Materials that the Contract documents designate for salvage, either for reuse in the Project or for
future use by the Owner, shall remain the property of the Owner. The Contractor shall carefully
remove such materials in transportable sections and stockpile them near the site at a location
designated by the Engineer or deliver them to the place indicated by the Owner. The Contractor shall
restore or replace damaged or destroyed material without additional compensation.
To remove rivets and bolts from steel structures to be salvaged, the Contractor shall cut the heads
with a chisel. Then, the Contractor shall punch or drill the rivets and bolts from the hole, or use any
other method that will not damage the members for reuse and that has the Engineer’s approval.
Before dismantling members or sections of steel structures, the Contractor shall match-marked them
with paint in accordance with the appropriate engineering diagram or a plan that has the Engineer’s
approval.
29.2.7 Removing Abandoned Structures

All abandoned existing structures shall be broken off and removed to a depth of not less than 150
mm below the foundation grade of new structure. When sewer lines, water lines, and similar
structures are to be abandoned, they must be tightly plugged at each end with concrete in the manner
that has been approved by the Engineer.
Manholes and similar structures to be abandoned shall be removed to the depth specified, and shall
be filled and compacted with suitable material. If an abandoned structure to be backfilled will reside
under paving or another structure, the Contractor shall tamp and compact the backfill material in
uniform layers not more than 150 mm thick.
If an abandoned structure is not under paving or other structures, the Contractor may obtain
settlements by thoroughly flushing with water during backfill operations.
Page 29-7
29.2.8 Disposal of Materials after Removal

All material removed and all debris, rubbish or other unsuitable material produced as a result of
demolition shall be disposed of by the Contractor in a dumping area previously approved by the
Competent Authority.
The Contractor shall identify all hazardous materials, properly dispose them, and maintain the
appropriate records.
The Contractor shall conduct his operations in such a manner as to avoid hazards to persons and
vehicles. After work is started on any existing structure, the work on that structure shall be continued
to completion, promptly and expeditiously.
29.3 General Requirements for Structures Foundations

Available soil samples or rock cores obtained during the soil boring operations shall be examined by
the Contractor at the Owner’s approved laboratory.

When the Contract plans require foundation construction operations in close proximity to existing
structures, the Contractor shall take all precautions to prevent damage to such structures.
Requirements described herein apply to all types of roadway structures on or off the Right of Ways
(ROW) that may be adversely affected by foundation construction operations, including phase
construction, vibrations, ground loss, ground heave, or dewatering. Utilities shall be protected, as
described in the applicable provisions and sections of Chapter 11, Utilities, of these Standard
Specifications.
Existing structures shall be monitored for settlement in a manner approved by the Engineer,
recording elevations to an accuracy of 0.3 mm. The Contractor shall monitor the following structures:
a. Structures shown in the Contract plans.
b. Structures within a distance, in metres, of pile-driving operations equal to 0.131 times the
square root of the impact hammer energy, in meter-Newton. Required measurements shall
be taken before the initiation of driving and then daily on days when driving occurs, or as
indicated in the Contract plans, and weekly for two weeks after driving has stopped.
c. Structures within a distance of 10 pile diameters or the estimated depth of excavation,
whichever is greater.
d. Structures within a distance of three times the depth of excavation for the footing.
The Contractor shall obtain the Engineer’s approval of the number and location of monitoring points.
Elevation shall be taken for the following:
1. Before beginning construction;
2. Daily during the driving of any casings, piling, or sheeting;
3. Weekly for two weeks after stopping driving;
4. During excavation;
5. During blasting (if approved); or,
6. As directed by the Engineer.
Any movements detected shall be reported by the Contractor to the Engineer and the Contractor
shall take any remedial measures required to prevent damage to the existing structures.
A qualified specialty engineer shall be employed by the Contractor to survey all structures, or
portions thereof, within the following:
Page 29-8
• A distance, in metres, of pile-driving operations equal to 0.0655 times the square root of the
impact hammer energy, in meter-Newton;
• A distance of 10 pile diameters or the estimated depth of excavation, whichever is greater;
• Three times the excavation depth for footings and caps; or,
• As shown in the Contract plans.
The Owner will assist the Contractor to make the necessary arrangements to provide right-of-way
entry for the Contractor to survey. Structure conditions and all existing cracks shall be adequately
documented with descriptions and pictures by the Contractor, which shall prepare two reports
documenting the condition of the structures: one report before beginning foundation construction
operations and a second report after completing foundation construction operations. The Owner will
take ownership of both reports. Pre- and post-driving surveys of the condition of bridges shall not be
performed by the Contractor, except when shown in the Contract documents or requested by the
Engineer.
When shown in the Contract documents, the Contractor shall employ a qualified specialty engineer
to monitor and record vibration levels during the driving of casings, piling, sheeting, or blasting
operations. Vibration monitoring equipment capable of detecting velocities of 2.5mm/s or less shall
be provided by the Contractor.
Upon detecting settlement or heave of 1.5 mm, vibration levels reaching 12.5 mm/s, levels otherwise
shown in the Contract documents, or damage to the structure, the Contractor shall immediately stop
the source of vibrations, backfill any open pile excavations, and contact the Engineer for instructions.
When the Contract plans require excavations for construction of footings or caps, the Contractor
shall evaluate the need for, design of, and provide for any necessary features to protect adjacent
structures. When sheeting and shoring are not detailed in the Contract plans, the Contractor shall
employ a specialty engineer to design the sheeting and shoring, and to sign and seal the plans and
specification requirements. These designs shall be sent to the Engineer for his approval and record
before beginning construction.
When shown in the Contract documents, or when authorized by the Engineer, the Contractor shall
install the piling to the depth required to minimize the effects of vibrations or ground heave on
adjacent structures by approved methods other than driving, including preformed holes, predrilling,
and jetting. If the Owner authorizes the use of preformed pile holes to meet this requirement, the
Contractor shall carry out the work without extra charge to the Owner.
If not otherwise provided in the Contract plans, the Contractor shall evaluate the need for, design of,
and provide for all reasonable precautionary features to prevent damage, including, but not limited
to, selecting construction methods and procedures that will prevent damaging caving of the pile
excavation and monitoring and controlling the vibrations from construction activities, including driving
of casings, driving of sheeting, and blasting.
When shown in the Contract plans, or directed by the Engineer, the Contractor shall install a
Piezometers near the ROW line and near any structure that may be affected by lowering the
groundwater when dewatering is required. The Contractor shall monitor the Piezometers and record
the groundwater elevation level daily and the Contractor shall notify the Engineer of any groundwater
lowering near the structure of 0.3 m or more.
29.3.2 Excavation
All excavation of the foundations shall be completed by the Contractor prior to installing piles, unless
otherwise authorized by the Engineer. After completing pile installation, the Contractor shall remove
all loose and displaced materials from around the piles, leaving a clean, solid surface. Soil surfaces
on which concrete is to be placed, or which will support the forming system for the concrete to support
the load of the plastic concrete, shall be compacted by the Contractor to avoid settling or causing
the concrete to crack, as shown in the Contract documents. Compaction for excavations made below
Page 29-9
water for seals — or when the footing, cap, or forming systems, including supports — does not rest
on the ground surface shall not be required by the Engineer.
29.3.2.1 Abutment (End Bent) Fill

Fill shall be placed and compacted by the Contractor before installing end-bent piling, except when
the following occurs:
a. Driving specified test piling in end bents; or,
b. When the Contract plans show uncased piles through proprietary retaining wall fills.
When installing piles or casing prior to placing fill, the Contractor shall take necessary precautions
to prevent displacement of piles during placing and compacting fill materials within 4.5 m of the piles
and casing. Positions of the piles and casing shall be referenced and checked by the Contractor at
three approximately equal intervals during construction of the embankment.
Embankment material shall be placed by the Contractor in 150-mm loose lifts in the 4.5-m area
around the piles and casing. The Contractor shall compact embankment material within the 4.5-m
area adjacent to the piles and casing to the required density with compaction equipment weighing
less than 4.448 KN. When installing piles prior to the completion of the surrounding fills, the
Contractor shall not cap them until placing the fills as near to final grade as possible, leaving only
the necessary working room for construction of the caps.
Permanent casings shall be installed by the Contractor prior to placement of the fill, for all drilled
piles through mechanically stabilized fills; for example, behind proprietary retaining walls, for piles
installed after fill placement. Temporary casings shall be installed by the Contractor through the
completed conventional fill when permanent casings are not required.
Permanent casings shall be provided by the Contractor, if required, before the fill is placed extending
a sufficient distance into the existing ground to provide stability to the casings during construction of
the abutment fill.
29.3.3 Cofferdams
Cofferdams shall be constructed by the Contractor as detailed in the Contract plans. When
cofferdams are not detailed in the Contract plans, the Contractor shall employ a specialty engineer
to design cofferdams, and to sign and seal the plans and specification requirements. Designs shall
be sent to the Engineer for its records before beginning construction.
A qualified diver and a safety diver shall be provided by the Contractor to inspect the conditions of
the foundation enclosure or cofferdam when the Contract documents require a seal for construction.
These divers shall be equipped by the Contractor with suitable voice communications, and have
them inspect the foundation enclosure and cofferdam periphery — including each sheeting
indentation and around each piling to ensure that no layers of mud or other undesirable materials
were left above the bottom of seal elevation during the excavation process. The Contractor shall also
have the divers check to make sure the surfaces of the piles are sufficiently clean to allow bond of
the concrete down to the minimum bottom of seal elevation. When required, the Contractor shall
ensure that there are no mounds of stone, shell, or other authorized backfill material left after
placement and grading. To ensure that the seal is placed as specified and evaluate the adequacy of
the foundation soils or rock, the Contractor shall assist the Engineer, as required. Deficiencies found
by the divers shall be corrected by the Contractor. Upon completion of inspection by the divers, the
Owner may also elect to inspect the work before authorizing the Contractor to proceed with
subsequent construction operations. A written report by the divers that indicates the results of their
underwater inspection shall be furnished by the Contractor to the Engineer before requesting
authorization to place the seal concrete.
Page 29-10
29.3.4 Vibrations on Freshly Placed Concrete (Drilled Piles and

Piers)
Until the concrete has attained its final set, as defined by ASTM C403 / C403M - 08, freshly placed
concrete shall not be subjected to vibrations greater than 38 mm/s from pile-driving or drilled-pile
casing installation sources located within the greater dimension of three pile diameters, as measured
from the perimeter of the pile closest to the vibration source; or 9 m from the nearest outside edge
of freshly placed concrete to the vibration source — except as required to remove temporary casings
before the drilled pile elapsed time has expired.
29.4 Bridge Drainage Systems

The Contractor shall construct drainage facilities and accessories to collect and dispose of water
from drains on the bridge structures, in accordance with the details shown in the Contract plans and
the specifications in this section.
Construction of bridge drainage systems shall consist of furnishing and installing drainage facilities,
including drainage inlets and channel grates and frames on bridge deck, subways, and underpasses,
to collect surface water from structures, draining pipes, and down-pipes that are connected to the
drainage inlets and channel grates by hoppers. Such inlets and channel grates and frames may be
of cast iron or cast steel with or without integral cast hoppers. When not using integral cast hoppers,
a bridge drainage system shall have fabricated U-PVC or GRP hoppers as approved by the
Engineer.
This work shall also consist of furnishing and installing concrete gutters, weep holes, drainage
blankets, and geocomposite drainage systems for all earth retaining systems.
The Contractor shall submit, as early as possible, a proposal with details of all drainage material and
components to the Engineer for approval. The Contractor shall not incorporate any material or
component into a bridge drainage system without written approval from the Engineer.
29.4.1 Bridge Drainage Terminology

This section defines core terminology for constructing bridge drainage systems.
Gutter: A channel along the eaves or on the roof that collects and carries away rainwater.
Hopper: Funnel-shaped receptacle through which contents pass, by gravity, into a receptacle
below.
Scupper: An opening for draining water from the bridge deck.
Weep Hole: A small opening that enables water that accumulates behind a retaining wall to drain
away.
29.4.2 Materials for Bridge Drainage Systems

29.4.2.1 Materials Related to Superstructure
This article outlines specifications for materials related to superstructures.
a. Drainage Inlets and Channel Grates and Frames for Superstructures

Drainage inlets and channel grates and frames shall be heavy duty and of the types indicated on the
Contract plans. They shall be class No 25 S or equivalent structural steel or gray cast iron that
conforms to the specifications in AASHTO M 105-09.
Integral cast hoppers shall be of the same grade and quality as the drainage inlet or channel grate
and frame. Fabricated U-PVC or GRP shall conform to the requirements of the Engineer, who may
require material and load testing for such approval.
Page 29-11
b. Fibreglass Pipe for Superstructures

Fibreglass pipe and fittings shall conform to ASTM D2996 - 01(2007)e1 Designation Code RTRP-
11AE-5112. Pipe and fittings with Class C or Class F liners are acceptable. Finish colour for such
pipes shall be concrete gray.
c. PVC and U-PVC Pipes for Superstructures

Pipes of synthetic material for general drainage use shall be polythene, polypropylene, or
polyvinylchloride and shall have the approval of the Engineer. Unplasticized polyvinylchloride pipes
shall be class 2 or 3 pipes that conform to the specifications of ASTM D3333 – 07 (2012). PVC pipes
and sleeves shall comply with DIN 8061-8062. Fittings shall be 10 bars class that comply with BS
EN ISO 1452-1:2009.
d. Aluminium Pipes for Superstructures

Aluminium pipes, sleeves, and fittings shall be alloy 6061-T6 that conforms to ASTM B211 - 12e1.
e. Steel Alloy Pipe for Bridge Storm Drains for Superstructures

Steel alloy pipe and fittings shall be grade B alloy steel that conforms to the chemical analysis of
ASTM A53 / A53M - 12 or ASTM A500 / A500M - 10a. As an alternative, the Contractor may provide
pipes of ductile iron that conforms to ASTM A377 - 03(2008)e1 (ANSI/AWWA C151/A21.51-09), and
as approved by the Engineer. Steel alloy pipe, alternative ductile iron pipe, and fittings shall be zinc-
coated (galvanized) according to ASTM A123 / A123M - 12. The Contractor shall weld steel pipes
and fittings to connect them before galvanizing.
Ductile iron pipe fittings shall be class 30 iron that conforms to ASTM A48 / A48M – 03 (2008). Pipe
bends shall have long radii. Pipe joints shall be formed using groove-type couplings that consist of
a housing clamp keyed into a groove cut around the pipe’s full circumference. A gasket of moulded
or extruded butyl or EPDM (ethylene propylene diene M-class rubber) shall provide a sealed joint.
The Contractor shall use track bolts that conform to ASTM A183 - 03(2009), with oval necks and
heavy hexagon standard nuts. The Contractor shall galvanize such assemblies as described in
Section 23.4.10 of Chapter 23, Steel Structures.
f. Zinc Coating on Steel for Superstructures

Zinc coating (hot-dip galvanizing) applied on iron and steel products shall conform to the
specifications outlined in Section 23.4.10 of Chapter 23, Steel Structures.
g. Castings, Materials, and Components for Drainage Structures

Upon completion, all inlet and manhole castings, grates, extension rings, extension frames, and
covers shall be able to withstand the Abu Dhabi Vehicular Load (ADVL) in accordance to Abu Dhabi
Road Structures Design Manual (AD-D-06). All inlet and manhole castings, grates, extension rings,
extension frames, and covers shall conform to the following requirements:
1. Gray iron castings shall conform to AASHTO M 105-09 and AASHTO M 306-10 for Class
30B and Class 35B and shall be true to pattern in form and dimensions. They shall also be
free from pouring faults, sponginess, cracks, blowholes, and other defects that could diminish
their strength and value for their intended service.
2. Castings shall be sandblasted or otherwise effectively cleaned of scale and sand to present
smooth, clean, and uniform surfaces.
3. Carbon steel extension frames and rings for inlets and manholes shall be galvanized
according to AASHTO M 111M/M 111-11, when specified. Welding of fabricated steel shapes
and structures shall conform to ANSI/AWS D1.1/D1.1M:2010. No punching, drilling, reaming,
welding, or cutting shall be allowed in the field. Without additional compensation, the
Contractor shall repair any damage to the galvanized coatings that occurs during or before
installation.
Page 29-12
4. Structural steel shapes used in the fabrication of drainage structures and components shall
conform to the applicable requirements of Chapter 12, Strom Water Drainage, Chapter 23,
Steel Structures, and Chapter 30, Miscellaneous Metals, of these standard specifications.
5. Ductile iron castings shall be grade 65-45-12 iron or grade 80-55-06 iron that conforms to the
requirements outlined in ASTM A536 - 84(2009).
29.4.2.2 Materials Related to Retaining Systems

This article outlines specifications for materials related to retaining systems.
a. Pipe and Perforated Pipe for Retaining Systems

Pipes, including perforated pipes, shall conform to AASHTO GSH-9, Guide Specifications for
Highway Construction, 9th Edition. Subsections 708, "Concrete, and Plastic Pipe" and 709 "Metal
Pipe" of that guide apply.
b. Filter Fabric for Retaining Systems

Filter fabric shall conform to AASHTO GSH-9, Guide Specifications for Highway Construction, 9th
Edition. Subsection 620, "Filter fabric" applies. Filter fabric shall prevent clogging of the drain and
transmission of fines from the backfill.
c. Permeable Material for Retaining Systems

Permeable material shall meet the specifications outlined in AASHTO GSH-9, Guide Specifications
for Highway Construction, 9th Edition. Subsection 704 (Aggregate for Drainage) applies, unless the
Contract documents or approved working drawings specify otherwise.
d. Geocomposite Drainage Systems

Geocomposite drainage systems shall conform to the requirements specified in the Contract
documents or approved working drawings.
29.4.3 Construction Requirements for Bridge Drainage Systems

Drainage facilities shall be constructed in accordance with the details shown on the Contract
documents, approved working drawings, and the specifications in this chapter.
29.4.3.1 Inlet Frames, Grates, and Scuppers for Bridge Drainage

Systems
Bearing surfaces of frames and grates shall be machined so that the grates have uniform bearing
on frames. They shall be match-marked before being delivered. Inlet frames, grates, and scuppers,
if fabricated from steel, shall be zinc-coated.
29.4.3.2 Steel Alloy Pipe for Bridge Drainage Systems

Areas where galvanizing has been damaged shall be repaired by any of the three methods specified
in ASTM A780 / A780M - 09. In all cases, such repair shall achieve the minimum coating thickness
specified for the item. The Contractor shall obtain approval for the type of threaded concrete inserts
for support brackets and clamps.
29.4.3.3 Fibreglass Pipe and Fittings for Bridge Drainage Systems

The Contractor may use fibreglass pipes and fittings wherever a bridge drainage system design
specifies steel alloy pipes.
Runs of pipe shall be supported at intervals not greater than those recommended by the
manufacturer of the pipe. The Contractor shall avoid installing supports that have point contact or
narrow supporting areas. The Contractor may use standard sling, clamp, and clevis hangers and
Page 29-13
shoe supports that are designed for use with steel pipe. Strap widths for hangers shall be at least 37
mm for pipe with a diameter of 150 mm and at least 50 mm for pipe with a diameter of 300 mm.
Straps shall contact at least 120 degrees of a pipe’s surface. Pipe supported on surfaces with less
than 120 degrees contact shall have a split fibreglass pipe protective sleeve bonded in place with
adhesive.
All fibreglass pipe and fittings shall be pigmented resin throughout the wall. Colour shall be standard
concrete gray or another colour designated in the Contract documents. The Owner shall not accept
painted gel-coat or exterior coating. Fibreglass pipe and fittings shall be handled and installed
according to the manufacturer‘s recommendations.
29.4.3.4 Concrete Gutters for Bridge Drainage Systems

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
outlined in Article 4.3.10.5 of Chapter 4, Concrete Works, of these standard specifications. The
Contractor shall provide outlet working at sags in the profile at the low ends of the gutter and at other
locations indicated in working drawings.
29.4.3.5 Weep Holes for Bridge Drainage Systems

Weep holes, if specified, shall be constructed at the locations shown in the Contract documents or
on the approved working drawings. A minimum of 0.06 cubic metres 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. Such filter fabric shall be bonded to the face panels with adhesive that
conforms to Federal Specification MMM-A-121. Face panels that are to receive filter fabric shall be
dry and thoroughly cleaned of dust and loose material.
29.4.3.6 Drainage Blankets for Bridge Drainage Systems

Drainage blankets that consist of permeable material encapsulated in filter fabric, collector pipes,
outlet pipes, and clean-out pipes shall be constructed as specified in the Contract documents or on
the approved working drawings.
Subgrade to receive filter fabric shall conform to the specified compaction and elevation tolerance
and shall be free of loose or extraneous material and sharp objects that may damage the filter fabric
during installation. Filter fabric shall be stretched, aligned, and placed without wrinkles. Adjacent
borders of the filter fabric shall overlap from 300 mm to 450 mm. Should filter fabric be damaged,
the Contractor shall repair any torn or punctured section by placing a piece of filter fabric that is large
enough to cover the damaged area and to meet the overlap requirement.
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 that is adjacent to permeable material shall not be permitted. When
spreading and compacting permeable material and structural backfill or embankment material, the
Contractor shall maintain at least 150 mm of such material between the filter fabric and the
Contractor's equipment.
A perforated collector pipe shall be placed within the permeable material at the designated flow line
elevations.
The Contractor shall place outlet pipes at sags in the flow line, at the low end of the collector pipe,
and at other locations shown or specified in the Contract documents. Rock slope protection, when
required at the end of outlet pipes, shall conform to the details in the Contract documents or approved
working drawings and the applicable requirements outlined in Section 7.4 of Chapter 7, Incidental
construction, and Chapter 12, Storm Water Drainage, of these standard specifications.
Page 29-14
Clean-out pipes shall be placed at the high ends of collector pipes and at other locations as specified
29.4.3.7 Geocomposite Drainage Systems

The Contractor shall install geocomposite drainage systems at the locations shown in the Contract
documents or on approved working drawings. 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 placing concrete against geocomposite drainage materials, the Contractor shall
protect such drainage material against physical damage and grout leakage.
29.5 Resin Injection of Cracks in Concrete Structures

Resin types such as epoxy, polyurethane, acrylic, etc., as appropriate, shall be used when injecting
cracks in concrete structures. When injecting resins into cracks in Portland cement concrete or
pozzolanic concrete, the Contractor shall comply with the specifications outlined in this section. The
epoxy resin injection system shall be used for dry, wet and damp cracks. In general epoxy resins
shall be used only for dry cracks whereas polyurethane and acrylic resins shall be used for wet
(producing flowing water) and damp cracks. The Contractor shall procure the services of a qualified
and specialized company to carry out resin injection works.
29.5.1 Materials for Resin Injections

In addition to complying with the requirements outlined in Section 29.7, the Contractor’s specialized
applicator shall adhere to the following directions when using epoxy injection for dry cracks:
• Use Type E compound epoxy for injection.
• Use Type F-1 compound epoxy for sealing crack surfaces in preparation for injection.
• Use epoxy materials as approved by the Engineer.
When using polyurethane and/or acrylic resin injection for wet and/or damp cracks, the Contractor’s
specialized applicator shall strictly adhere to the guidelines and recommendations of the resin
manufacturer.
29.5.2 Equipment for Resin Injections

For the equipment used to inject the resins, the Contractor shall comply with the recommendations
of the resin injection material’s manufacturer and shall adhere to the following directions:
a. Use equipment that has the capacity to automatically proportion the material components
within the mix ratio tolerances set by the resin materials’ manufacturer.
b. Use equipment that has the capacity to automatically mix a resin’s component materials
within the pump and injection apparatus. No batch mixing shall be allowed unless approved
by the Engineer in writing.
c. Use equipment that has the capacity to inject resin under controlled variable pressures up to
1.4 MPa, with a pressure gauge mounted at or near the nozzle to indicate actual working
pressure.
29.5.3 Qualifications for Resin Injection Personnel

The Contractor shall employ personnel with training and experience in injecting resins into cracks in
concrete in ways that are similar to that required for the Project. The Contractor shall provide an on-
site supervisor for the resin injection work. This supervisor shall have one of the following
qualifications methods:
Page 29-15
a. Supervisor shall have been certified by the manufacturer of the resin injection material as
having the necessary competence to satisfactorily and safely accomplish the resin injection
work in compliance with the specifications in this chapter.
b. Supervisor can furnish documented evidence that he has a minimum of three years of
experience performing on-site supervision of resin injection work similar to that required for
the Project and a list of five contracts who can attest to the supervisor’s acceptable
completion of relevant resin injection work. The Contractor shall ensure that the listed
experience in on-site supervision and completed contracts contains the project name and
location, names of contracting parties, the Owner’s name, brief description of the work, and
dates on which resin injection work was completed.
The Contractor shall furnish written evidence that verifies personnel training and the on-site
supervisor’s qualifications to the Owner before beginning any resin injection work.
29.5.4 Cracked Surface Preparation and Cleaning

The Contractor shall clean areas surrounding cracks of all deteriorated concrete, efflorescence, and
other contaminants that are detrimental to the adhesion of the surface sealing epoxy compound. The
Contractor shall clean the interiors of the cracks with air under sufficient pressure to remove loose
materials, including efflorescence, that are entrapped in cracks.
29.5.5 Sealing Cracks for Resin Injection

After cleaning, the Contractor shall drill injection port holes using a swivel drill chuck and hollow drill
bits. They shall also use a vacuum attachment to remove dust and debris that were generated during
drilling. The Contractor shall determine the spacing of the injection port holes by the size of the crack
and the depth of the crack in the concrete substrate. Generally, injection ports shall be spaced from
100 mm to 200 mm apart. The Contractor shall conduct field trials to determine the actual spacing
of injection ports. For dry cracks, the Contractor shall drill the holes to a minimum depth of 16 mm,
being careful to align the hole along the plane of the crack so that the hole follows the crack for the
full 16 mm depth. For wet/damp cracks, the Contractor shall drill the holes to a minimum depth equal
to one-half the thickness of the concrete element into which resin injection will be applied to ensure
that the entire crack is filled with resin.
The Contractor shall insert injection ports in the drilled holes to an appropriate depth, allowing for a
small reservoir below the injection port.
After cleaning cracks and drilling injection port holes, the Contractor shall seal the crack surface and
the injection ports with suitable epoxy mortar.
29.5.6 Resin Injection

The Contractor shall inject resin in accordance with the resin manufacturer’s instructions. The
Contractor shall conduct field trials to determine the actual injection procedures and pressures,
based on crack widths, crack depths into the substrate and the sufficiency of the results.
29.5.7 Cleaning after Resin Injection

After completing resin injection work, the Contractor shall clean concrete surface areas of excess
resin materials and injection ports. When cleaning after injecting resin, the Contractor shall not
damage the concrete by scraping, light sand blasting, grinding, using solvents, or applying any other
cleaning method. The Contractor shall apply only cleaning methods that have been approved by the
Engineer. Excess materials shall be cleaned so that no resin material or injection ports extend
beyond the plane surface of the concrete.
29.5.8 Acceptance of Resin Injection

The Contractor shall drill three cores located in each day’s work as directed by the Engineer. The
Contractor shall take drilled core samples that contain representative crack sizes. The Engineer will
Page 29-16
accept the resin injection work represented by the core samples when the core samples indicate that
90% of the crack void greater than 0.15 mm wide has been filled with resin and the concrete of the
core sample is bonded through the crack into a unit.
When resin injection work does not satisfy the acceptance criteria, the Contractor shall perform the
work again and correct it as necessary at no expense to the Owner. The Contractor shall install
additional injection ports, as required, to achieve satisfactory reinjection of resin.
After resin injection work is completed and accepted, the Contractor shall fill the core holes with a
suitable proprietary epoxy mortar as approved by the Engineer.
29.6 Sealing Concrete Surfaces and Cracks

All exposed concrete surfaces for structures indicated on the Contract plans not to be painted or
waterproofed shall be sealed by the Contractor using materials, surface preparation, and application
of penetrant sealers and high molecular weight mathacrylates as applicable, as specified in this
section, and in accordance with each material manufacturer’s recommendations. The Contractor
shall consult with the Engineer in the event of conflict between a manufacturer’s recommendations
and this specification. The Contractor shall perform surface preparation and application for all areas
as shown in the Contract plans or in accordance with the Engineer’s directions.
29.6.1 Penetrant Sealers

Penetrant sealers shall meet the requirements outlined in this section.
29.6.1.1 Materials for Penetrant Sealers

The Contractor shall use alkylalkoxysilane penetrant sealers with 40% solids and active materials
dispersed in water. Such sealers shall meet the requirements shown in Table 29-3.
Table 29-3: Physical properties of penetrant sealers
Property Characteristic
Appearance Clear
VOC content (EPA method 24) Less than 350 g/l
Flash point (ASTM D3278 - 96(2011)) Greater than 93o C SETA
Resistance to chloride ion penetration AASHTO T 259- Less than 0.18 kg/m3 (criteria of 1.5)
2002(R 2006) and AASHTO T 260-97 (2011) at 12.5 mm level; 0.00 kg/m3 (criteria
of 0.75) at 25 mm level
0.50% maximum / 48 hours;
Water absorption test (ASTM C642 - 06)
1.5% maximum / 50 days
NCHRP 244
Water weight gain 85% reduction (minimum)

Absorbed chloride 95% reduction (minimum)
Scaling resistance test (ASTM C672 / C672M - 12) (Non-air-entrained concrete) 0 rating
No scaling (100 cycles)
Page 29-17
29.6.1.2 Surface Preparation for Penetrant Sealers

The Contractor shall prepare concrete surfaces to receive a penetrant sealer in accordance with
these specifications, dependent on whether the surfaces are of recently cast concrete (new
construction) or of existing concrete.
a. Surface Preparation for New Construction

The Contractor shall remove substances such as dust, grime, dirt, curing compounds, form oil, and
debris by water blasting, light sandblasting, wire brushing, or any other methods that are acceptable
to the Engineer, all in accordance with the penetrant sealer manufacturer’s recommendations. As a
final cleaning operation, when using cleaning methods other than water blasting, the Contractor shall
wash cleaned surfaces with water as described in Section 4.3.8 of Chapter 4, Concrete Works, of
b. Surface Preparation for Existing Concrete

The Contractor shall remove substances such as dust, grime, dirt, stains, mineral deposits, oil,
bituminous materials, debris, and all other deleterious material by using water blasting equipment of
sufficient operating capacity and pressure, all in accordance with the penetrant sealer manufacturer’s
recommendations.
c. Cleaning Equipment for Penetrant Sealer

The Contractor shall use approved water blasting equipment to clean existing concrete surfaces.
The Contractor shall use water blasting equipment that is specifically manufactured to clean concrete
surfaces. Such equipment shall have a minimum rated nozzle capacity of 41.5 MPa using the spray
head proposed for use in the work.
d. Water for Blasting to Prepare for Penetrant Sealer

The Contractor shall use water that meets the requirements outlined in Section 4.3.8 of Chapter 4,
Concrete Works, of these standard specifications.
e. Method for Cleaning Concrete Surface for Penetrant Sealer

During the cleaning operation, the Contractor shall be sufficiently careful to minimize the removal of
the concrete matrix. The Contractor shall furnish hand tools, power grinders, and other similar
equipment to remove materials that cannot be removed by water blasting without abrading the
concrete matrix beyond acceptable limits. As a final cleaning step, the Contractor shall use water
blasting equipment to wash all concrete surfaces that have been cleaned by other methods.
The Contractor shall limit the duration of water blasting to provide a light abraded surface. The
Contractor shall not allow surface abrasion to exceed 0.4 mm. The Engineer may not require further
cleaning of stains that are still apparent after abrading to a depth of 0.4 mm. The Contractor shall
avoid exposing coarse aggregate to water blasting.
If any concrete surfaces become contaminated after cleaning, the Contractor shall clean them again
at no expense to the Owner before applying the penetrant sealer.
29.6.1.3 Application of Penetrant Sealers

The Contractor shall apply a penetrant sealer only to surfaces that have been prepared in
accordance with these specifications and in a way that has been approved by the Engineer. When
applying penetrant sealer, the Contractor shall comply with the specifications in this article and the
penetrant sealer manufacturer’s recommendations.
Before applying any penetrant sealer, the Contractor shall cure concrete for at least 21 days.
Page 29-18
The Contractor shall apply penetrant sealer no later than ten days after completing the surface
preparation, in a way determined by the Engineer, before any contamination of the prepared
surfaces.
a. Equipment for the Application of Penetrant Sealer

The Contractor shall apply the penetrant sealer using any suitable air or airless sprayer with an
operating pressure of approximately 0.14 MPa.
b. Limitations to the Application of Penetrant Sealer

The Contractor shall apply penetrant sealer material only when the ambient air temperature is
between 10º C and 32º C. The Contractor shall apply penetrant sealer only to concrete surfaces that
have dried for at least 48 hours after water last contacted the concrete surfaces. A penetrant sealer
shall not be applied when winds are blowing 40 km/h or more, during rainfall, or when water spray
or mist is present.
c. Method for Applying Penetrant Sealers

The Contractor shall apply penetrant sealer only to concrete surfaces that have been prepared in
accordance with the requirements and limitations set forth in the specifications of Article 29.6.1.3.
To determine the actual coverage rate in square metres per gallon, the Contractor shall conduct a
field trial at the beginning of any penetrant sealer application operation. The Contractor shall conduct
additional confirmation field trials once for every 465 square metres of sealant applied, on each
production day during the application process, or when the character of the work changes, whichever
occurs sooner. For each field trial, the Contractor shall determine the optimum coverage rate for 46.5
square metres of surface area. The Contractor shall maintain a rate of application that ensures
coverage of from 14.4 to 20.9 square metres per gallon of penetrant sealer used. Application of
penetrant sealer shall be uniform, without puddling or skips. The Contractor shall use a squeegee to
redistribute any penetrant sealer that, after application, puddles in low areas over concrete surfaces.
Generally, the Contractor shall begin applying penetrant at the lowest elevation and proceed upward
to higher elevations.
The Contractor shall maintain operating pressures in the sprayers used for application of the
penetrant sealer material sufficiently low to prevent atomization or misting of the material.
29.6.1.4 Control of Concrete Sealing Materials

The Contractor shall control sealing materials in accordance with the specifications and requirements
outlined in this article.
a. Packaging and Identification of Concrete Sealing Materials

The Contractor shall deliver the penetrant sealer to the Project in unopened, sealed containers with
the manufacturer’s label identifying the product and with numbered seals intact. The Contractor shall
ensure that each container is clearly marked by the manufacturer with the following information:
• Manufacturer’s name and address
• Product name
• Expiration date
• Lot identification number
• Container serial number
Page 29-19
b. Manufacturer’s Certification for Penetrant Sealer

The Contractor shall give the Engineer a certification from the manufacturer that confirms that the
penetrant sealer meets the requirements outlined in Article 29.6.1.4. The Contractor shall not
incorporate sealer into the Project until the Engineer has accepted and approved the certification for
the material. The Contractor shall submit such certification for each lot of material delivered to the
Project. In each certification, the Contractor shall identify the serial or lot numbers of the containers
certified.
c. Sampling Sealing Materials for Tests

The Engineer may require samples from each lot or container of materials delivered to the Project
or from containers at the point of use. When samples are required, the Contractor shall furnish
samples in accordance with the Engineer’s instructions.
d. Storage of Sealing Materials

The Contactor shall store materials delivered to the job site in original unopened containers within
an appropriate storage facility. The Contractor shall use a storage facility that provides protection
from the elements and safe and secure storage of the materials.
e. Disposal of Unused Sealing Materials

The Contractor shall not return unused material in opened containers to storage for later use. The
Contractor shall either apply such material to appropriate areas on concrete surfaces or remove and
dispose of it at offsite locations that have been provided by the Contractor.
f. Acceptance of Sealing Materials

The Engineer shall accept an application of penetrant sealer after determining that the Contractor
has properly cleaned all surface areas to be sealed and has applied the penetrant sealer within the
required rates of application.
29.6.2 High Molecular Weight Methacrylate Sealers

The Contractor shall perform the surface preparation and application of a high molecular weight
methacrylate (HMWM) to seal cracks on horizontal and slightly sloped concrete surfaces in a manner
approved by the Engineer. Applications on bridge decks and other concrete roadway surfaces
require the addition of sand over the treated areas to increase the friction (skid) number, as described
in ASTM E274 / E274M - 11.
The Engineer must approve the rate of application (amount of sealant in cubic metres per square
metre of concrete), the application method, and equipment before the Contractor shall commence
working. The Contractor shall submit a written sealer application plan based on the total area of
cracked surfaces, size and depth of cracks, and internal conditions of cracks to the Engineer for
approval. In addition, the Contractor shall provide at least 14 days advanced notice to enable
personnel from the Owner to be present at the beginning of work to evaluate the cracks and provide
final approval of the application rate. The Contractor shall make arrangements with the material
manufacturer to provide on-site technical assistance for the initial application and to certify that the
mixing ratio, application methods, and sand broadcasting are correct and in accordance with their
recommendations.
The Contractor shall maintain a daily log of resin material used, which shall be verified by the
Engineer. In this log, the Contractor shall include the drum or container identification number, the
date, and the location of use. The Contractor shall retain the empty resin containers at the jobsite
until the Engineer verifies the use of the resin and authorizes removal of the containers from the site.
29.6.2.1 Materials for a Methacrylate System

A methacrylate system shall consist of the following three components:
Page 29-20
• Methacrylate monomer
• Cumene hydroperoxide (CHP) initiator
• Cobalt promoter
The Contractor shall use an HMWM monomer that has been approved by the Engineer. The
Contractor shall use an initiator and promoter that have been recommended and produced by the
same monomer manufacturer. The manufacturer shall submit the following documentation for the
Engineer’s approval:
• Manufacturer’s material installation instructions showing that the product can be installed in
accordance with the requirements in this article.
• Independent laboratory test data and results showing that the product has been tested in
accordance with the requirements of this article and meets the requirements.
a. Properties of Methacrylate Material

The Contractor shall use a methacrylate material that meets the physical and performance
requirements outlined in Table 29-4 .
Table 29-4: Physical properties of methacrylate resin
Viscosity (Brookfield RVT) 14-20 cps at 50 rpm
Density (ASTM D1481 - 02(2007)) 1,018 – 1,078 kg/m3 at 25o C
Flash point (ASTM D3278 - 96(2011)) > 93o C (Pensky Martens CC)
Odour Low
Bulk cure speed 3 hours at 23o C (maximum)
Surface cure 8 hours at 23o C (maximum)
Gel Time (ASTM D2471-99) 60 minutes (maximum)
Tack free time 5 hours (maximum) at 22o C and
50% relative humidity
Compressive strength (AASHTO T 106M/T 106-12) 45 MPa (minimum)
Tensile Strength (ASTM C307 - 03(2012)) 9.0 MPa (minimum)
Shear bond adhesion (ASTM C882 / C882M - 12) 4.5 MPa (minimum)
Wax content 0%
All three components of the methacrylate system shall have a shelf life of at least 12 months and
shall be no more than 8 months old at the time of application. The Contractor shall provide each
container shipped to the job site with the following information on a manufacturer’s label:
• manufacturer’s name
• product name
• lot or batch number
• date of production
• drum serial number
Page 29-21
The Contractor shall identify the catalysts by their generic classification and provide the date of
manufacture for each.
b. Sand for a Methacrylate System

The Contractor shall use uniformly graded 0.2 - 0.6 mm (or similar), clean, bagged, blast sand for
spreading over the applied material on bridge decks and other riding surfaces as recommended by
the manufacturer. They shall certify that the sand has a maximum moisture content of 0.25% or less
and that the maximum amount of dust or other material that may pass through a No. 200 sieve does
not exceed 0.75%.
The Contractor shall store the sand at a location that will preserve the above described conditions
and characteristics of the sand until it has been applied.
29.6.2.2 Surface Preparation for a Methacrylate System

Preparing a surface for a methacrylate system requires cleaning and containment.
a. Cleaning a Surface for a Methacrylate System

On the day of application, the Contractor shall thoroughly power sweep the area to be treated to
remove all dust, dirt, and debris. On bridge decks and other riding surfaces, the Contractor shall use
a tractor-mounted power broom with non-metallic bristles (or a suitable alternative tool) that is
suitable for the intended purpose. The Contractor shall use a power vacuum after sweeping when
sealing cracks on grooved bridge decks. The Contractor shall clean the deck again as necessary
just before the application to remove debris that may have been blown back onto the work area by
adjacent traffic or other means. If oils and oil-based substances are present, the Contractor shall
remove them from the concrete surface using an approved solvent.
b. Containing Sealing Material for a Methacrylate System

The Contractor shall provide adequate containment to prevent the sealer material from flowing
beyond the designated area of application. The Contractor shall plug any drain holes or openings
within the work area. Airborne material shall be prevented from dispersing onto open traffic lanes or
outside the work area.
29.6.2.3 Method for Applying Methacrylate

When applying methacrylate, the Contractor shall comply with the standards and requirements
outlined in this article.
a. Equipment for Applying Methacrylate

The Contractor shall apply the material according to the manufacturer’s specifications using mobile
equipment capable of distributing material on large areas of decks and riding surfaces. Such material
shall be applied by hand using adequate containers for isolated or localized applications.
b. Mixing Methyl Methacrylate

The Contractor shall mix the methylmethacrylate material following the manufacturer’s specified
mixing proportions for the catalysts. Initial mixing shall be performed by equally dividing the resin to
be used into two separate containers. In all instances, the Contractor shall mix the initiator (CHP) at
the HMWM manufacturer’s specified volume with 50% of the monomer resin in one container and
the cumene promoter at the HMWM manufacturer’s specified volume with the other 50% in the
second container. After properly blending the monomer resin and cumene promoter, the Contractor
shall combine the two resins and mix them in accordance with the manufacturer’s instructions. For
spray bar application, the Contractor shall mix the activator and resin blend and the promoter and
resin blend through a static mixer in the feed line that is located ahead of the material distribution
bars where polymerization will start. The Contractor shall calibrate the valves to the static mixer to
ensure a one to one mixing ratio of the two blends.
Page 29-22
c. Mobile Distribution Method for Material Application

The Contractor shall apply the material only under weather conditions recommended by the
manufacturer and when no rainfall has occurred during the previous 48 hours and no rain is expected
for the next 6 hours following completion of the application. Unless the Engineer directs otherwise,
the Contractor shall distribute the monomer uniformly over the work area using a pressure nozzle or
spray head distribution bar system. The Contractor shall provide feed to the distribution bars using
positive displacement pumps that move equal amounts of the two monomer blends from two
calibrated drums.
Material application equipment shall be calibrated to mix the two monomer blends to the
recommended ratio (by volume) within ±5%. The Contractor shall calibrate discharge volume to the
moving speed to provide a discharge rate capability ranging from 1,230 to 4,900 m2/m3 at a pressure
ranging from 0.10 to 0.41 MPa.
A typical application rate of the material is approximately 2,450 m2/m3. Before the Contractor applies
the monomer, the Engineer will determine the final production application rate based on the internal
characteristics of the cracks as determined from the cores that the Contractor supplied that the
Engineer approves as being representative of the overall cracking conditions.
d. Localized Distribution Method for Material Application

In localized small areas or areas where the Engineer considers the use of mobile distribution
equipment to be impractical, the Contractor shall distribute the material by hand over the work area
using pails or other suitable containers that are adequate for the size of the area. In areas that the
Engineer deems to be sufficiently large, the Contractor shall use mobile distribution equipment.
The Contractor shall apply the material only under weather conditions recommended by the
manufacturer and only on areas that have remained dry for at least 48 hours. The Contractor shall
ensure that the area remains dry for the next 6 hours following completion of the application.
e. Sealing of Cracks
Regardless of the method used to apply the material over a concrete surface, the Contractor shall
work the material back and forth over the cracks to maximize the amount of material to be absorbed
by the cracks. The Contractor shall move the material over the cracks using brooms, squeegees, or
paint brushes, as appropriate for the size of the area. The Contractor shall commence this operation
immediately after distributing the material on the concrete surface. This operation shall be continued
until no additional material is flowing inside the cracks or the material begins to exhibit signs of
polymerization.
The Contractor shall not distribute material over areas larger than what the available personnel can
effectively work over the cracks within the limits of the pot life.
f. Sand Distribution after Material Application

The Contractor shall apply sand over the monomer-treated area within a timely period after the
application of the material. This length of time shall be based on the manufacturer’s
recommendations for the existing conditions. The Contractor shall use equipment that will produce
a uniform distribution of the sand over the treated area. Any wheel-mounted sand spreader used
shall have pneumatic tires that are compatible with the treatment material and that leave no tire
footprints on the deck surface.
The Contractor shall use an initial application rate of 3.25 (±0.027) kg of sand per square meter of
treated area, and adjust the rate as necessary to produce a skid number (SN) of no less than 25 at
24 hours and 30 at 7 days as described in ASTM E274 / E274M - 11. The Contractor shall coordinate
with the Engineer to conduct a preliminary on-site skid test to determine the actual sand application
rate prior to the beginning of production application. If friction numbers below those specified are
obtained, the Contractor shall completely remove all loose sand from the surface and apply the
material again at a rate of 3,680 m2/ m3, spreading additional sand as necessary to achieve the
Page 29-23
specified skid numbers. The Contractor shall remove surface material by grinding or other approved
method if satisfactory friction values are not achieved. In accordance with the Engineer’s directions,
the Contractor shall conduct friction tests.
29.6.2.4 Opening Roadway Surfaces to Traffic

The Contractor shall protect the sand covered area from vehicular traffic until the material has fully
cured. When curing is complete, the Contractor shall use a power vacuum to remove excess sand
from the riding surface before opening the area to traffic.
29.6.2.5 Cure Test

The Contractor shall test curing on the treated area using a cotton strand or cotton ball. The
Contractor shall consider the material fully cured and ready for traffic when the material does not
adhere to the cotton ball when pressed against the treated surface and then pulled away. Before
reopening the area to traffic, the Contractor shall obtain approval from the Engineer.
29.7 Epoxy Compounds

When using epoxy compounds, the Contractor shall comply with the standards and requirements
29.7.1 Types of Epoxy Compounds

Epoxy resin compounds for the application to Portland cement concrete, bituminous cement
concrete, metals, and other type surfaces shall be two component systems of applicable types, as
designated in Table 29-5.
Table 29-5: Types of epoxy compounds
Type Description
A An epoxy resin, for bonding fresh concrete to hardened concrete.
B An epoxy resin adhesive, for bonding hardened concrete to hardened
concrete and constructing doweled splices in precast prestressed concrete
piles.
E A fluid epoxy for crack injection in the repair of old structures.
F An epoxy for repairing spalled areas on concrete bridge structures with

these subtypes:
F-1 • A non sagging gel type for vertical surfaces.
F-2 • A pourable type for repairs where forms are to be used.
G An epoxy for rebuilding expansion joints and associated wearing surfaces.

H An epoxy for structural bonding where asphalt overlays are to be in
contact with the hardened compound.
I An epoxy for filling small holes in concrete such as lifting bolt cut-outs on
beams, etc.
J An epoxy for installing rebar and anchor bolts into hardened concrete.
K An epoxy for underwater sealing of the bottom of the jacket of an integral
pile jacket system.
L An epoxy for coating the interior of sewage disposal tanks.
Page 29-24
Type Description
M A coal tar epoxy coating for steel sheet piles and H piles (water
immersion).
N An epoxy for preparing mortars and concrete for patching Portland cement
concrete pavement.
P An epoxy for bonding metals.
Q An epoxy for use in post tensioning anchorage protection systems.
T Hot applied coal tar epoxy tape.
29.7.2 Epoxy Design Requirements

All types of compounds, except L and M, shall contain no volatile solvent.
All types of compounds, except F, J, L, M, and N, shall be basically pure reactive material with a
maximum ash content of 2%.
All types of compounds shall have simple mix ratios of one-to-one or two-to-one or shall be supplied
in pre-measured containers in which all of the contents of both packages are to be mixed.
Epoxy design terms have the following meanings:
Low modulus: A stress-strain property for which ultimate tensile strength is attained at over
10% elongation.
High modulus: A stress-strain property for which ultimate tensile strength is attained at under
6% elongation.
Non-sagging gel: Grades of mixed compounds that will not perceptibly flow under their own
weight on a vertical surface in their unhardened state.
Pourable: Grades of mixed compound that are sufficiently fluid that they (either neat or
filled) can be cast into a mould and will take the shape of that mould.
29.7.2.1 Certifications for Epoxy Products

The Contractor shall give the Engineer certification documents from the manufacturer of the epoxy
confirming that the epoxy meets the requirements outlined in Section 29.7.2. Each such certification
shall cover one batch of epoxy materials and shall conform to the specifications in Section 29.7.
29.7.3 Specific Requirements for Type A and Type B Epoxy

Compounds
Type A and type B epoxy compounds shall comply with the requirements outlined in this section.
29.7.3.1 Mixing and Applying Type A and Type B Epoxy Compounds

Types A and B epoxy compounds (for bonding fresh concrete to hardened concrete or bonding
precast concrete parts) shall be mixed, applied, and cured in accordance with the manufacturer’s
directions, or as might be directed otherwise by the Engineer.
Epoxy compounds shall be used only under conditions that are compatible with the material being
applied and in accordance with the specific directions of their manufacturers. Extreme care shall be
taken to avoid a de-bonding effect after the application.
Page 29-25
29.7.3.2 Performance Tests for type A and type B Epoxy Compounds

The Contractor shall test type A and type B epoxy compounds in accordance with the specifications
in this article.
• Epoxy Bonding Compounds shall be prepared and tested in accordance with FM 3-C882 to
ensure that the ratio of the compressive strength of the composite cylinder to the compressive
strength of the weaker concrete is not be less than 0.90.
• Epoxy mortar shall be prepared and tested in accordance with FM 3 C-882 to ensure that the
average compressive strength of the three test specimens is at least 34.5 MPa.
29.7.4 Specific Requirements for Type E Epoxy Compounds

In addition to the specifications for type B compounds, type E epoxies (which are used for crack
injection) shall also comply with the requirements shown in Table 29-6. The epoxy resin compound
shall be used only for dry cracks.
Table 29-6: Additional requirements for type E epoxy compounds
Viscosity five minutes after mixing 300 to 600 cps at 25o C by ASTM D2393-86
Wet bond strength to concrete (minimum) 1.72 MPa at seven days by FM 5-518
29.7.5 Specific Requirements for Type F Epoxy Compounds

Type F epoxies (which are for repairing spalled areas) shall meet the requirements in this section.
For repairs to surfaces, including vertical surfaces, subtype F-1 epoxy shall be a trowellable, low
modulus, non-sagging gel epoxy compound that can bond to wet surfaces with the properties shown
in Table 29-7.
Table 29-7: Properties for subtype F-1 compounds
Colour Match gray in accordance with instructions from the
Engineer
Viscosity Gel
Maximum sand loading 2.25 parts sand to one part mixed epoxy by volume
Elongation in tension (minimum) 10% by ASTM D638 - 10, seven day cure
Wet bond to steel and concrete (minimum) 1.72 MPa by FM 5-518
For filling larger spalls where a form is required to build back to the original surface, subtype F-2
shall be a pourable, low modulus compound that can bond to wet surfaces with the properties shown
in Table 29-8.
Table 29-8: Properties for subtype F-2 compounds
Colour Match gray in accordance with instructions from the
Engineer
Maximum sand loading 2.25 parts sand to one part mixed epoxy by volume
Page 29-26
Elongation in tension (minimum) 10% by ASTM D638 - 10, seven day cure
Exotherm 43o C by ASTM D2471-99, one pint sample
Wet bond to steel and concrete (minimum) 1.72 MPa by FM 5-518
29.7.6 Specific Requirements for Type G Epoxy Compounds

Type G epoxies (which are for rebuilding expansion joints) shall be pourable epoxies that can mix
with sand and meet the requirements shown in Table 29-9.
Table 29-9: Requirements for the mix of type G epoxy compounds
Compressive strength Characteristic

At 24 hours (minimum) 31.03 MPa
At seven days (minimum, by the method
51.71 MPa
outlined in Article 29.7.3.2)
Bond to wet concrete at seven days (by
1.72 MPa
FM 5-518)
Maximum sand loading 2.25 parts to one part mixed epoxy by volume
Elongation in tension at seven days
2%
(minimum, based on ASTM D638 - 10)
Colour Natural
Exotherm (maximum, by test method
43o C
ASTM D2471-99, one pint size)
29.7.7 Specific Requirements for Type H Epoxy Compounds

Type H epoxies (which are for structural bonding where bituminous pavement overlays will come in
contact with the hardened compound) shall meet the requirements for type A and type B compounds.
In addition, the manufacturer shall provide test data that shows that cutback and emulsified asphalts,
asphalt cement, and bituminous mixes shall bond to but not soften or otherwise damage the epoxy
after a curing period of four days.
29.7.8 Specific Requirements for Type I Epoxy Compounds

Type I epoxies (which are for cosmetic patching of small areas on new concrete structures and
components) shall be of any non-sagging grade that has a gray colour, as selected by the Engineer,
and that has been demonstrated to the Engineer to bond satisfactorily to the concrete.
29.7.9 Specific Requirements for Type J Epoxy Compounds

Type J epoxies (which are for installing rebar and anchor bolts into the hardened concrete) shall
meet the requirements of Section 29.8 and shall be installed in accordance with the directions in
Section 29.9. When the Contract documents call for the use of Type J, Class I, II, III, IV, epoxy or a
Class IV Adhesive Anchor System, the Contractor shall use materials that meet the requirements of
Section 29.8, constructed in accordance with Section 29.9.
Page 29-27
29.7.10 Specific Requirements for Type K Epoxy Compounds

Type K epoxies (which are for sealing the bottom of integral pile jackets in the repair of concrete
piles) shall harden underwater and meet the requirements outlined in Table 29-10 for the sand-epoxy
mix.
Table 29-10: Requirements for the sand epoxy mix of type K compounds
Compressive strength at seven days (minimum,
31.03 MPa
by the method outlined in Article 29.7.3.2)
Bond
Bond to wet concrete (minimum) 1.72 MPa
Bond to wet pile jacket (minimum, by Florida
1.03 MPa
Method FM 5-518)
2.25 parts to one part mixed epoxy, by
Maximum sand loading
volume
Viscosity of mixed epoxy component at 25°C,
1,000 to 2,000 cps
five minutes by ASTM D2393-86
An epoxy sand mix shall be capable of flowing through water in the void area of the jacket to provide
a water tight seal of the depth indicated on the Contract plans or approved shop drawings and to
maintain this seal during subsequent construction steps.
29.7.11 Specific Requirements for Type L Epoxy Compounds

Type L epoxies (which are for coating the interior of sewage disposal system tanks) shall be of an
approved type. Manufacturers shall submit data and a record of previous usage showing satisfactory
performance in the protection of concrete from the aggressive effect of sewage for a five year
minimum to the Engineer.
29.7.12 Specific Requirements for Type M Epoxy Compounds

Type M epoxy coatings (which are for steel sheet and H piles used in bridges, fender systems and
other structures that are subject to immersion in water) shall comply with the requirements of US
Army Corps of Engineers Guide Specifications (USACE C-200). Products not meeting these
requirements may be approved by the Engineer on the basis of data furnished by the manufacturer
that documents equal or superior performance.
29.7.13 Specific Requirements for Type N Epoxy Compounds

Type N epoxy adhesives (which are for making epoxy mortar or concrete for patching Portland
cement concrete pavement) shall be any of approved products listed at the time of the work. The
Contractor shall submit mix designs for mortar and concrete to the Engineer at the time of the
preconstruction conference. To obtain approval, the Contractor shall conduct a field demonstration
that verifies that the epoxy meets the criteria of bonding to the pavement, matching colour, having
sufficient durability, and lacking excessive surface slicking under traffic flow.
Basic approval of new adhesives shall be made by the Engineer using a six month road test with
mortar-concrete mix designs as recommended by the epoxy manufacturer.
29.7.14 Specific Requirements for Type Q Epoxy Compounds

Type Q epoxy materials (which protect anchorages of posttensioning tendons or bars and may serve
other uses indicated in the Contract plans) shall produce a low exothermic reaction and have flow
Page 29-28
and fill characteristics that are suitable for machine base plate applications. Such material shall be
extended with the aggregate supplied by the manufacturer. The Contractor shall mix with the full
aggregate loading unless the use of less aggregate is approved by the Engineer.
Such material shall be factory pre-proportioned and shall include factory-supplied aggregate. The
Contractor shall deliver such products in their original containers with the manufacturer’s name, the
date of manufacture, a product identification label, and batch numbers. Such materials must be
within the manufacturer’s recommended shelf life. The Contractor shall store and condition the
product in full compliance with manufacturer’s recommendations.
Epoxy grout plus aggregate mix shall meet or exceed the specified physical properties stated in this
section as determined by the standard ASTM test methods identified in Table 29-11.
Table 29-11: Standard ASTM test methods for epoxy grout plus aggregate mix for type Q
epoxy
Property Test value Test method

Compressive strength cubes seven day ASTM C579 - 01(2012)
> 68.95 MPa
cure at 25o C Test Method B
Tensile strength at seven days > 14.48 MPa ASTM C307 - 03(2012)
Flexural strength at seven day cure at 25o C > 24.82 MPa ASTM C580 - 02(2012)
Modulus of Elasticity, seven day cure at 25o

< 14,480 MPa ASTM C580 - 02(2012)
C
Coefficient of thermal expansion at 23o to < 36 x 10-6
ASTM C531 - 00(2012)
99o C mm/mm/oC
Peak exotherm, specimen
< 66o C ASTM D2471-99
300 mm x 300 mm x 75 mm
Slant shear at seven days (bond strength to
> 20.68 MPa ASTM C882 / C882M - 12
concrete)
ASTM C884 / C884M -
Thermal compatibility Five cycles passed
98(2010)
Linear shrinkage at seven days 0.025% ASTM C531 - 00(2012)
Flowability and bearing area 90% contact area ASTM C1339 - 02(2012)
Gel time, specimen
< 4.00 hours ASTM D2471-99
300 mm x 300 mm x 75 mm
29.7.15 Specific Requirements for Type T Tape Compounds

Type T hot applied coal tar epoxy tape (which protects tie back rods on sheet pile walls and
bulkheads) shall comply with the requirements of the ANSI/AWWA C203-08. Application shall
comply with the manufacturers’ published recommendations.
29.7.16 Packaging, Labelling, and Safety for Epoxy

All containers shall be identified as Component A - contains epoxy resin or Component B - contains
hardener, and shall show the type, mixing directions, batch numbers, manufacturer’s name, date of
packaging, shelf life expiration date and quantity (in kilograms or liters). Mix ratios shall be
prominently shown on labels. Potential hazards shall be stated on each package in accordance with
the Federal Hazardous Products Labeling Act.
Page 29-29
29.7.17 Storage of Epoxy

The Owner shall not accept the use of epoxy materials that have been in storage for more than 12
months.
29.7.18 Fillers for Mixing Mortars and Grouts

Fillers for mixing mortars and grouts may be as recommended by the manufacturer of the particular
epoxy compound and may be supplied as packages accompanying the epoxy or premixed in
accordance with approved properties.
If a manufacturer recommends only the gradation of filler, it shall be a silica sand that is commercially
available in UAE and shall be a gradation listed in Table 29-12 or a specified blend of these
gradations.
The silica sands specified in Table 29-12 shall be clean, kiln dried, packaged in strong moisture proof
bags, and be chloride free. They shall contain no more than 0.2% organic trash.
Fillers shall not be used with type E, type J, type L, or type M compounds.
When the fillers specified in Table 29-12 are used, the maximum amount shall be 2.25 volumes to
one volume of mixed compound.
Table 29-12: Gradation requirements for fillers for use with epoxy compounds
Grade A B C* D**
Sieve opening size Required passing percentage
No. 4 95-100% 95-100%
No. 6 90-100%
No. 8 0-15% 85-100%
No. 16 65-97%
No. 20 80-100% 0-20%
No. 30 0-40% 25-70%
No. 50 0-10% 5-35%
No. 100 0-7%
*For use only in sections 38 mm or greater in thickness.
**Same as quartz sand fine aggregate for cement concrete.
29.8 Adhesive Bonding Material Systems

Adhesive bonding material systems for structural applications shall consist of pre-packaged two-part
chemical components. Material systems shall be specifically intended for use in structural
applications for bonding anchors and dowels to hardened concrete. Applications are limited to
anchors and dowels installed in positions ranging from vertically downward to horizontal.
The Contractor shall not use material from containers that are damaged or have been previously
opened. The Contractor shall use only full packages of components and shall not combine epoxy
bonding components from bulk supplies.
Material systems for Type HV (High Viscosity) and Type HSHV (High Strength and High Viscosity)
shall be pre-packaged to automatically proportion and mix the materials for use. The Owner shall
not permit the Contractor to manually proportion components.
Page 29-30
Type HV Adhesives: The Contractor shall use Type HV adhesive bonding materials for all horizontal
installations and vertical installations other than constructing doweled pile splices, except when Type
HSHV is required. Type HV adhesives may not be substituted for Type HSHV adhesives.
Type HSHV Adhesives: The Contractor shall use higher strength Type HSHV adhesive bonding
materials to install traffic railing barrier reinforcement and anchor bolts in existing concrete bridge
decks and approach slabs. The Contractor may substitute Type HSHV adhesives for Type HV
adhesives.
29.8.1 Certification of Adhesive Bonding Products

The Contractor shall provide the Engineer with certification documents from the manufacturer of the
adhesive bonding material system that confirm that the bonding products meet the requirements
outlined in this section. Each certification shall conform to the requirements described in these
specifications and shall cover only one lot of adhesive materials.
29.8.2 Minimum Performance Requirements for Adhesive Bonding

Materials
When tested in accordance with FM 5-568, the adhesive bonding material system, for general use,
shall meet the requirements shown in Table 29-13.
Table 29-13: Uniform bond stress for adhesive bonding material
Uniform bond stress Type HV Type HSHV

Confined tension 15.79 MPa 21.10 MPa
Damp-hole installation 11.58 MPa 12.62 MPa
Elevated temperature 15.79 MPa 21.10 MPa
Horizontal orientation 14.20 MPa 14.20 MPa
Short-term cure 11.79 MPa 11.79 MPa
Specified bond strength 7.45 MPa 12.62 MPa
The Contractor shall apply the following rules to determine the maximum coefficient of variation for
uniform bond stress at 20% of long-term load (creep):
1. Rate of displacement shall decrease during the 42 day application of load.

2. At 42 days, the total displacement due to creep (with load still applied) shall be less than 0.75
mm; during the last 14 days of the 42 day load duration, the total displacement due to creep
shall be less than 0.075 mm.
3. After removal of the 42 day load, the uniform bond stress from a subsequent confined tension
test shall be at least 12.59 MPa.
29.8.3 Product Identification (Fingerprint) Properties for Adhesive

Bonding Materials
References for comparison, including infrared absorption, density or average weight, gel time or
setting time, and bond strength shall be determined in accordance with FM 5-569.
Page 29-31
29.8.4 Packaging and Marking Adhesive Bonding Materials

An adhesive bonding material system shall be delivered to the Project site in original unopened
containers with manufacturer’s labelling that identifies each product. Each package shall be clearly
marked with the following information:
• Manufacturer’s name and address
• Product name
• Expiration date
• Lot identification number
• Storage and handling requirements
Each package shall include the manufacturer’s instructions for anchor and dowel installation. Such
instructions shall include the following information:
a. Diameters of drilled holes for applicable anchor and dowel sizes
b. Cleaning procedure for drilled holes, including a description of permitted and prohibited
equipment and techniques
c. Allowable temperature ranges for storage, installation and curing
d. Identification of acceptable mixing/dispensing nozzles
e. Fabrication requirements for anchors and dowels
f. Description of tools permitted or required for installation
g. Method of identifying properly proportioned and mixed adhesive materials
h. Time and temperature schedule for initial set and full-strength cure
i. Special requirements for special installation conditions, such as damp holes, or horizontal
or near horizontal orientation of the anchor or dowel.
29.9 Adhesive-bonded Anchors and Dowels

The Contractor shall prepare and install adhesive bonded anchors and dowels in hardened concrete
as indicated in the Contract plans, as directed by the Engineer, and in accordance with the
manufacturer’s instructions and the requirements described in this section.
Anchors and dowels described in this section are intended for use in structural applications where
designated on the Contract plans.
29.9.1 Adhesive-bonded Anchors and Dowels

The Contractor shall use adhesive bonding material systems that meet the requirements of Section
29.8. For applications that involve the installation of traffic railing barrier reinforcement and anchor
bolts on existing bridge decks and approach slabs, the Contractor shall use only type HSHV
adhesives.
29.9.2 Storage of Adhesive-bonded Anchors and Dowels

The Contractor shall store materials delivered to the job-site in the original unopened containers
within an appropriate facility that is capable of maintaining storage conditions consistent with the
manufacturer’s recommendations.
Page 29-32
29.9.3 Equipment for installing Adhesive-bonded Anchors and

Dowels
The Contractor shall ensure that the equipment used to install adhesive-bonded anchors and dowels
is in conformance with the recommendations of the anchor and dowel manufacturer.
29.9.4 Preparing Concrete Members for Adhesive-bonded Anchors

and Dowels
The Contractor shall ensure that concrete members that receive adhesive-bonded anchors or dowels
are structurally sound and free of cracks in the vicinity of the anchor or dowel to be installed. Unless
the adhesive manufacturer recommends the use of other equipment, the Contractor, using a rotary
hammer drill and bit, shall drill holes to the diameter required by the manufacturer, but no less than
105% of the diameter including deformations, and no more than 150% of the nominal diameter of
the steel bar anchor or dowel.
The Contractor shall use a metal detector that is specifically designed for locating steel in concrete
to avoid conflicts with existing steel reinforcement whenever placement tolerances and edge
clearances permit. The Contractor shall perform core drilling to clear existing steel reinforcement
only when approved by the Engineer. The Contractor shall dry drilled holes completely before
cleaning and installing the anchors or dowels.
The Contractor shall clean and prepare drilled holes in accordance with the manufacturer’s
recommendations, but shall use no method that is less effective than using oil-free compressed air
to remove loose particles from drilling, brushing inside surface to free loose particles that are trapped
in pores, and using compressed air again to remove any loose particles that still remain. The
Contractor shall use a non-metallic bristle brush and shall avoid over-brushing to the point of
polishing the inside surface of the drilled hole.
29.9.5 Method of Installing Adhesive-bonded Anchors and Dowels

The Contractor shall remove all debris, oils, and any other deleterious material from the anchors and
dowels to avoid contamination of the adhesive bonding material. The Contractor shall install anchors
or dowels in accordance with the details shown on the Contract plans and the manufacturer’s
instructions, paying particular attention to any requirements and limitations caused by anchor
position, dampness, ambient temperatures, and curing.
The Contractor shall use adequate quantities of the adhesive bonding material to fill each drilled hole
to within 6.0 mm of the concrete surface, as measured after placement of the steel bar or anchor.
For horizontal and inclined installations, the Contractor shall provide temporary supports to maintain
the anchors or dowels in the centre of the drilled holes until adhesive bonding material has cured.
29.9.6 Testing Adhesive-bonded Anchors and Dowels

The Contractor shall field test installed anchors and dowels for traffic railing barrier applications using
type HSHV adhesives. The Engineer may also require testing of installed anchors and dowels for
other applications.
29.9.6.1 Field Tests for Adhesive-bonded Anchors and Dowels

The Contractor shall engage an independent testing agency to perform field testing of the installed
anchors and dowels under the direction of a Professional Engineer. The Contractor shall submit test
reports for each lot that has been signed and sealed by the Professional Engineer. The Contractor
shall perform restrained static tension tests to prevent damage to the surrounding concrete. A
restrained test is defined as a test conducted in accordance with ASTM E488 / E488M - 10, except
that the ASTM E488 / E488M - 10 support clearance requirements for test equipment do not apply.
A reaction base shall be approximately equal to a drilled hole’s diameter for the anchor to preclude
concrete or masonry failure while allowing bond failure. Field testing does not require a displacement
Page 29-33
measurement. The Contractor shall test individual anchors and dowels by proof loading in tension
to 85% of the specified bond strength defined in Section 29.8, based on the nominal anchor or dowel
diameter and embedment depth. Tension shall not exceed 90% of the yield strength of the anchor
or dowel, unless otherwise shown in the Contract documents.
The Contractor shall divide the anchors and dowels into lots for testing and acceptance. Each lot
shall contain no more than 100 anchors or dowels, of the same diameter, embedment length, and
adhesive bonding material system. Randomly, the Contractor shall select four of the anchors and
dowels in each lot for testing, except if there are three or fewer anchors or dowels in a lot, in which
case, the Contractor shall test all anchors, unless otherwise directed by the Engineer. If three
consecutive lots have no failing tests, the Contractor shall sample the next three lots at a 2% rate; if
these lots have no failing tests, the Contractor shall sample at a rate of 1% for the remaining lots
unless there is a failure.
Regardless of lot size, however, the Contractor shall sample at least one dowel per lot. For every
failed field test, the Contractor shall perform two additional field tests on adjacent untested anchors
or dowels within a lot. The Contractor shall continue additional field tests until no more test failures
occur, or until all anchors and dowels within a lot have been tested. After any lot fails, the Contractor
shall increase the sampling rate to 4% for the next lot to be tested, but shall not test fewer than one
dowel per lot and shall conform to the sampling rate procedure above, including rate reductions as
appropriate.
29.9.6.2 Removal and Replacement of Adhesive-bonded Anchors and

Dowels that Have Failed Testing
The Contractor shall remove all anchors and dowels that fail the field test, without damage to the
surrounding concrete. The Contractor shall drill holes again to remove adhesive bonding material
residue and clean them in accordance with the directions in Section 29.9.4. New anchors and dowels
shall be reinstalled in accordance with the directions in Section 29.9.5. The Contractor shall not
reuse anchors and dowels that have failed testing unless the Engineer has approved doing so.
Reinstalled anchors shall be assigned only for new lots with anchors or dowels of the same diameter,
embedment length, and adhesive bonding material system. The Contractor shall field test reinstalled
anchors in accordance with the directions in Article 29.9.6.1.
29.9.7 Acceptance of Installed Adhesive-bonded Anchors and

Dowels
The Engineer will accept adhesive-bonded anchors and dowels after determining that they meet the
material requirements outlined in Section 29.8, the installation and testing requirements described
in this section, and the placement requirements of the Contract plans.
29.10 Embedment Anchors

Using embedment anchors includes installation and field testing of cast-in-place, grouted, adhesive-
bonded, expansion, and undercut steel anchors.
29.10.1 Prequalification for Embedment Anchors

The Contractor shall prequalify the following materials:
• Concrete anchors, including cast-in-place
• All bonded anchor systems, including grout, chemical compounds, and adhesives
• Undercut steel anchors
For such prequalification, the Contractor shall use universal test standards that are designed to allow
approved anchor systems to be employed for any construction attachment use.
Page 29-34
Tests for adhesive-bonded and other bonding compounds shall be conducted in accordance with
ASTM’s Standard Test Methods for Testing Bond Performance of Bonded Anchors (ASTM E1512 -
01(2007)).
Expansion anchors shall be tested in accordance with ASTM’s Standard Test Methods for Strength
of Anchors in Concrete Elements (ASTM E488 / E488M - 10).
Embedment anchor details shall comply with Appendix B, Steel Embedments in ACI’s Code
Requirements for Nuclear Safety Related Concrete Structures and Commentary (ACI 349-06).
For anchor systems other than mechanical expansion anchors, the Contractor shall provide the
Engineer with certified test reports that have been prepared by an independent laboratory. Such
reports shall document that the system is capable of achieving the minimum tensile strength of the
embedment steel.
29.10.2 Materials for Embedment Anchors

The Contractor shall provide mill test reports to the Engineer to certify the physical properties,
chemistry, and strengths used to manufacture the anchors.
Either an epoxy, vinylester, or polyester chemical compound shall be acceptable for adhesive
anchors. Moisture-insensitive, high-modulus, low shrinkage, and high-strength adhesives shall be
used.
The Owner prohibits the use of additives to grout and bonding materials that are corrosive to steel
or zinc/cadmium coatings.
29.10.3 Construction Methods for Embedment Anchors

Adequate edge distance, embedment depth, and spacing to develop the required strength of the
embedment anchors shall be provided. The correct drill-hole diameter, as specified by the
manufacturer, shall be used. Rotary impact drilling shall be used unless diamond core drilling has
been specified or tested. If a reinforcing bar is encountered during drilling, the hole shall be moved
to a different location or the reinforcing steel shall be drilled through using a diamond core bit as
directed by the Engineer. Abandoned holes shall be patched with an approved bonding material.
Holes shall be thoroughly cleaned as recommended by the manufacturer.
The Contractor shall remove all loose dust and concrete particles from the hole and shall prepare
bonding material and install anchors according to the manufacturer's instructions or direction from
the Engineer.
Improperly installed embedded anchors or anchors that lack the required strength shall be removed
and replaced, at the Contractor's expense, to the satisfaction of the Engineer.
29.10.4 Inspection and Testing for Embedment Anchors

Where specified, sacrificial tests of the anchor system shall be done at the job site to the ultimate
loads to document that the system can achieve pullout loads equalling the full minimum tensile value
of the anchor employed. Anchor testing shall be done on fully cured concrete samples. At least three
anchors shall be tested by ASTM E488 / E488M - 10 methods, unless otherwise specified. The
Contractor may use any prequalified anchor systems that meet the requirements outlined above.
Provision shall be made for use of an alternative system that will reach the designated pullout
requirement, without delay in progress, if the job site proof loading proves incapable of achieving
minimum tensile values or the load required by the Engineer, or if too little concrete exists in which
to develop full ductile loads.
After bonding material has been installed and has cured, the Contractor shall torque each anchor
system to its specified values using approved torque methods. If torque values are not specified, the
Contractor shall use the manufacturer's recommendations or values provided by the Engineer.
Page 29-35
29.11 Bridge Deck Wearing Surfaces

Installing wearing surfaces shall consist of placing a wearing surface of durable and impervious
material on the roadway surface of bridge decks, tunnels, and underpasses. It includes the
preparation of surfaces of either existing or new decks to receive such an overlay of surfacing
material.
Wearing surfaces of bridge decks, tunnels, and underpasses shall be asphaltic concretes. The
thickness of wearing surfaces shall be as designated in the Contract documents. Materials and
installation requirements for asphaltic concrete wearing surfaces shall be in compliance with the
applicable requirements of Chapter 3, Pavement, of these standard specifications. Unless otherwise
specified in the Contract documents or directed by the Engineer, an asphaltic concrete overlay shall
not be used directly on a Portland cement concrete deck without waterproofing the roadway surface
as per Section 28.5 of Chapter 28, Waterproofing, of these standard specifications.
If the type of wearing surfaces is not specified in the Contract documents, the selection of a wearing
surface by the Contractor shall subject to the Engineer’s approval and shall include evaluation of the
• Sufficient ductility and strength to accommodate expansion, contraction, and imposed
deformation without cracking or debonding
• Sufficient fatigue strength to withstand flexural stresses due to composite action of the
wearing surface with the bridge deck resulting from local flexure
• Sufficient durability to resist rutting, shoving, and wearing
• Imperviousness to water, motor vehicle fuels, and oils
• Resistance to deterioration from solar radiation and aging
• Provision of skid-resistant surface
• Ability to distribute wheel loads
When specified in the particular specifications, Latex-modified Concrete type wearing surfaces shall
be furnished and installed in accordance with the requirements of the following sections.
29.11.1 General Requirements for the Installation of Latex-modified

Concrete Type Wearing Surfaces
All equipment used to prepare the surface and to proportion, mix, place, and finish the latex concrete
shall be subject to approval by the Engineer before use. This approval will be contingent on
satisfactory performance and will be rescinded in the event such performance is not being achieved.
Equipment shall be on hand sufficiently ahead of the start of construction operations to be examined
and approved. Any equipment that leaks oil or any other containment onto the deck shall be
immediately removed from the job site until repaired.
A technician who is well-experienced in the proportioning, mixing, placing, and finishing of latex-
modified concrete shall be employed by the Contractor and shall be present and in technical control
of the work whenever these operations are underway. The Contractor shall submit the qualifications
of this technician, including a list of projects on which the technician was employed and the
technician's level of responsibility on each, to the Engineer, who must approve the employment of
this technician before operations start.
Approval by the Engineer of equipment or technicians shall not relieve the Contractor of any
responsibility for the successful completion of the work.
If not otherwise specified in the Contract documents, the minimum thickness of latex-modified
concrete wearing surfaces shall be 32 mm.
Page 29-36
29.11.2 Materials for the Installation of Latex-modified Concrete

Wearing Surfaces
29.11.2.1 Portland Cement
Portland cement shall conform to the requirements outlined in Section 4.3.1 of Chapter 4, Concrete
Works, of these Standard Specifications, except that only types I or II shall be used.
29.11.2.2 Aggregates
Aggregate shall conform to the requirements of AASHTO M 6-08 for fine aggregate and to AASHTO
M 80-08 for coarse aggregate. Coarse aggregate shall be graded 13 mm to 4.75 mm per AASHTO
M 43-05 (2009) (ASTM D448 - 08).
29.11.2.3 Water
Water for mixing concrete shall conform to the requirements outlined in Section 4.3.8 of Chapter 4,
29.11.2.4 Latex Emulsion for the Wearing Surfaces

Formulated latex emulsion admixture shall be a non-hazardous, film forming, polymeric emulsion in
water, to which all stabilizers have been added at the point of manufacture, and shall be
homogeneous and uniform in composition.
a. Physical Properties of Latex Emulsion for the Wearing Surfaces

The latex modifier shall conform to the requirements shown in Table 29-14.
Table 29-14: Polymer type stabilizers styrene butadiene
Property Value
Latex Nonionic surfactants
Portland cement composition Polydimethyl siloxane
Percent solids 46.0% to 49.0%
Mass per litre at 25o C 1.0 kg
Colour White
A Certificate of Compliance signed by the manufacturer of the latex emulsion, certifying that the
material conforms to the above Specifications, shall be furnished for each shipment used in the work.
Latex admixture to be stored shall be kept in suitable enclosures that will protect it from prolonged
exposure to temperatures in excess of 30° C. Containers of latex admixture may be stored at the
bridge site for a period not to exceed ten days. Such stored containers shall be covered completely
with suitable insulating blanket material to avoid excessive temperatures.
29.11.3 Mix Design of Latex-modified Concrete for Wearing Surfaces

The latex-modified concrete for use on the Project shall be a workable mixture that meets the
requirements specified in Table 29-14 and Table 29-15.
• Following sampling of the discharged, normally mixed material, the commencement of the
slump test shall be delayed from 4 to 5 minutes.
• Water may be added to obtain slump within the prescribed limits.
Page 29-37
• Dry weight ratios are approximate and should produce good workability; due to gradation
changes, however, these may be adjusted within limits established by the Engineer. Parts by
weight of sand may be increased by as much as 0.2 if the coarse aggregate is reduced by
an equivalent volume.
Table 29-15: Approximate latex-modified concrete mixture proportions
Ingredient Amount for a volume of one cubic metre

Cement 299 kg
Sand 776 kg
Coarse aggregate 517 kg
Latex* 92.7 litres
Water 71.9 litres
*Assumed 48% solids, 52% water by mass
Because of the surfactants used in the manufacture of latex, excessive amounts of air can be
entrained when latex is mixed into a Portland-cement system, unless an antifoam agent is
incorporated in the latex.
For styrene-butadiene latexes, these are usually silicone products and are often added by the latex
supplier. The relationship between air content and antifoam agent content is a function of the specific
latex, in particular, the level and type of its surfactant system and antifoam agent used. Field
experience has shown that the composition of the cement and the aggregates can affect air content,
so it is important to evaluate the mixture before use. No reported work has been done to identify the
components of the cement or aggregates that affect the air content.
29.11.4 Applying Latex-modified Concrete for Wearing Surfaces

Procedures to apply wearing surfaces shall comply with the requirements and specifications outlined
in this section.
29.11.4.1 Preparing the Surface

When preparing the surface for a wearing surface overlay, the Contractor shall comply with the
specifications and requirements outlined in this article.
a. Preparing New Deck Surface for the Wearing Surface Overlay

Surfaces of new decks upon which a wearing surface overlay is to be placed shall be finished to a
rough texture by coarse brooming or other approved methods.
After curing of the deck concrete is complete and before placement of the overlay, the Contractor
shall blast-clean the entire area of the deck surface and the vertical faces of curbs, concrete
parapets, and barrier walls up to a height of 25 mm above the top elevation of the overlay. Such
blast-cleaning shall produce a bright, clean appearance that is free from laitance, curing compound,
dust, dirt, oil, grease, bituminous material, paint, and all foreign matter. Blast cleaning for an area of
the deck shall normally be performed within 24 hours before placement of the overlay on the area.
Blast cleaning may be performed by either wet sandblasting, high-pressure water blasting, blasting
grits, shrouded dry sandblasting with dust collectors, or another method approved by the Engineer.
Water blasting equipment shall operate with a minimum pressure of 24.5 MPa. Any blast cleaning
method used shall conform to applicable air and water pollution regulations and to applicable safety
and health regulations. All debris, including dirty water, that results from blast cleaning operations
shall be immediately and thoroughly cleaned from the blast-cleaned surfaces and from other areas
where debris may have accumulated. All blast-cleaned areas shall be protected as necessary
against contamination before placement of the overlay. Contaminated areas and areas exposed for
Page 29-38
more than 36 hours after cleaning shall be blast-cleaned again, as directed by the Engineer, and at
the Contractor's expense.
Immediately before placing the overlay, the Contractor shall remove all dust and other debris by
flushing the area with water or blowing the area with compressed air. Prepared surfaces shall then
be soaked with clean water for at least one hour before the placement of the latex overlay. Before
the overlay is applied, all free water shall be blown out and off, and this procedure shall continue
until the surface appears dry or barely damp.
An air supply system for blast cleaning and blowing shall be equipped with an oil trap in the air line,
and provisions shall be made to prevent oil or grease contamination of the surface by any equipment
before placement of the overlay.
b. Preparing Existing Deck Surface for Wearing Surface Overlay

Any surfaces of existing decks that have become contaminated by traffic usage shall be scarified to
the depth specified in the Contract documents. If no depth is shown or specified, a minimum of 6
mm of material shall be removed by scarification.
Before beginning scarification and until operations are completed, all deck drains, expansion joints,
and other openings where the Engineer determines that damage could result shall be temporarily
covered or plugged to prevent entry of debris.
Scarifying shall be done with power operated mechanical scarifiers, or other approved devices, that
are capable of uniformly removing the existing surface to the depths required without damaging the
underlying concrete. Machine scarifiers shall not be operated in ways that damage hardware, such
as drain grates and expansion joint armour. In areas that machine scarifying cannot reach and in
areas of spalling and where steel reinforcement is exposed, scarifying and the removal of
deteriorated or unsound concrete shall be accomplished with hand tools. Pneumatic hammers
heavier than nominal 200 N shall not be used.
No scarifying or chipping shall be allowed within 1.8 m of a new overlay until 48 hours after its
placement.
In areas where the Engineer determines that deteriorated or unsound concrete has been
encountered, such concrete shall be removed to a depth of 20 mm below the top mat of reinforcing
steel. A minimum of 20 mm clearance shall be required around the reinforcing steel, except where
lower bar mats make this impractical. Care shall be exercised to prevent damaging the exposed
reinforcing steel. All reinforcing steel shall be blast-cleaned. Repaired areas are to be filled during
the overlay operation.
After scarification and removal of unsound concrete has been completed, the deck surface shall be
blast-cleaned and prepared as specified in Sub-article a of Article 29.11.4.1.
29.11.4.2 Proportioning and Mixing to Apply the Wearing Surfaces

The Contractor shall submit to the Engineer for approval, 14 days prior to date of placement, the
proposed mix design in writing and samples of all mix materials in sufficient quantity to produce a
minimum of 0.08 m3 of concrete for laboratory mix design testing.
Proportioning and mixing equipment shall be a self-contained, mobile, continuous mixing, volumetric
proportioning-type mixer.
Continuous-type mixers shall be equipped so that the proportions of the cement, natural sand, and
coarse aggregate can be fixed by calibration of the mixer and cannot be changed without destroying
a seal or other indicating device affixed to the mixer. In addition to being equipped with a flow meter
for calibrating the water supply portion of the mixer, the mixer shall also be equipped with a
cumulative-type water meter that can be read to the nearest 0.4 Litres. Water meters shall be readily
accessible, accurate to within one percent, and easy to read. Both water meters shall be subject to
checking by the Engineer each time the mixer is calibrated. The Contractor shall provide approved
methods for adding an admixture. Admixtures shall be added so as to be kept separated as far as is
Page 29-39
practicable. The Contractor shall calibrate a continuous-type mixer to the satisfaction of the Engineer
before starting the work. Yield checks normally will be made for each 38 m3 of mix. Recalibration
will be necessary when indicated by the yield checks and at any other times that the Engineer deems
necessary to ensure proper proportioning of the ingredients. Continuous-type mixers that entrap
unacceptable volumes of air in the mixture shall not be used.
The mixer shall be kept clean and free of partially dried or hardened materials at all times. It shall
consistently produce a uniform, thoroughly blended mixture within the specified air content and
slump limits. Malfunctioning mixers shall be immediately repaired or replaced with acceptable units.
Aggregate stockpiles being used should be of uniform moisture content. Mixing capability shall be
such that finishing operations can proceed at a steady pace, with final finishing completed before
the formation of the plastic surface film.
29.11.4.3 Installation Procedures for the Wearing Surfaces

The Contractor shall provide a detailed work plan, which shall include equipment and manpower, for
approval before beginning any work.
Concrete batches shall not be carted over the completed overlay until the overlay concrete has
attained a compressive strength of 21 MPa. If carts are used, the Contractor shall provide timber
planking of at least 20 mm thickness for the remainder of the curing period. The Contractor shall
provide carts equipped with pneumatic tires. Curing operations shall not be interrupted for the
purpose of carting concrete over finished slabs.
a. Weather Restrictions for the Wearing Surface Installation

The Contractor shall not start the placement of latex-modified concrete when the temperature is or
is expected to fall below 7° C or rise above 27° C), or when high winds, rain, or low humidity
conditions are expected to occur before final set of the concrete. If any of these conditions occur
during placement, placement shall be terminated and a straight construction joint formed. Placement
at night may be necessary when daytime conditions are not favourable. If placement is performed at
night, adequate lighting shall be provided by the Contractor.
b. Equipment for the Wearing Surface Installation

Placing and finishing equipment shall include hand tools for placing and brushing in freshly mixed
latex-modified concrete and for distributing it to approximately the correct level for striking off with
the screed. Hand-operated vibrators, screeds, and floats shall be used for consolidating and finishing
small areas.
An approved finishing machine complying with the following requirements shall be used for finishing
all large areas of work:
1. The finishing machine shall be self-propelled and capable of forward and reverse movement
under positive control. The length of the screed shall be sufficient to extend at least 150 mm
beyond the edge of both ends of the section being placed. This finishing machine shall also
be capable of consolidating the concrete by vibration and of raising all screeds to clear the
concrete for travelling in reverse. This machine shall be either a rotating roller-type or an
oscillating screed-type.
2. Rotating roller-type machines shall have one or more rollers, augers, and 25 to 40 Hz
vibratory pans.
3. Oscillating screed-type machines shall have vibrators on the screeds whose frequency of
vibration can be varied between 50 and 250 Hz. The screed’s bottom face shall be not less
than 100 mm wide and shall be metal.
Rails shall be required for the finishing machine to travel on. Rails shall be sufficiently rigid to support
the weight of the machine without appreciable deflection and shall be placed outside of the overlay
Page 29-40
area. Rail anchorages shall provide horizontal and vertical stability and shall not be shot ballistically
into concrete that will not be overlaid.
A suitable portable lightweight or wheeled work bridge shall be furnished for use behind the finishing
operation.
c. Placing the Wearing Surface

The finishing machine shall be test-run over the entire area to be overlayed each day before
placement is started to ensure that the required overlay thickness will be achieved.
Immediately ahead of placing the overlay mixture, a thin coating of the polymer modified concrete
mixture to be used for the overlay shall be thoroughly brushed and scrubbed onto the surface as a
grout-bond coat for the overlay. More coarse particles of the mixture that cannot be scrubbed into
contact with the surface shall be removed and disposed of in a manner approved by the Engineer.
The Contractor shall be careful to ensure that all vertical and horizontal surfaces receive a thorough,
even coating and that the rate of progress is limited so that the material brushed on does not become
dry before it is covered with the full depth of latex-modified concrete.
The latex-modified concrete shall be placed on the prepared and grout-coated surface immediately
after being mixed. This mixture shall be placed and struck off approximately 6 mm above final grade,
then consolidated by vibration and finished to final grade with the approved finishing machine. Spud
vibrators may be used in deep pockets, along edges, and adjacent to joint bulkheads. Supplemental
vibration shall be provided along the meet lines where adjacent pours come together and along curb
lines. Hand finishing with a float may be required along the edge of the pour or on small areas of
repair.
Screed rails and construction bulkheads shall be separated from the newly placed material by
passing a pointing trowel along their inside face. Expansion dams shall not be separated from the
overlay. The Contractor shall be careful to ensure that this trowel cut is made for the entire depth
and length of rails after the mixture has stiffened sufficiently.
d. Finishing the Wearing Surface

Finishing equipment shall be operated to produce a uniform, smooth, and even-textured surface.
The final surface shall not vary more than 3 mm from a 3 metre straightedge placed longitudinally
on it. Before the plastic film forms, the surface shall be textured by tinning in accordance with the
requirements of Section 21.10.1 of Chapter 21, Concrete Structures, of these Standard
Specifications.
e. Installing Construction Joints for the Wearing Surfaces

Planned construction joints shall be formed by bulkheads set to grade. Before placing concrete
against previously placed overlay material, the construction joint shall be sawed to a straight vertical
edge. Sawing of joints may be omitted if the bulkhead produces a straight, smooth, vertical surface.
The joint’s face shall be sand or water blasted to remove loose material.
The Owner shall permit longitudinal construction joints only at the centreline of roadway or at lane
lines unless otherwise shown in the Contract documents or permitted by the Engineer.
If delays in the placement operation exceed one hour, an approved construction joint shall be formed
by removing all material not up to finish grade and sawing the edge in a straight line. During minor
delays of one hour or less, the end of the placement may be protected from drying with several layers
of clean, wet burlap.
29.11.5 Curing Latex-modified Concrete Wearing Surfaces

The wearing surface shall be promptly covered with a single layer of clean, wet burlap as soon as
the surface can support it without deformation.
Page 29-41
Within one hour after covering a surface with wet burlap, the Contractor shall wet the burlap again,
if necessary, place a layer of 100 μm polyethylene film or wet burlap-polyethylene sheets over the
wet burlap, and cure the surface 24 hours.
During cold weather, freshly placed LMC shall be protected from temperatures below 7° C during
the first 72 hours of curing. If the temperature falls below 7° C during curing, the duration of the wet
cure shall be extended as directed by the Engineer.
The Owner shall prohibit traffic on an overlay while it is curing.
29.11.6 Testing and Acceptance of Latex-modified Concrete Wearing

Surfaces
After curing is completed, the Contractor shall visually inspect an overlay for cracking and other
damage. The Contractor shall also use a chain drag or other suitable device to inspect wearing
surfaces for de-laminations and bond failures.
The Contractor shall seal surface cracks that are10 mm deep or less with an epoxy penetrating
sealer followed by an application of approved sand.
To repair cracks that are deeper than 10 mm, the Contractor shall use methods approved by the
Engineer or remove and replace the affected portions of the wearing surface. The Contractor shall
remove and replace any delaminated or unbounded portions of a wearing surface or portions that
have been damaged by rain.
After completion of the wet cure, the surface shall be tested for flatness and corrected, if necessary,
as provided in Section 21.10.1.4 of Chapter 21, Concrete Structures, of these Standard
Specifications.
All corrective work shall be at the Contractor's expense.
29.11.6.1 Compression Strength Test for the Wearing Surfaces

Compression strength test shall be done according to ASTM C31 / C31M - 12. Specimens shall be
cured at the job site under the same conditions as the overlay. Specimens shall be tested to
determine when overlay has achieved a specified strength of 21 MPa or as specified in the Contract
documents for opening to traffic.
29.12 Drip Check Angle

Where shown on the Contract plans, the Contractor shall fix 25 x 25mm stainless steel angle bedded
on approved gun applied sealant to outside faces of bridge deck concrete. The Contractor shall
design fixings of stainless steel and drill them on the Project site.
29.13 Lockable Doors, Access Covers, and Internal Access

Walkways
Lockable doors, access covers, frames, and internal access steelwork shall be as detailed on the
Contract plans. All doors and access covers shall include an approved arrangement for locking from
the outside. Access covers in the soffit and top slab of decks and cross beams shall include a means
of securing in the open position.
29.14 End walls for ducts

Ends of contingency utility ducts shall terminate in cast-in-situ cantilevered concrete retaining walls
(duct end wall) to help protect the roadway, sidewalk, curbs, and other works over the ducts from
damage due to excavation. Such protection shall enable workers to open the end of the ducts for
utility placement at some future date. Duct end walls shall be constructed at the locations and to the
details as shown on the Contract plans and as approved by the Engineer, and in accordance with
Page 29-42
the applicable requirements of Chapter 4, Concrete Works, Chapter 5, Reinforcing Steel, and
Chapter 21, Concrete Structures, of these standard specifications.
29.14.1 Materials for the Construction of End Walls for Ducts

All concrete and reinforcing steel for duct end walls shall comply with the requirements under Section
4.3 of Chapter 4, Concrete Works, and Section 5.3 of Chapter 5, Reinforcing Steel, of these Standard
Specifications. Blinding concrete shall be of Class 15/20 concrete. The structural end wall concrete
shall be of Class 35/20. Reinforcement shall be Grade 60, uncoated rebar, unless designated
otherwise.
Waterproofing shall meet the requirements outlined in Section 28.2 of Chapter 28, Waterproofing.
Coal tar epoxy protective coatings shall meet the requirements outlined in Section 24.5 of Chapter
24, Painting. Duct pipe extending through the headwall shall meet the appropriate pipe requirements
for the various types and sizes of contingency utility ducts as otherwise specified in Chapter 12,
Storm Water Drainage, of these Standard Specifications. End caps for the contingency utility ducts
shall be commercially manufactured of materials similar to the respective contingency utility duct
pipe material and sized to match the belled joint end of the duct pipe, using a rubber gasketed seal,
meeting the requirements as otherwise specified for pipe joints for the respective contingency utility
duct pipe material type. Each cap shall have a pulling handle and attachment for a wire pulling rope
where such is applicable for electrical and telephone ducts. For smaller PVC ducts (ducts with 20
cm or smaller diameters), the Contractor may use a tight fitting PVC cap as an option to the gasketed
cap; such cap can be inserted into the bell end of a typical PVC-bonded type pipe joint fitting that is
sealed with a liberal application of silicone sealer.
All contingency utility duct pipe end caps shall be suitable for long term buried conditions and shall
makes the duct water tight.
29.14.2 Construction Methods for End Walls for Ducts

Each duct end wall shall be designed site specific by the Contractor and shown in plans and sections
of shop drawings, which shall conform to the typical details and locations shown on the Contract
plans, or as otherwise approved by the Engineer.
Excavation, dewatering, construction and backfilling for duct end walls shall meet the applicable
construction requirements for surface drainage structures as detailed in Chapter 12, Storm Water
Drainage, of these Standard Specifications. Forms shall be smooth and tight fitting forms that can
be held rigidly to line and grade during placement of concrete and that can be readily removed
without injuring the green concrete. Duct end wall base slab shall be placed in conjunction with the
contingency utility duct construction such that the contingency utility duct pipe can be placed true to
grade with the capped bell end of the duct pipe installed flush with the face of the end wall. The
contingency utility duct pipe shall be fixed and held securely in position such that it is not displaced
during the duct end wall concrete placement. The backfilled back-side surface of a duct end wall and
base slab shall be protected with waterproofing membrane that complies with Section 28.2 of
Chapter 28, Waterproofing. The duct end wall’s backfilled front surface (the side that can be
excavated for utility placement at some future date) shall be protected with a coal tar epoxy coating.
Exposed portions of the duct end wall surfaces along the top shall be protected with a clear
penetrating epoxy sealant.
The duct end wall’s top shall be rubbed finish to match the particular curb or top configuration in
accordance with each site's requirements, as shown on the shop drawings and approved by the
Engineer. The duct end wall’s final finish shall be obtained by rubbing with a fine carborundum stone
and water. Rubbing shall be continued until a duct end wall’s entire surface is of a smooth texture
and uniform colour. After the final rubbing is completed and the surface has dried, it shall be rubbed
with burlap to remove loose powder and shall be left free from all unsound patches, paste, powder,
and objectionable marks.
Page 29-43
Appropriate utility markers shall be installed in the top of the duct end wall on the centreline of the
matching duct type, immediately after towelling smooth the freshly placed concrete. The utility
marker shall be pushed into the wet concrete, on duct and end wall width centrelines, such that the
marker is flush with the surface of the end wall. The Contractor shall be careful to remove any wet
concrete from the surface of the utility marker and to leave the top of the end wall equal to the rubbed
type finish, as described above.
Before backfilling, the Contractor shall allow the duct end wall concrete to cure to 7-day concrete
strength, clean the ducts, and cap and seal the contingency utility duct pipe ends. After obtaining
final approval from the Engineer, the Contractor shall backfill the end wall with load bearing borrow
material. Such backfill shall be compacted as specified for the placement of load bearing borrow
materials, in equal height lifts on each side of the end wall, such that uneven pressure is not exerted
on the wall from either side.
29.15 Scour Protection

If scour protection is specified in the Contract documents or Contract plans, it shall comprise a layer
of 5kg to 100kg rock and shall be installed around the marine bridge piers as shown on the Contract
plans, with a geo-textile layer (having minimum grade 600 g/m2) under the rock.
29.15.1 Method Statement

No later than two (2) months before commencement of construction of the scour protection, the
Contractor shall submit to the Engineer for consent, full details of the proposed construction methods
for the structure(s).
The details shall include, but not be limited to:
a. Proposed source(s) of rock material including documentation showing that the proposed
materials from each quarry or quarry face comply with the specification, and evidence that
the source(s) can supply the required quantity at the required rates.
b. Method statement for quarrying, grading, sorting, stacking, inspection, weighing and
transportation of the rock materials. The Contractor shall give his proposals for sampling and
testing rock and for ensuring compliance with the requirements of these specifications.
Details shall include the sampling rate and size of sample and shall take into account such
factors as the number of quarries or quarry faces, rate of delivery to site, methods of
stockpiling and handling and rate of placing.
c. Method statement for the construction of the scour protection including, but not limited to,
• Proposed plant and labour resources
• Method of placing the rock materials
• Founding of the seabed
• Geo-textile placement
• Aggregate bedding layers over geo-textile
• Construction programme
• Setting out control, inspection and survey procedures
• Monitoring of seabed and fill displacements and settlement
• Environment protection and silt screens
d. Health and Safety considerations
Page 29-44
29.15.2 Rock Materials

29.15.2.1 Physical Properties
Rock shall comply with Requirements (1) to (4) presented in Table 29-16 when tested in accordance
with BS 812-103.1:1985, Requirement (5) when tested in accordance with ASTM C131 - 06 and
Requirement (6) when tested in accordance with Appendix B of BS 6349-1:2000: Part 1. Submerged
rock means all material below -0.5m NADD (New Abu Dhabi Datum), wetted rock means all material
that lies above -0.5m NADD. The frequency of testing shall be as per the particular specifications
and as approved by the Engineer.
The petrography analysis of the rocks shall be submitted by the Contractor for the Engineer’s
evaluation and approval.
Table 29-16: Rock physical properties for scour protection
Material property Submerged rock Wetted rock

1 Saturated surface dry density > 2,600 kg/m3 >2,750 kg/m3
2 Water absorption < 3% by weight < 1% by weight
3 Aggregate impact value < 30% <30%
4 Ten percent fines value > 100kN >150kN
5 Los Angeles abrasion value < 30% < 20%
Soundness of coarse agg. (5 cycles
6 < 10% < 5%
MgSO4)
29.15.2.2 Cracks, Laminations and Other Deficiencies

Individual rocks for rock armour units shall be free from cracks, laminations and cleavage planes,
weathered material and solution cavities. All rocks shall be free of all remains of quarry blasting
materials.
29.15.2.3 Length to Thickness Ratio

No more than 50% of the rock armour units shall have a length to thickness ratio (L/d) greater than
2, and no rock shall have an L/d ratio greater than 3, where the length, L, is defined as the greatest
distance between any two points on the rock, (ie. diametrically opposite corners of a cuboidal block),
and the thickness, d, the minimum distance between two parallel straight lines through which the
rock can just pass.
29.15.2.4 Grading of Rock

The grading for rock shall be in accordance with the system described in the Rock Manual 2007
(CIRIA-C683), the Use of Rock in Hydraulic Engineering.
The system is analogous to particle size distribution charts for aggregates but the horizontal axis is
the weight of a rock instead of a sieve size, and the vertical axis is the "cumulative percentage by
weight of all rocks in a given sample that are lighter than", instead of the "percentage passing".
Rather than using grading envelopes drawn on a cumulative plot to define the limits of standard
grading, the system adopted shall refer to a series of specified weights of stones, (rock sizes a, b, c
and d in increasing size order), and the associated allowable range of "y", the "cumulative
percentage by weight lighter than" values.
In addition, an effective mean weight, W em, is specified. It is the arithmetic mean weight of all rocks
in a given sample, excluding those lighter than the lightest rock size (a). Rock for the structure(s)
shall be classified by weight and comply with the grading(s) indicated in
Page 29-45
Table 29-17.
The Contractor shall provide and display in a prominent location, to the agreement of the Engineer,
a series of sample rocks clearly marked with their weight covering the range of rock sizes to be used
on the Project. These rocks shall be used as a visual reference to assist in rock inspections.
Table 29-17: Rock grading(s)
Rock Class Rock Size (kg) Wem (kg)

Class Description (a) (b) (c) (d) min max
A 5 to 100 kg rock 1 5 100 150 15 45
Allowable range of y y<2% 0%<y<10% 70%<y<100% 97%<y
29.15.2.5 Quality Control

The Contractor shall undertake sampling and testing for each quarry, quarry face or other source in
accordance with the schedule set out in Table 29-18 for the tests set out in Article 29.15.2.1, Article
29.15.2.2, Article 29.15.2.3, and Article 29.15.2.4
Table 29-18: Rock test requirements for scour protection
Sample Size for Grading and Visual

Frequency of Testing
Inspection
Class A Every 2,000 tonnes 5 tonnes
The Contractor shall undertake sampling and testing for each quarry, quarry face or other source
before commencement of the work for the tests (2), (3), (4), (5) and (6) set out in Article 29.15.2.1.
In addition, the Contractor shall undertake additional sampling and testing when circumstances so
dictate or as instructed by the Engineer.
Any rock in non-compliance shall be rejected and removed from the site by the Contractor.
29.15.3 Placing of Rock Materials

29.15.3.1 Transporting and Depositing Rock Materials
The Contractor shall supply and transport rock material by land or sea, or a combination of both, and
deposit it by means of marine or land operated plant. The Contractor shall take all precautions and
provide all means necessary to ensure that the various classes of rock material are deposited in the
position and to the slopes indicated on the Contract plans. The rock materials shall be placed using
techniques to achieve a dense fill with no segregation and no contamination from seabed deposits.
29.15.3.2 Grading of Armouring to be Maintained

The grading of armouring within each class shall be correctly maintained and to this end the
Contractor shall take all actions necessary to remove any rocks that may have been displaced by
wave or other action and washed, or swept or otherwise moved into voids of previously placed
armouring, before any further armouring necessary to complete the sections is placed.
Page 29-46
29.15.3.3 Survey Equipment

The Contractor shall provide and operate all necessary equipment required for progress surveying
of the structure(s). This shall include but not be limited to suitable optical/ electronic survey
equipment for above water surveys and a launch fitted with approved echo sounding equipment for
executing soundings. The soundings shall be expressed as reduced levels and shall be fully
compensated for tides and motion of the survey vessel. Soundings shall be accurate to ± 0.05m.
29.15.3.4 Construction Survey

Surveys shall be carried out before rock placing commences, and on the completion of any rock
layer. As a minimum these shall comprise cross sections at 5m centres across the scour protection
perpendicular to the pile caps. No surface shall be covered until the profile survey for the previous
layer has been completed, and it has been agreed by the Engineer that this layer meets the specified
requirements.
29.15.3.5 Above Water Survey Technique for Rock Armour

Rock armour above 0.0m NADD shall be surveyed using optical/electronic survey equipment. The
level and position of each rock on each profile shall be measured and recorded. The location of the
staff or target on each rock shall be discussed and agreed with the Engineer but shall generally be
on the highest point of the outermost part of the rock. Consistency of measurements is of the essence
to obtain meaningful results.
29.15.3.6 Below Water Survey Techniques for Rock Structures

Rock profiles below low water level shall be surveyed using a suitable echo sounder. The vessel on
which this equipment is installed shall also be fitted with suitable positioning equipment to allow the
survey lines sailed to be repeated to allow accurate comparisons of changes between surveys. For
the portions of the scour protection close to low water level the surveys shall be carried out at high
tide to allow the greatest possible overlay with the above water surveys as set out in this article.
29.15.3.7 Presentation of Results

At each profile, the actual measured profile of each part of the rock shall be plotted on the same plot
so that actual profile and layer thicknesses may be compared to the specified requirements. These
plots shall be at a minimum scale of 1:50.
Rock materials shall be placed to the levels, dimensions and slopes shown on the Contract plans.
Rock Materials shall comply with the tolerances given in the Table 29-19.
Table 29-19: Rock material tolerances
Armour Class Description Tolerance on layer thickness
-100mm
Class A 5 to 100kg
+300mm
Notwithstanding the tolerances tabulated above, the following requirements shall apply:
a. No two adjacent actual measured profiles shall both be in the negative tolerance band.
b. No two adjacent layer thicknesses shall both be in the negative tolerance band.
In addition to the above tolerances, all profiles shall be reviewed for general acceptability and
undesirable trends shall be corrected. In particular, attention shall be paid to deviation from the
design slope and unacceptable deviations shall be corrected.
Page 29-47
29.16 Sea Port Authority Works

When a marine bridge crosses a navigable waterway and includes permanent piers with submerged
obstructions close to the navigation channel(s), the navigable channel(s) must remain open to sea
traffic during construction.
29.16.1 Navigation beacons

Within the navigation channel and in close proximity to its sides, upon each corner of the submerged
pile caps shall be fixed approved solar powered navigation beacons. They shall be of the Pharos
Marine type LBEA-85/R complete with SZ-10-100 solar system (or equal approved) mounted on
3.5m painted steel posts secured to the top of the pile caps with stainless steel fixing sockets cast
into the concrete.
The Contractor shall submit full details of the proposed beacons together with the fixing details in a
timely manner to ensure the necessary approvals are obtained without any delay to pier construction.
During construction, the Contractor shall ensure that any obstructions placed within or close to the
navigation channel(s) are suitably protected by temporary warning beacons to the approval of the
Sea Port Authority.
29.16.2 Navigation direction signs

The Contractor shall provide such navigation direction signs together with any lights, power supply
and cabling as are required by the Sea Port Authority for the purposes of delineating the shipping
channels beneath the marine bridge spans. The Contractor shall submit for the Engineer’s approval
details of suitable signing in accordance with the recommendations of the International Association
of Marine Aids to Navigation and Lighthouse Authorities (IALA)
Page 29-48
INDEX
abandoned existing structures, 29-7 ducts, 29-1, 29-42, 29-43, 29-44

absorption, 29-17, 29-31, 29-45 edge distance, 29-35
access covers, 29-1, 29-42 End walls, 29-1, 29-42
Adhesive, 29-1, 29-2, 29-27, 29-30, 29-31, 29- end-bent piling, 29-10
32, 29-33, 29-34 Epoxy compounds, 29-1, 29-25
adhesives, 29-28, 29-31, 29-32, 29-33, 29-34, Epoxy injection, 29-1
29-35 equipment, 29-9, 29-10, 29-14, 29-15, 29-18,
alternative system, 29-35 29-20, 29-22, 29-23, 29-32, 29-33, 29-36,
anchors, 29-1, 29-30, 29-32, 29-33, 29-34, 29- 29-38, 29-39, 29-40, 29-41, 29-46, 29-47
35 excavation, 29-5, 29-7, 29-8, 29-9, 29-10, 29-
asphaltic concretes, 29-36 42
average weight, 29-31 Excavation, 29-9, 29-43
backfilling, 29-5, 29-43, 29-44 existing bridge structures, 29-1
blast cleaning, 29-38, 29-39 Explosives, 29-6
blasting, 29-6, 29-7, 29-8, 29-9, 29-16, 29-18, falsework, 29-7
29-38, 29-45 field test, 29-33, 29-34
borrow materials, 29-44 Fillers, 29-30
bridge deck, 29-11, 29-36, 29-42 finishing machine, 29-40, 29-41
Bridge Deck, 29-1, 29-36 fluid, 29-24, 29-25
Bridge drainage systems, 29-1 frames, 29-11, 29-12, 29-13, 29-42
casing, 29-10, 29-11 freshly placed concrete, 29-11, 29-44
castings, 29-12, 29-13 geocomposite drainage systems, 29-11, 29-
Certificate of Compliance, 29-37 15
channel grates, 29-11 grading, 29-10, 29-44, 29-45, 29-46
chipping, 29-6, 29-39 grinding, 29-6, 29-16, 29-24
coal tar, 29-25, 29-29, 29-43 ground elevation, 29-6
coarse brooming, 29-38 hazardous materials, 29-8
Cofferdams, 29-10 heat straightening, 29-6
components, 29-11, 29-13, 29-15, 29-20, 29- high winds, 29-40
21, 29-27, 29-30, 29-38 hot applied, 29-29
Compression strength test, 29-42 independent testing, 29-33
concrete gutters, 29-11 initiator, 29-21, 29-22
contamination, 29-19, 29-33, 29-38, 29-39, internal access walkways, 29-1
29-46 latex-modified concrete, 29-36, 29-37, 29-38,
Continuous-type mixers, 29-39 29-40, 29-41
cotton ball, 29-24 Lockable doors, 29-1, 29-42
cotton strand, 29-24 low humidity conditions, 29-40
cracks, 29-1, 29-9, 29-12, 29-15, 29-16, 29- major structures, 29-5
20, 29-22, 29-23, 29-33, 29-42, 29-45 mix designs, 29-28
culverts, 29-6 mobile distribution, 29-23
curing, 29-18, 29-24, 29-27, 29-32, 29-33, 29- monomer, 29-21, 29-22, 29-23
38, 29-40, 29-42 mortar, 29-14, 29-26, 29-28
daily log, 29-20 navigation beacons, 29-48
demolition, 29-6, 29-8 navigation channel, 29-48
density, 29-10, 29-31, 29-45 navigation direction signs, 29-48
deteriorated concrete, 29-16 Oscillating screed-type machines, 29-40
dewatering, 29-8, 29-9, 29-43 penetrant sealers, 29-17
dimensions, 29-12, 29-47 perforated pipes, 29-13
dowels, 29-1, 29-30, 29-32, 29-33, 29-34 personnel, 29-15, 29-16, 29-20, 29-23
drainage blankets, 29-11 Piezometers, 29-9
drilling, 29-6, 29-12, 29-16, 29-33, 29-35 promoter, 29-21, 29-22
Drip check angles, 29-1 rain, 29-23, 29-40, 29-42
Page 29-49
Repairs, 29-6 stress-strain, 29-25

retaining walls, 29-5, 29-10, 29-42 structures foundations, 29-1
Right of Ways, 29-8 subgrade elevation, 29-6
roadway surface, 29-36 subways, 29-11
rock armour, 29-45 Supervisor, 29-16
rock cores, 29-8 surface water, 29-11
Rotating roller-type machines, 29-40 surveying, 29-46
rough texture, 29-38 tanks, 29-24, 29-28
sacrificial tests, 29-35 tolerances, 29-15, 29-33, 29-47
Safety considerations, 29-44 traffic, 29-5, 29-6, 29-22, 29-24, 29-28, 29-31,
Salvaged, 29-7 29-32, 29-33, 29-39, 29-42, 29-48
sand, 29-12, 29-16, 29-17, 29-20, 29-22, 29- underpasses, 29-11
23, 29-24, 29-26, 29-27, 29-28, 29-30, 29- unsuitable material, 29-8
38, 29-39, 29-41, 29-42 unused material, 29-20
Scour protection, 29-1 utilities, 29-6
Sealing, 29-1, 29-16, 29-19, 29-20, 29-22, 29- variable pressures, 29-15
23 vibrations, 29-8, 29-9, 29-11
setting time, 29-31 volatile solvent, 29-25
shafts, 29-9, 29-10 wearing surfaces, 29-1, 29-24, 29-36, 29-38,
sleeves, 29-12 29-42
slopes, 29-46, 29-47 weather conditions, 29-23
slump, 29-37, 29-40 weep holes, 29-11, 29-14
soil samples, 29-8 welding, 29-6, 29-12
spacing, 29-16, 29-35 wrecking balls, 29-6
Page 29-50
PART 2
ROAD STRUCTURES
CHAPTER 30 - MISCELLANEOUS METALS
DOCUMENT NO: TR-

FIRST EDITION
JANUARY 2018
Chapter 30: Miscellaneous Metals

TABLE OF CONTENTS
List of Tables .................................................................................................................................. ii
30 Miscellaneous Metals ...................................................................................................... 30-1
30.1 Description................................................................................................................... 30-1
30.3 Materials ...................................................................................................................... 30-5
30.4 Miscellaneous Iron and Steel ....................................................................................... 30-6
30.4.1 Frames, Grates, Rings, and Covers ...................................................................... 30-7
30.4.1.1 Documentation .............................................................................................. 30-7
30.4.1.2 Construction .................................................................................................. 30-7
30.4.2 Stainless Steel Bolts ............................................................................................. 30-7
30.5 Miscellaneous Bridge Metal ......................................................................................... 30-8
30.6 Bridge Joint Restrainer Units ..................................................................................... 30-10
30.7 Miscellaneous Metal Pipes......................................................................................... 30-13
30.7.1 Ductile Iron Culvert Pipe ..................................................................................... 30-13
30.7.2 Slotted Drain Pipe ............................................................................................... 30-13
30.7.3 Metallic-coated Spiral Rib Pipe ........................................................................... 30-13
30.7.4 Aluminium-alloy Spiral Rib Pipe .......................................................................... 30-13
30.7.5 Concrete-lined Corrugated Steel Pipe................................................................. 30-13
30.7.6 Invert-paved Corrugated Steel Pipe .................................................................... 30-13
30.7.7 Cast-iron Soil Pipe and Fittings ........................................................................... 30-13
30.7.8 Seamless Copper Water Tube and Fittings......................................................... 30-14
30.8 Corrugated Metal Units .............................................................................................. 30-14
30.9 Aluminium for Signs ................................................................................................... 30-14
30.10 Other Miscellaneous Metals ....................................................................................... 30-15
30.10.1 Steel Castings .................................................................................................... 30-15
30.10.2 Bronze Castings ................................................................................................. 30-15
30.10.3 Cold-finished, Carbon Steel Shafting .................................................................. 30-15
30.10.4 Lubricated Bronze Plates .................................................................................... 30-15
30.10.5 Steel Forgings .................................................................................................... 30-16
30.10.6 Welded and Seamless Steel Pipe ....................................................................... 30-16
30.10.7 Pipe Fittings ........................................................................................................ 30-16
30.10.8 Sheet Lead ......................................................................................................... 30-16
30.10.9 Sheet Copper ..................................................................................................... 30-16
30.10.10 Sheet Zinc .......................................................................................................... 30-16
30.11 Fabrication ................................................................................................................. 30-16
30.12 Galvanizing ................................................................................................................ 30-17
30.13 Transporting Materials ............................................................................................... 30-17
30.14 Storage of Materials ................................................................................................... 30-17
30.15 Clean-up .................................................................................................................... 30-17
Index ...................................................................................................................................... 30-18
Page i
CHAPTER 30: MISCELLANEOUS METALS First Edition -January 2018
LIST OF TABLES
Table 30-1: Designations and titles for AASHTO and ASTM standards that apply to miscellaneous
metals ........................................................................................................................................ 30-2
Table 30-2: Materials specifications ........................................................................................... 30-5
Table 30-3: Values of sustained tension test loads for mechanical expansion and resin capsule
anchors ...................................................................................................................................... 30-9
Table 30-4: Ultimate tensile loads for studs of different diameters ............................................. 30-9
Table 30-5: Installation torque values, (Newton meters)........................................................... 30-10
Table 30-6: Minimum Size of Fillet Weld for Different Thicknesses .......................................... 30-12
Page ii
30 MISCELLANEOUS METALS
30.1 Description
This work shall consist of furnishing and installing miscellaneous iron and steel, miscellaneous metal
(bridge), miscellaneous metal (restrainer), miscellaneous metal pipe, corrugated metal units,
aluminium for signs, and other items specifically identified as miscellaneous metal in the Contract
documents, all as shown on the Contract plans or as directed by the Engineer, and as specified in
these specifications and the Contract documents.
Miscellaneous iron and steel, miscellaneous metal (bridge), and miscellaneous metal (restrainer)
shall be inspected at the fabrication site. The Contractor shall notify the Engineer when materials
have been delivered to the fabrication site and shall give the Engineer at least two weeks’ notice
after delivery before commencing the fabrication of the miscellaneous metal. Materials to be used
shall be made available to the Engineer so they can be examined. The Engineer shall have free
access at all times to any portion of the fabrication site where the material is stored or where work
on the material is being performed.
The Contractor shall submit to the Engineer four sets of working drawings two weeks prior to the
fabrication of the miscellaneous metal works. Working drawings shall show all information necessary
for the fabrication of the metal work and shall be in the same system of units as the Contract plans.

Standards and codes for materials of miscellaneous metals and related construction works shall be
as specified in this section, in the Contract documents, if any, and the following, in their latest edition:
and Testing;
AISI American Iron and Steel Institute;
D1.1/D1.1M:2010
D1.5M/D1.5:2010
FED RR-W-410F Wire Rope and Strand, Federal Specifications and Standards, 06-Dec-2007.
and American Society for Testing and Materials (ASTM) Standards that are related to materials for
miscellaneous metals. It also includes designations and titles.
Page 30-1
miscellaneous metals
AASHTO ASTM
TITLE
ASTM A36 /
A36M - 08
ASTM A575 - Standard Specification for Steel Bars, Carbon, Merchant
96(2007) Quality, M-Grades
ASTM A576 - Standard Specification for Steel Bars, Carbon, Hot-
90b(2012) Wrought, Special Quality
ASTM A307 - 10
AASHTO M
Standard Specification for Steel Anchor Bolts
314-90 (2008)
Standard Specification for Hex Cap Screws, Bolts and
ASTM A449 - 10 Studs, Steel, Heat Treated, 120/105/90 ksi Minimum
Tensile Strength, General Use
ASTM A563 -
Standard Specification for Carbons and Alloy Steel Nuts
07a
ASTM F844 - Standard Specification for Washers, Steel, Plain (Flat),
07a Unhardened for General Use
AASHTO M Standard Specification for Structural Bolts, Steel, Heat
ASTM A325 - 10
164-05 Treated, 120/105 ksi Minimum Tensile Strength
Standard Specification for “Twist Off” Type Tension
ASTM F1852 -
Control Structural Bolt/Nut/Washer Assemblies, Steel,
11
Heat Treated, 120/105 ksi Minimum Tensile Strength
ASTM F436 - 11 Standard Specification for Hardened Steel Washers
Standard Specification for Compressible-Washer-Type

ASTM F959 - 09
Direct Tension Indicators for Use with Structural Fasteners
ASTM F593 - Standard Specification for Stainless Steel Bolts, Hex Cap
02(2008)e1 Screws, and Studs
ASTM F738M - Standard Specification for Stainless Steel Metric Bolts,
02(2008) Screws, and Studs
ASTM F594 -
Standard Specification for Stainless Steel Nuts
09e1
ASTM F836M - Standard Specification for Style 1 Stainless Steel Metric
02(2010) Nuts
ASTM A536 -
84(2009)
AASHTO M ASTM A27 / Standard Specification for Steel Castings, Carbon, for
103M/M 103-12 A27M - 10 General Application
Page 30-2
AASHTO ASTM
TITLE
ASTM A47 /
A47M - Standard Specification for Ferritic Malleable Iron Castings
99(2009)
ASTM A48 /
AASHTO M
A48M - Standard Specification for Gray Iron Castings
105-09
03(2008)
AASHTO M Standard Specification for Drainage, Sewer, Utility, and
306-10 Related Castings
AASHTO M 36- ASTM A760 / Standard Specification for Corrugated Steel Pipe, Metallic-
03 (R2011) A760M - 10 Coated, for Sewers and Drains
AASHTO M Standard Specification for Steel Sheet, Zinc-Coated
218-03 (R2011) (Galvanized), for Corrugated Steel Pipe
AASHTO M Standard Specification for Steel Sheet, Aluminum-Coated
274-87 (2012) (Type 2), for Corrugated Steel Pipe
AASHTO M Standard Specification for Aluminum-Zinc Alloy Coated
289-91 (2012) Sheet Steel for Corrugated Steel Pipe
ASTM B745 /
AASHTO M Standard Specification for Corrugated Aluminum Pipe for
B745M -
196-92 (2012) Sewers and Drains
97(2005)
AASHTO M Standard Specification for Bituminous-Coated Corrugated
190-04 (2012) Metal Culvert Pipe and Pipe Arches
AASHTO M
243- Standard Specification for Field-Applied Coating
1996(R2008)
ASTM A761 / Standard Specification for Corrugated Steel Structural
AASHTO M
A761M - Plate, Zinc-Coated, for Field-Bolted Pipe, Pipe-Arches,
167M/M 167-09
04(2009) and Arches
ASTM B746 / Standard Specification for Corrugated Aluminum Alloy
AASHTO M
B746M - Structural Plate for Field-Bolted Pipe, Pipe-Arches, and
219-92 (2012)
02(2012) Arches
AASHTO M Standard Specification for Corrugated Steel Pipe,
245-00 (2012) Polymer-Precoated, for Sewers and Drains
ASTM A742 /
AASHTO M Standard Specification for Steel Sheet, Metallic-Coated
A742M -
246-05 (R2011) and Polymer-Precoated, for Corrugated Steel Pipe
03(2008)
AASHTO ASTM
Standard Specification for Steel Castings for Highway
M192M/M192- A486/A486M -
Bridges
1994 87
AASHTO M Standard Specification for Steel Bars, Carbon, and Alloy,
ASTM A108 - 07
169-09 Cold-Finished
ASTM A240 /
Nickel Stainless Steel Plate, Sheet, and Strip for Pressure
A240M - 12
Vessels and for General Applications
Page 30-3
AASHTO ASTM
TITLE

ASTM B221 - 12
Extruded Bars, Rods, Wire, Profiles, and Tubes
ASTM B26 /
Standard Specification for Aluminum-Alloy Sand Castings
B26M - 12
ASTM A722 / Standard Specification for Uncoated High-Strength Steel
A722M - 12 Bars for Prestressing Concrete
Standard Specification for Steel Sheet, Zinc-Coated
ASTM A653 /
(Galvanized) or Zinc-Iron Alloy-Coated (Galvannealed) by
A653M - 11
the Hot-Dip Process
ASTM A684 / Standard Specification for Steel, Strip, High-Carbon, Cold-
A684M - 12 Rolled
ASTM D1056 - Standard Specification for Flexible Cellular Materials—
07 Sponge or Expanded Rubber
ASTM A716 - 08 Standard Specification for Ductile Iron Culvert Pipe
ASTM Standard Specification for Steel Sheet, Zinc and Aramid

A885/A885M- Fiber Composite Coated for Corrugated Steel Sewer,
96(2002) Culvert, and Underdrain Pipe (Withdrawn 2006)
ASTM A1011 / Rolled, Carbon, Structural, High-Strength Low-Alloy, High-
A1011M - 12a Strength Low-Alloy with Improved Formability, and Ultra-
High Strength
Standard Specification for Post-Applied Coatings, Pavings,
ASTM A849 - 10
and Linings for Corrugated Steel Sewer and Drainage Pipe
ASTM A74 - 09 Standard Specification for Cast Iron Soil Pipe and Fittings
ASTM B88 - 09 Standard Specification for Seamless Copper Water Tube

ASTM B209 - 10
Sheet and Plate
ASTM B211 - Standard Specification for Aluminum and Aluminum-Alloy
12e1 Rolled or Cold Finished Bar, Rod, and Wire
ASTM B108 / Standard Specification for Aluminum-Alloy Permanent
B108M - 12e1 Mold Castings
ASTM B22 - Standard Specification for Bronze Castings for Bridges
09e2 and Turntables
ASTM A434 - Standard Specification for Steel Bars, Alloy, Hot-Wrought
06(2012) or Cold-Finished, Quenched and Tempered
Standard Specification for Wrought Copper-Alloy Bearing
ASTM B100 - 08 and Expansion Plates and Sheets for Bridge and Other
Structural Use
Page 30-4
AASHTO ASTM
TITLE
ASTM A668 /
Standard Specification for Steel Forgings, Carbon and
A668M -
Alloy, for General Industrial Use
04(2009)
ASTM B29 -
Standard Specification for Refined Lead
03(2009)
ASTM B152 / Standard Specification for Copper Sheet, Strip, Plate, and
B152M - 09 Rolled Bar
ASTM B6 - 12 Standard Specification for Zinc
The Contractor shall manufacture and test miscellaneous metals in accordance with these
specifications and in compliance with AASHTO/ASTM standards. Where miscellaneous metals are
manufactured and tested by standards other than AASHTO/ASTM, products conforming to
equivalent or higher standards will be acceptable if proven to be suitable.
30.3 Materials
Miscellaneous metal items shall be constructed of materials conforming to the following AASHTO
(or ASTM) material specifications as shown in Table 30-2, unless otherwise specified in the Contract
documents or subsequent sections:
Table 30-2: Materials specifications
Materials AASHTO and ASTM Designation
Steel bars, plates, and shapes ASTM A36 / A36M - 08, Grade 36 or ASTM A575 -
96(2007), ASTM A576 - 90b(2012) (AISI or M
Grades 1016 through 1030 except Grade 1017)
Steel fastener components for general

applications:
• Bolts and studs • ASTM A307 - 10
• Headed anchor bolts • ASTM A307 - 10, Grade B, including S1
supplementary requirements
• Non-headed anchor bolts • ASTM A307 - 10, Grade C, including S1
supplementary requirements and S1.6 of AASHTO
M 314-90 (2008) supplementary requirements or
AASHTO M 314-90 (2008), Grade 250 or 380,
including S1 supplementary requirements
• High-strength bolts and studs,
threaded rods, and non-headed • ASTM A449 - 10, Type 1
anchor bolts
• Nuts • ASTM A563 - 07a, including Appendix X1*
• Washers • ASTM F844 - 07a
Page 30-5
Materials AASHTO and ASTM Designation
Components of high-strength steel

fastener assemblies for use in
structural steel joints:
• Bolts • AASHTO M 164-05 (ASTM A325 - 10, Type 1)
• Tension control bolts • ASTM F1852 - 11, Type 1
• Nuts • ASTM A563 - 07a, including Appendix X1*
• Hardened washers • ASTM F436 - 11, Type 1, circular, including S1
supplementary requirements
Direct tension indicators • ASTM F959 - 09, Type 325, zinc-coated
Stainless steel fasteners (Alloy 316) for

general applications:
• Bolts, screws, studs, threaded rods, • ASTM F593 - 02(2008)e1 or ASTM F738M -
and non-headed anchor bolts 02(2008)
• Nuts
• Washers • ASTM F594 - 09e1 or ASTM F836M - 02(2010)
• ASTM A240 / A240M - 12 and ANSI B 18.22M
Stainless steel plates (Alloy 316) for
general applications • ASTM A240 / A240M - 12
AASHTO M 103M/M 103-12 or ASTM A27 / A27M -

Carbon-steel castings
10, Grade 450-240, Class 1
Malleable iron castings ASTM A47 / A47M - 99(2009), Grade 32510/ 22010
AASHTO M 105-09 or ASTM A48 / A48M - 03(2008),

Gray iron castings
Class 30B
Ductile iron castings ASTM A536 - 84(2009), Grade 450-310-85
Aluminium alloy ladder rung material ASTM B221 - 12, Alloy 6061-T6
Aluminium castings ASTM B26 / B26M - 12, Alloy 356.0-T6
Cast iron pipe Commercial quality
Steel pipe Commercial quality, welded or extruded
Sheet metal Commercial quality
Other parts for general applications Commercial quality
* Zinc-coated nuts that will be tightened beyond snug or wrench tight shall be furnished with a dyed
dry lubricant conforming to Supplementary Requirement S2 in ASTM A563 - 07a.
30.4 Miscellaneous Iron and Steel

Miscellaneous iron and steel items shall conform to the dimensions and details shown on the
Contract plans and as specified in these specifications and the Contract documents.
Page 30-6
30.4.1 Frames, Grates, Rings, and Covers

Unless otherwise specified elsewhere in these standard specifications or in the Contract particular
specifications, the Contractor shall furnish and install frames, grates, rings, and covers for inlets,
manholes, and other structures in conformance with the following.
Fabrication shall be performed in a workmanlike manner in conformance with the practice in modern
commercial shops. Burrs, rough and sharp edges, and other flaws shall be removed. Warped pieces
shall be straightened after all fabrication and galvanizing.
Grates, manhole frames, and covers shall be fabricated from ductile iron castings. The Contractor
shall:
a. Provide clean castings conforming to the shape and dimensions shown on the plans.
b. Ensure that the castings are free from sand and blowholes or other defects, and that surfaces
of the castings are reasonably smooth.
c. Remove runners, risers, fins, and other cast-on pieces from the castings, and grind these
areas smooth.
d. Cast or machine the bearing surfaces between manhole rings and covers and between
grates and frames with such precision that uniform bearing is provided throughout the
perimeter area of contact.
e. Matchmark pairs of machined castings for proper identification at installation. Grates and
covers shall fit into their frames without rocking.
Frame, grate, ring, and cover castings shall meet the proof-load testing requirements of AASHTO M
306-10. The Contractor shall use commercial type frames, rings, risers, or appurtenances only with
prior approval of the Engineer.
30.4.1.1 Documentation
The Contractor shall furnish mill test reports or a manufacturer’s certification to the Engineer for each
lot or shipment of iron materials. For castings, the Contractor shall also furnish a manufacturer’s
certification stating that the castings meet the proof-load testing requirements of AASHTO M 306-
10.
The Contractor shall construct and install frames, grates, rings, and covers in accordance with the
details shown on the Contract plans. Welding shall be in accordance with the current AASHTO/AWS
D1.5M/D1.5:2010, Bridge Welding Code. The Contractor shall tack-weld grates and covers to the
frame or ring when directed by the Engineer.
The Contractor shall provide galvanized bolts and nuts in accordance with Section 30.12,
Galvanizing.
All other cast iron items shall be painted with or dipped in commercial quality asphaltum.
30.4.2 Stainless Steel Bolts

Unless otherwise specified in the Contract documents or other sections of these standard
specifications, stainless steel bolts shall conform to ASTM F593 - 02(2008)e1 Alloy Groups 1, 2, or
3. Stainless steel nuts shall conform to ASTM F594 - 09e1.
ASTM F593 - 02(2008)e1 Alloy Groups 1, 2, and 3 are 300 series stainless steel alloys. Fasteners
for stainless steel Alloys 304 and 316 shall be used uncoated in aluminium structures. Three-
hundred series stainless steel in contact with aluminium need not be painted.
Page 30-7
30.5 Miscellaneous Bridge Metal

Miscellaneous bridge metal shall conform to the provisions in Section 30.4, Miscellaneous Iron and
Steel, and the provisions in this section. Miscellaneous metal used in constructing bridges and other
structures described as bridge work in the Contract documents, excluding miscellaneous metal
identified under separate Contract items, shall conform to the details shown on the Contract plans
and as specified in these specifications and the Contract documents.
Miscellaneous bridge metal shall consist of the following:
1. Bearing assemblies and equalizing bolts
2. Expansion joint armor in steel and concrete bridge decks and sliding plate and finger-type
expansion joints
3. Manhole frames and covers, frames and grates, ladder rungs, guard posts, access opening
covers, and access door assemblies
4. Deck drains, area drains, retaining wall drains, and drainage piping
Bearing assemblies shall be fabricated from structural steel conforming to the requirements in ASTM
A36 / A36M - 08.
High-strength bolted connections shall conform to the provisions for high-strength steel fasteners
and bolted connections in Sections 23.4.2 and 23.6.9 of Chapter 23, Steel Structures, of these
standard specifications.
Equalizing bolts shall consist of bolts or threaded bars. Threaded bars identified as prestressing steel
on the Contract plans shall conform to the requirements for plain bars in ASTM A722 / A722M - 12,
including Supplementary Requirements. When noted on the Contract plans, nuts, bolts, threaded
bars, and plate washers shall be cleaned by blast cleaning or hand cleaning, at the option of the
Contractor. Unless otherwise specified, all surfaces, except the portion of threads engaged by nuts,
shall be painted with two applications of zinc-rich primer that has not been thinned (organic vehicle
type), and conforms to the provisions of Article 24.3.2.2 of Chapter 24, Painting. Aerosol cans shall
not be used. The second application shall be applied to nuts and threads after installation.
An approved thread locking system, consisting of a cleaner, primer, and anaerobic adhesive shall
be applied where shown on the Contract plans. Lubricants and foreign materials shall be removed
from the threaded areas of both parts using the cleaner and small wire brush. The primer shall be
applied to cover the threaded areas of both parts. The anaerobic adhesive shall be applied to fill the
male threads in the area of the final position of the nut. The nut shall be installed at the location or
to the torque shown on the Contract plans, and an additional fillet of anaerobic adhesive shall be
applied completely around the exposed junctions of the nut and male part.
Access opening covers shall be fabricated from commercial quality sheet steel. Sheet steel for
access doors shall be galvanized sheet conforming to the requirements in ASTM A653 / A653M -
11, Coating Designation G 210.
Springs for deck drain grating latches shall be made from commercial quality type 304 stainless steel
spring wire containing a nominal composition of 18% chromium and 8% nickel. Spring latches and
other mechanical devices shall be tested before delivery, and shall operate smoothly and properly.
Cast steel and cast iron shall conform to the applicable provisions in Chapter 23, Steel Structures,
Pipe bends shall be commercial quality tube bends or fabricated bends of substantially equal
smoothness. Miter-joint bends will not be accepted.
Transition fittings between pipes of different diameters shall be smooth, uniform, without sags,
projections, or off-sets, and shall be at least 100 mm in length for each 25 mm reduction in pipe
diameter.
Page 30-8
Mechanical expansion anchors shall be the integral stud type or the shell type with internal threads
and an independent stud. Self-drilling mechanical expansion anchors shall not be used.
All metal parts of anchorage devices shall be fabricated from steel or stainless steel, except iron
castings for cast-in-place inserts, which shall be malleable iron or ductile iron.
When installed in accordance with the manufacturer's instructions and these specifications,
mechanical expansion and resin capsule anchors shall withstand the application of a sustained
tension test load of at least the values in Table 30-3 for a period of at least 48 hours with a movement
not greater than 0.9 mm.
Table 30-3: Values of sustained tension test loads for mechanical expansion and resin
capsule anchors
Stud Diameter (mm) Sustained Tension Test Load (kN)

29.01 - 33.00 137.9
25.01 - 29.00 79.6
21.01 - 25.00 64.1
19.01 - 21.00* 22.2
15.01 - 19.00 18.2
12.01 - 15.00 14.2
9.01 - 12.00 9.34
6.00 - 9.00 4.23
* Maximum stud diameter permitted for mechanical expansion anchors.

When installed in conformance with the manufacturer's instructions and these specifications, cast-
in-place inserts shall withstand the minimum ultimate tensile loads indicated in Table 30-4.
Table 30-4: Ultimate tensile loads for studs of different diameters
Stud Diameter (mm) Ultimate Tensile Load (kN)

30 - 33 112.1
27 - 30 88.1
24 - 27 71.2
20 - 24 51.6
16 - 20 32.0
14 - 16 29.4
12 - 14 18.7
Concrete anchorage devices shall be subject to the approval of the Engineer. Approval of anchorage
device types and sizes shall be contingent upon the Contractor submitting to the Engineer one
sample of each type of concrete anchorage device, the manufacturer's installation instructions and
certified results of tests, by an approved independent testing laboratory, indicating compliance with
the above requirements. Anchorage devices previously tested and found to be in compliance with
the above requirements and approved by the Engineer need not be re-tested.
Concrete anchorage devices shall be installed in the concrete as shown on the Contract plans, as
recommended by the manufacturer of the devices, and as specified herein, so that the attached
equipment or fixtures will bear firmly against the concrete. Shell type mechanical expansion anchors
Page 30-9
shall be installed so that the top surface of the anchor body remains 12 mm to 25 mm below the
surface of the concrete after expansion. After installation of shell type mechanical expansion
anchors, and prior to mounting any equipment or fixture, the Contractor shall demonstrate, in the
presence of the Engineer, that the expansion anchor is firmly seated within the above tolerances.
If the manufacturer's instructions do not include specific torque requirements, nuts used to attach
equipment or fixtures to anchorage devices shall be tightened to the following installation torque
values indicated in Table 30-5.
Table 30-5: Installation torque values, (Newton meters)
Shell Type Integral Stud Type
Resin Capsule
Stud Diameter Mechanical Mechanical
Anchors and
(mm) Expansion Expansion
Cast-in-Place Inserts
Anchors Anchors
29.01 - 33.00 — — 650
25.01 - 29.00 — — 400
21.01 - 25.00 — — 290
19.01 - 21.00 110 235 180
15.01 - 19.00 45 120 90
12.01 - 15.00 30 65 40
9.01 - 12.00 15 35 20
6.00 - 9.00 5 10 7
Joints in drain pipe shall be watertight, and shall be smooth and free from projections or off-sets in
excess of 2 mm on the inside. Mechanical couplings in piping shall be gasketed, short sleeve type
couplings consisting of a mild steel middle ring with pipe stop, two rubber-compounded wedge-
section ring gaskets, two mild steel follower rings, and sufficient mild steel bolts to compress the
gaskets.
Galvanizing of miscellaneous bridge metal will not be required for portions of plates, shapes, or other
items embedded more than 50 mm in concrete; embedded steel pipe terminating at or below the
surface of encasing concrete; and items shown on the Contract plans to receive a different finish.
Where local conditions require that pipes under walkways and other improved areas be of smaller
diameter than the down-drain pipes, a transition section shall be provided.
During construction operations, deck drain grates and other grating openings shall be securely
covered to prevent intrusion of debris until after final cleanup of the deck and other drainage areas.
After the cleanup of the deck and other drainage areas, each drain pipe and facility, except short
free-fall pipes, shall be tested in the presence of the Engineer by discharging approximately 400
liters of water into the drain to demonstrate the proper operation of the drain pipe and facility. If
evidence of obstructions in the pipe is observed, the pipe shall be cleared and the test repeated until
the drain pipe and facility are unobstructed.
30.6 Bridge Joint Restrainer Units

Bridge joint restrainer units, of the type or types shown on the Contract plans, consisting of cables
or cable assemblies and associated materials or components, shall conform to the details shown on
the Contract plans and the requirements of these specifications and the Contract documents.
The associated materials or components required for each restrainer unit type shall be as shown on
the Contract plans or as specified in the Contract documents and include various combinations of
the following:
Page 30-10
• Structural steel components

• Bolts
• Bearing plates
• Cable drum units
• Pipe sleeves
• Polyvinyl chloride pipe
• Elastomeric pads
• Expansion joint filler
• Expanded neoprene
• Expanded polystyrene
• Sheet neoprene
• Hardboard
• Incidentals
Cables shall be 19 mm pre-formed, 6 by 19, wire-strand core or independent wire rope core (IWRC),
galvanized, right regular lay, manufactured of improved plow steel with a minimum breaking strength
of 200 kN, and in conformance with the requirements in Specification FED RR-W-410F, Wire Rope
and Strand.
Cable assemblies shall consist of cables, swaged fittings, studs, nuts, cable yield indicators, disk
springs, and when shown on the Contract plans, turnbuckles, and shall conform to the following
requirements:
a. The swaged fitting shall be machined from hot, rolled bars of steel conforming to the
requirements in the AISI C1035, and shall be annealed, suitable for cold swaging. A lock pin
hole to accommodate a 6 mm plated spring steel pin shall be drilled through the head of the
swaged fitting to retain the stud in proper position. The manufacturer's identifying mark shall
be stamped on the body of the swaged fitting.
b. The 25 mm-diameter stud shall conform to the requirements in ASTM A449 - 10 after
galvanizing. Prior to galvanizing, a 10 mm slot for the locking pin shall be milled in the stud
end.
c. Nuts shall conform to the requirements in ASTM A563 - 07a including Appendix X1, except
that lubrication is not required.
d. The cable yield indicator shall be machined from hot rolled bars of steel conforming to the
requirements in AISI C 1035 and shall be annealed, suitable for cold swaging. The heat
number and manufacturer's identifying mark shall be stamped on the end surface of each
cable yield indicator. The wall thickness of the reduced section of the cable yield indicator
shall be machined by the Contractor so that the indicator yields at a load between 160.2 kN
and 169.1 kN when tested in compression along the major axis at a test speed not to exceed
12 mm per minute.
e. The disc springs shall be made from steel conforming to the requirements in ASTM A684 /
A684M - 12, Grade 1075. Galvanizing of the disc springs will not be required. The disc springs
shall be cleaned and painted with a paint recommended by the manufacturer and color-coded
as shown on the Contract plans.
f. Turnbuckles shall be the steel pipe type. Pulls for the turnbuckles shall consist of a swaged
fitting and stud assembly.
g. The swaged fittings, turnbuckles, stud, and nut assembly shall develop the specified breaking
strength of the cable.
h. The cable assemblies shall be shipped as a complete unit including cable yield indicator, disk
springs, stud and nut, and when required, turnbuckle.
i. The Contractor shall be responsible for determining the required lengths of the cable
assemblies.
Page 30-11
j. The Contractor shall notify the Engineer, in writing, at least two days prior to tightening and
setting of cable restrainer units.
The following materials shall be furnished to the Engineer at the manufacturer's plant:
• One sample cable assembly, consisting of a cable properly fitted with a swaged fitting and
right hand thread stud at both ends, 1 meter in total length, for each 200 cable assemblies or
fraction thereof produced.
• One turnbuckle fitted with a 200 mm stud at each end for each 200 turnbuckles or fraction
thereof produced.
• One percent of the cable yield indicators, but not fewer than eight, produced from each mill
heat.
• Two disc springs of each size produced from each mill heat.
Free ends of cable for restrainer units shall be securely wrapped at each end to prevent separation.
Bolts, thread locking systems, and concrete anchorage devices shall conform to the provisions in
Section 30.5, Miscellaneous Bridge Metal.
Unless otherwise specified, steel parts shall conform to the requirements in ASTM A36 / A36M - 08.
Steel for bearing bars or pins shall conform to the requirements in ASTM A36 / A36M - 08 or ASTM
A576 - 90b(2012) Grade 1030 (AISI 1030), and shall not be rimmed or capped steel.
Pipe sleeves shall be commercial quality welded steel pipe.
Steel parts shall be galvanized in conformance with the provisions in Section 30.12, Galvanizing.
Fabrication and welding shall conform to the provisions in Section 30.5, Miscellaneous Bridge Metal.
The minimum size of fillet welds shall conform to the requirements in ANSI/ AWS D1.1/D1.1M:2010,
except as indicated in Table 30-6.
Table 30-6: Minimum Size of Fillet Weld for Different Thicknesses
Base Metal Thickness of Thicker Part Minimum Size of Fillet Weld
Joined (mm) (mm)
19 - 38 8
30 - 57 10
58 - 150 13
Over 150 16
Concrete for filling cable drum units shall conform to the applicable provisions in Chapter 21,
Concrete Structures, or shall be a commercial-grade pea gravel mix with not less than 400 kg of
cement per cubic meter.
Existing structural steel paint areas damaged by the Contractor's operations and holes drilled
through existing steel members shall be repaired in conformance with the provisions for repair of
galvanized surfaces in Section 30.12, Galvanizing, at the Contractor's expense.
When shown on the Contract plans, bond breaker on PVC pipe shall consist of a mortar tight
wrapping of plastic sheet or rubber sheet, 0.25 mm minimum thick or equal.
Expansion joint filler shall conform to the provisions in Section 21.9.1 of Chapter 21, Concrete
Structures.
Closed-cell expanded neoprene material shall be of commercial quality conforming to the stiffness
requirements for Class SC Grade 43E material or firmer as set forth in ASTM D1056 - 07.
Each restrainer unit shall consist of the number of cable units shown on the Contract plans.
Page 30-12
Where shown on the Contract plans, the cable shall be covered with a piece of 19 mm inside
diameter neoprene tubing having a wall thickness of no less than 3 mm. Neoprene tubing shall be
held in place with stainless steel hose clamps. Neoprene tubing and hose clamps shall be of
commercial quality. Cadmium plated screws furnished with stainless steel clamps shall be
acceptable.
30.7 Miscellaneous Metal Pipes

Unless otherwise specified in the particular specifications or elsewhere in these standard
specifications, the Contractor shall furnish metal pipes in accordance with this section and as
30.7.1 Ductile Iron Culvert Pipe

The Contractor shall conform to ASTM A716 - 08 for the sizes specified in the Contract documents.
30.7.2 Slotted Drain Pipe

The Contractor shall furnish pipe conforming to AASHTO M 36-03 (R2011) and either AASHTO M
218-03 (R2011), AASHTO M 274-87 (2012), or AASHTO M 289-91 (2012) for the dimensions and
thicknesses specified in the Contract documents. The Contractor shall fabricate the pipe with either
angle slots or grate slots, and as shown on the Contract plans.
The Contractor shall furnish grate assemblies for the grate slot drain conforming to ASTM A1011 /
A1011M - 12a, Grade 250, and shall galvanize slot angles and grate slot assemblies according to
Section 30.4.1, Frames, Grates, Rings, and Covers.
30.7.3 Metallic-coated Spiral Rib Pipe

The Contractor shall furnish pipe, special sections (such as elbows and branch connections), and
coupling bands conforming to AASHTO M 36-03 (R2011), type IR and IIR, AASHTO M 218-03
(R2011), AASHTO M 274-87 (2012), or AASHTO M 289-91 (2012) for the dimensions and
thicknesses specified in the Contract documents.
30.7.4 Aluminium-alloy Spiral Rib Pipe

coupling bands conforming to AASHTO M 196-92 (2012) (ASTM B745 / B745M - 97(2005)), type IR
and IIR for the dimensions and thicknesses specified in the Contract documents.
30.7.5 Concrete-lined Corrugated Steel Pipe

coupling bands conforming to Section 31.1.4 of Chapter 31, Metal Culverts, for the dimensions and
thicknesses specified in the Contract documents. The Contractor shall fully-line the pipe and special
sections with concrete according to ASTM A849 - 10, Class C.
30.7.6 Invert-paved Corrugated Steel Pipe

coupling bands conforming to Section 31.1.4 of Chapter 31, Metal Culverts, for the dimensions and
thicknesses specified in the Contract documents. The Contractor shall pave the invert of the pipe
and special sections with concrete or asphalt material according to ASTM A849 - 10, Classes B or
C, as specified in the Contract documents.
30.7.7 Cast-iron Soil Pipe and Fittings

The Contractor shall furnish pipe and fittings conforming to ASTM A74 - 09, Class SV, for the
designated sizes.
Page 30-13
30.7.8 Seamless Copper Water Tube and Fittings

The Contractor shall furnish tube and fittings conforming to ASTM B88 - 09, Type L, for the
designated sizes.
30.8 Corrugated Metal Units

Unless otherwise specified in the particular specifications or elsewhere in these standard
specifications, the Contractor shall furnish steel corrugated units conforming to AASHTO M 36-03
(R2011) and aluminium corrugated units conforming to AASHTO M 196-92 (2012) (ASTM B745 /
B745M - 97(2005)). For coatings, the Contractor shall conform to the following:
• Asphalt-coated corrugated units, AASHTO M 190-04 (2012), Type A
• Polymer pre-coated corrugated units, AASHTO M 245-00 (2012), Grade 250/250
30.9 Aluminium for Signs

All aluminium shapes and materials shall be new. The Contractor shall comply with the following
requirements, unless otherwise indicated on the Contract plans:
a. Extruded aluminium shapes for panels and moldings shall comply with the requirements for
Aluminium Alloy ASTM B221 - 12, Alloy 6063-T6.
b. Aluminium alloy sheets and plates shall comply with the specifications for Aluminium Alloy
Sheet and Plate, ASTM B209 - 10, Alloy 6061-T6.
c. Panel bolts and post clip bolts shall be made from aluminium alloy, in compliance with ASTM
B211 - 12e1, Alloy 2024-T4. Thread fit for bolts shall comply with American National
Standards Institute Class 2A. All aluminium bolts shall have an anodic coating of 0.005 mm
minimum thickness with dichromate or boiling water seal.
d. Aluminium nuts (6.4 mm tap and under) and all bolts and machine screws shall be made from
Aluminium Alloy ASTM B211 - 12e1, Alloy 2024-T4. Nuts over 6.4 mm tap shall be Aluminium
Alloy ASTM B211 - 12e1, Alloy 6262-T9. The thread fit for bolts and machine screws shall
comply with American National Standards Institute Class 2A and the thread fit for the nuts
shall be Class 2B. All nuts (6.4 mm tap and under), bolts, and machine screws shall receive
an anodic coating of 0.005 mm minimum thickness with a dichromate or boiling water seal.
e. Flat washers for aluminium bolts and post clips shall be 9.9 mm I.D. by 19 mm 0.D. by
2.3 mm, and shall be made from Aluminium Alloy ASTM B209 - 10, Alloy 2024-T4.
f. Lock nuts shall be Aluminium Alloy ASTM B211 - 12e1, Alloy 2017-T4, and shall have an
anodic coating of 0.005 mm minimum thickness with dichromate or boiling water seal. Thread
fit for lock nuts shall be as recommended by the manufacturer. Aluminium spring-lock
washers shall be made from Aluminium Alloy ASTM B211 - 12e1, Alloy 7075-T6.
g. Extruded aluminium sign brackets for tubular posts shall be Aluminium Alloy ASTM B221 -
12, Alloy 6062- T6.
h. Sand-cast aluminium mounting brackets shall be Aluminium Alloy 356-T6, ASTM B26 / B26M
- 12, Alloy SG70A-T6.
i. Cast post clips shall be Aluminium Alloy 356-T6, ASTM B108 / B108M - 12e1, Alloy SG70G-
T6.
j. Side trim shall be Aluminium Alloy, ASTM B221 - 12, Alloy 6063-T6.
Corrosion protection measures should not be required for aluminium, except as specified herein.
Measures to provide protection from corrosion for the alloys listed above shall be specified where:
1. Aluminium is in contact with wood or other porous material that may absorb water; the
aluminium shall be painted.
Page 30-14
2. Aluminium is in contact with concrete or masonry where moisture is present; the aluminium
shall be painted.
3. Aluminium is in contact with steel and moisture is present; the steel shall be painted.
30.10 Other Miscellaneous Metals

30.10.1 Steel Castings
For other items specifically identified as miscellaneous metal in the Contract documents, the
Contractor shall use carbon steel castings conforming to Classes 70, 90, and 120 of AASHTO
M192M/M192-1994 (ASTM A486/A486M - 87) and the following:
a. The Contractor shall furnish the specific class of steel castings as shown in the Contract
plans or as specified in the Contract documents.
b. The Contract plans shall specify the non-destructive tests to perform and their extent.
c. The Contractor shall use steel castings that are true to pattern in form and dimensions and
free from defects affecting strength or service life.
d. The Contractor may weld defects using the Engineer’s approved process and perform weld
repairs before annealing the casting. If the Engineer requires it, the Contractor shall re-anneal
the castings after welding.
e. If the Engineer requires it, the Contractor shall test castings by radiography or ultrasonic
testing to determine the presence of cracks, flaws, or other defects.
f. The Contractor shall ensure that the metal thickness remaining after completing the
machining is not less than the thickness the Contract plans show.
g. The Contractor shall thread the ends of the tensile test specimens for at least 19 mm with
19 mm American N.C. threads.
30.10.2 Bronze Castings

If using bronze castings for bearings, trunnions, journals of bridges, and expansion plates, the
Contractor shall conform to ASTM B22 - 09e2, Alloy C91100.
30.10.3 Cold-finished, Carbon Steel Shafting

The Contractor shall use cold-finished, carbon steel shafting conforming to AASHTO M 169-09
(ASTM A108 - 07), Grades 1016 through 1030. If used for structural pins, then the Contractor shall
conform the shafting to ASTM A434 - 06(2012), Grade BC, quenched and tempered.
30.10.4 Lubricated Bronze Plates

Lubricated bronze plates shall be fabricated as the Contract plans show and with materials
conforming to ASTM B100 - 08, Copper Alloy C51000, or to ASTM B22 - 09e2, Alloy C91100.
The Contractor shall provide the Engineer with a certified report of tests or analyses indicating the
manufacturer’s test results for the lubricated bronze plates on their chemical and physical properties,
including the coefficient of friction of the material used.
The Fabricator shall bore or cast the surface of the lubricated bronze plates in a geometric pattern
of recesses. The Fabricator shall:
a. Fill the recesses with a lubricating compound consisting of graphite and metallic substances
with a lubricating binder capable of withstanding the atmospheric elements
b. Hydraulically press the compound into the recesses to form dense, non-plastic lubricating
inserts
Page 30-15
c. Ensure the lubricated area is within a range of 25 to 33%, inclusive of the bearing face, with
a coefficient of friction not greater than 0.1.
d. Unless the plans show or the Contract directs otherwise, only lubricate the top face of the
bronze plate.
30.10.5 Steel Forgings

The Contractor shall use steel forgings for pins, rollers, trunnions, and other forged parts conforming
to the requirements for class M quenched and tempered forgings of ASTM A668 / A668M - 04(2009).
The Contractor shall thread the ends of the tensile test specimens for at least 19 mm with 19 mm
American N.C. threads.
30.10.6 Welded and Seamless Steel Pipe

The Contractor shall furnish welded and seamless steel pipe for railings and general use conforming
to ASTM A53 / A53M - 12, Types F or E, Grade B, or Type S, Grade B. Unless provided otherwise,
the Contractor shall use black, standard weight pipe.
30.10.7 Pipe Fittings

The Contractor shall use malleable cast iron or pressed steel pipe fittings for railings and other
required uses. If zinc-coated fittings are required, the coating shall conform to ASTM A123 / A123M
- 12.
30.10.8 Sheet Lead

The Contractor shall furnish lead in sheet form conforming to ASTM B29 - 03(2009), using lead
sheets of uniform thickness throughout, free from cracks, seams, slivers, scale, and other surface
defects.
Unless the Contract plans show otherwise, the Contractor shall use sheet lead 3.2 mm thick with a
tolerance of ± 0.8 mm. The Contractor shall ensure that the length and width are within 3.2 mm of
the Contract plan dimensions.
30.10.9 Sheet Copper

The Contractor shall furnish strip or sheet copper conforming to ASTM B152 / B152M - 09 and
suitable for the purpose intended. Unless specified otherwise, the Contractor shall use sheet copper
with a minimum thickness of 0.5 mm.
30.10.10 Sheet Zinc

For sheet or plate zinc, the Contractor shall conform to Prime Western Grade ASTM B6 - 12, using
sheet and plate zinc of uniform thickness, free from cracks, seams, slivers, scale, surface corrosion,
adhering matter, and other surface defects.
The Contractor shall use sheet and plate zinc conforming to the zinc gauge shown on the Contract
plans, with a thickness tolerance of ± 6%. The Contractor shall use sheets within 3.2 mm of the
length and width the Contract plans show.
30.11 Fabrication
Fabrication of miscellaneous metal items shall be performed in a manner conforming to the practice
in modern commercial shops. Burrs, rough and sharp edges, and other flaws shall be removed.
Warped pieces shall be straightened after fabrication and galvanizing.
Page 30-16
30.12 Galvanizing
Unless otherwise specified in the Contract documents, all steel items that are not embedded at least
50 mm in concrete and all cast iron sidewalk frames and covers shall be galvanized in accordance
with Section 23.4.10 of Chapter 23, Steel Structures. Assemblies shall be galvanized after
fabrication.
30.13 Transporting Materials

All miscellaneous metal works as specified herein and as indicated on the Contract plans shall be
transported and protected during all handling to prevent distortion, deformation, or damage of any
kind. Any metal materials damaged during transportation, handling, or otherwise shall be rejected
and the Contractor shall provide new material as required at no additional expense to the Owner.
30.14 Storage of Materials

All miscellaneous metal works as specified herein and as indicated on the Contract plans shall be
stored above the ground on platforms, skids, or other supports. All metal materials shall be kept free
from dirt, grease, and other foreign matter, and shall be protected from corrosion.
30.15 Clean-up
At the completion of the Contract, all miscellaneous metal works shall be cleaned of concrete spatter,
mud, oil, shop markings if visible to the public, and other foreign materials
Page 30-17
INDEX
access door assemblies, 10 grates, 9, 10, 12

access opening covers, 10 guard posts, 10
aluminium, 3, 9, 16, 17 Hardboard, 13
area drains, 10 Incidentals, 13
Bearing assemblies, 10 inlets, 9
bearing surfaces, 9 journals of bridges, 17
bolts, 7, 8, 9, 10, 12, 16 ladder rungs, 10
bridge, 3, 10, 12 manholes, 9
cable assemblies, 12, 13, 14 metal pipe, 3
Cable drum units, 13 mill test reports, 9
castings, 8, 9, 11, 17 non-destructive tests, 17
certification, 9 restrainer, 3, 12, 14
corrugated metal, 3 retaining wall drains, 10
covers, 9, 10, 19 rings, 9, 12
Culverts, 15 seamless, 18
Deck drains, 10 signs, 3
Department of Transport, ii sliding plate, 10
drainage piping, 10 stainless steel, 9, 10, 11, 15
Expansion joint armor, 10 steel forgings, 18
Fabrication, 9, 14, 18 tensile test specimens, 17, 18
fabrication site, 3 transportation, 19
finger-type expansion joints, 10 trunnions, 17, 18
frames, 9, 10, 19 Turnbuckles, 13
Galvanizing, 9, 12, 13, 14, 19
Page 30-18
PART 2
ROAD STRUCTURES
CHAPTER 31 - METAL CULVERTS
DOCUMENT NO: TR-

FIRST EDITION
JANUARY 2018
Chapter 31: Metal Culverts

TABLE OF CONTENTS
List of Tables .................................................................................................................................. ii
31 Metal Culverts ................................................................................................................. 31-1
31.1 General ........................................................................................................................ 31-1
31.4 Materials ...................................................................................................................... 31-3
31.4.1 Corrugated Metal Pipe .......................................................................................... 31-3
31.4.2 Structural Plate ..................................................................................................... 31-3
31.4.3 Nuts and Bolts ...................................................................................................... 31-4
31.4.4 Mixing of Materials ................................................................................................ 31-4
31.4.5 Fabrication ............................................................................................................ 31-4
31.4.6 Welding ................................................................................................................ 31-4
31.4.7 Protective Coatings............................................................................................... 31-4
31.4.8 Bedding and Backfill Materials .............................................................................. 31-4
31.4.8.1 General Specifications for Bedding and Backfill Materials .............................. 31-4
31.4.8.2 Long-span Structural Plate Structures ........................................................... 31-5
31.4.8.3 Box Culverts .................................................................................................. 31-5
31.4.8.4 Deep Corrugated Structures .......................................................................... 31-5
31.4.8.5 Concrete Backfill ............................................................................................ 31-5
31.5 Assembly ..................................................................................................................... 31-5
31.5.1 General................................................................................................................. 31-5
31.5.2 Joints .................................................................................................................... 31-6
31.5.2.1 Field Joints .................................................................................................... 31-6
31.5.2.2 Joint Types .................................................................................................... 31-6
31.5.2.3 Soil Conditions ............................................................................................... 31-6
31.5.2.4 Joint Properties .............................................................................................. 31-6
31.5.3 Assembly of Long-span Structures ....................................................................... 31-7
31.6 Installation ................................................................................................................... 31-8
31.6.1 General................................................................................................................. 31-8
31.6.2 Foundation............................................................................................................ 31-8
31.6.3 Bedding .............................................................................................................. 31-10
31.6.4 Structure Backfill ................................................................................................. 31-10
31.6.4.1 General........................................................................................................ 31-10
31.6.4.2 Arches ......................................................................................................... 31-11
31.6.4.3 Long-span Structural Plate Structures ......................................................... 31-11
31.6.4.4 Box Culverts ................................................................................................ 31-12
31.6.4.5 Concrete Backfill .......................................................................................... 31-12
31.6.5 Bracing ............................................................................................................... 31-12
31.6.6 Arch Substructures and Headwalls ..................................................................... 31-13
31.6.7 Inspection Requirements for CMP ...................................................................... 31-13
31.6.7.1 Visual Inspection.......................................................................................... 31-13
31.6.7.2 Installation Deflection ................................................................................... 31-14
31.6.7.3 Internal Inspection of Culverts...................................................................... 31-15
31.7 Construction Precautions ........................................................................................... 31-16
31.8 Salvaged Metal Culverts ............................................................................................ 31-17
31.8.1 Description.......................................................................................................... 31-17
31.8.2 Construction ....................................................................................................... 31-17
Index ...................................................................................................................................... 31-18
Page i
CHAPTER 31:METAL CULVERTS First Edition -January 2018
LIST OF FIGURES
Figure 31-1: Pipe Installation Nomenclature............................................................................... 31-9
Figure 31-2: Foundation Treatment for Localised Soft Spots or Rock ........................................ 31-9
Figure 31-3: Foundation Treatment for Settlement Control ...................................................... 31-10
Figure 31-4: Shaped Bedding for Large Pipe-Arch, Horizontal Elliptic, and Underpass Structures
................................................................................................................................................ 31-10
Figure 31-5: End Treatment of Skewed Flexible Culvert .......................................................... 31-11
LIST OF TABLES
Table 31-1: Designations and titles for AASHTO and ASTM standards that apply to metal culverts
construction works ..................................................................................................................... 31-1
Table 31-2: Corrugated Metal Pipe Types .................................................................................. 31-3
Table 31-3: Categories of Pipe Joint .......................................................................................... 31-7
Table 31-4: Minimum Cover for Construction Loads on Circular, Pipe-Arch, Elliptic, and Underpass
Shapes .................................................................................................................................... 31-16
Page ii
CHAPTER 31: METAL CULVERTS First Edition -January 2018
31 METAL CULVERTS
31.1 General
This work shall furnish, fabricate, install, and inspect metal pipes, structural plate metal pipes,
arches, pipe arches, box structures, and deep corrugated structures — as well as the associated
substructures and headwalls in conformance with these specifications and the details shown in the
Contract documents. As used in this specification, long-span structures shall consist of metal plate
horizontal elliptic, inverted pear, and multiple radius arch shapes — as well as special shape culverts,
as defined in Section 12 of the American Association of State Highway and Transportation Officials
(AASHTO) Load and Resistance Factor Design (LRFD) Bridge Design Specifications.
Terms referring to “metal pipes” and “metal structural plate pipes” include circular and pipe arches
and underpass and elliptical shapes. Metal structural plate arches consist of a metal plate arch
supported on reinforced concrete footings with or without a paved invert slab. Pipe arches are
constructed to form a pipe having an arch-shaped crown and a relatively flat invert. Structural plate
metal box structures are conduits, rectangular in cross section, and constructed of metal plates.
The metal culvert descriptions refer to Section 12, Buried Structures and Tunnel Liners, of the
AASHTO LRFD Bridge Design Specifications.

Standards and codes for metal culverts shall be as specified in these specifications, in the Contract
and Testing;
D1.5M/D1.5:2010
ANSI/AWS D1.2/ Structural Welding Code—Aluminum;
D1.2M:2003
Standards -29 CFR OSHA Regulations;
metal culverts. It also includes designations and titles.
Table 31-1: Designations and titles for AASHTO and ASTM standards that apply to metal
culverts construction works
Page 31-1
AASHTO ASTM
Title
AASHTO M 36- ASTM A760 / Standard Specification for Corrugated Steel Pipe,
03 (R2011) A760M - 10 Metallic-Coated for Sewers and Drains
AASHTO M Standard Specification for Steel Sheet, Zinc-Coated
218-03 (R2011) (Galvanised), for Corrugated Steel Pipe
ASTM B745 /
AASHTO M Standard Specification for Corrugated Aluminium Pipe for
B745M -
196-92 (2012) Sewers and Drains
97(2005)
ASTM B746 / Standard Specification for Corrugated Aluminium Alloy
AASHTO M
B746M - Structural Plate for Field-Bolted Pipe, Pipe-Arches, and
219-92 (2012)
02(2012) Arches
ASTM A761 / Standard Specification for Corrugated Steel Structural
AASHTO M
A761M - Plate, Zinc-Coated, for Field-Bolted Pipe, Pipe-Arches,
167M/M 167-09
04(2009) and Arches
ASTM A307 - Standard Specification for Carbon Steel Bolts and Studs,
10 60,000 PSI Tensile Strength
AASHTO M Standard Specification for Bituminous-Coated Corrugated
190-04 (2012) Metal Culvert Pipe and Pipe Arches
ASTM A742 /
AASHTO M Standard Specification for Steel Sheet, Metallic Coated
A742M -
246-05 (R2011) and Polymer Precoated for Corrugated Steel Pipe
03(2008)
Standard Practice for Classification of Soils for
ASTM D2487 -
Engineering Purposes (Unified Soil Classification
11
System)
Standard Specifications for Classification of Soils and
AASHTO M
Soil-Aggregate Mixtures for Highway Construction
145-91 (2008)
Purposes
Standard Specification for Hex Cap Screws, Bolts and
ASTM A449 -
Studs, Steel, Heat Treated, 120/105/90 ksi Minimum
10
Tensile Strength, General Use
Standard Specification for Nonferrous Bolts, Hex Cap
ASTM F468 - 10
Screws, and Studs for General Use
Standard Method of Test for Moisture-Density Relations
AASHTO T 99-
of Soils Using a 2.5-kg (5.5-lb) Rammer and a 305-mm
10
(12-in.) Drop
Standard Method of Test for Moisture-Density Relations
AASHTO T 180-
of Soils Using a 4.54-kg (10-lb) Rammer and a 457-mm
10
(18-in.) Drop

Whenever specified in the Contract documents, or requested by the Engineer, the Contractor shall
provide the Manufacturer's assembly instructions or working drawings and substantiating
calculations in sufficient detail to permit a structural review of the structural design. To allow for their
review, revision, and approval without delaying the work, the Contractor shall submit the working
drawings in advance of construction.
Page 31-2
Construction of any metal culvert, for which working drawings are required, shall not begin until the
Engineer has approved the drawings. Such approval will not relieve the Contractor of responsibility
for results obtained by use of these drawings or any other contractual responsibilities.
31.4 Materials
Materials for metal culverts shall comply with the requirements outlined in this section.
31.4.1 Corrugated Metal Pipe

Steel pipes, steel apron end walls, and other components conforming to the requirements of
AASHTO M 36-03 (R2011) (ASTM A760 / A760M - 10) shall be furnished by the Contractor. These
components shall be fabricated from either zinc-coated steel sheet or aluminium-coated steel sheet
except when fabrication from zinc-coated steel sheet is required by the Contract documents.
Zinc-coated steel sheets shall conform to the requirements in AASHTO M 218-03 (R2011).
If specified, aluminium pipes and aluminium apron end walls shall conform to the requirements of
AASHTO M 196-92 (2012) (ASTM B745 / B745M - 97(2005)). If steel apron end walls are delivered
attached to the corrugated aluminium pipe, the Contractor shall install a suitable insulating material
approximately 1.6 mm thick between the pipe and the end wall, at the joint. One, or more, of the
following materials may be used by the Contractor:
• Asphalt impregnated fabric;
• A sheet plastic;
• A rubber gasket; or,
• Other non-degradable material of substantial strength.
Pipe types and corresponding AASHTO designations are shown in Table 31-2.
Table 31-2: Corrugated Metal Pipe Types
Pipe Type AASHTO Classification

Circular Type I
Circular, smooth-lined Type IA
Circular, spiral rib Type IR
Arch Type II
Arch, smooth-lined Type IIA
Arch, spiral rib Type IIR
Corrugated metal pipe, of all types, shall be provided with annular, helical, or spiral rib corrugations
that project outward.
Pipes with helical end corrugations shall be provided only when joining new pipe to existing pipe with
helical end corrugations is necessary.
For precoated galvanised steel pipe, a minimum polymer coating thickness of 300 μm shall be
provided on each side.
31.4.2 Structural Plate

Steel structural plates shall conform to the requirements of AASHTO M 167M/M 167-09 (ASTM A761
/ A761M - 04(2009)). Aluminium alloy structural plates shall conform to the requirements of AASHTO
M 219-92 (2012) (ASTM B746 / B746M - 02(2012)).
Page 31-3
31.4.3 Nuts and Bolts

Nuts and bolts for steel structural plate pipes, arches, pipe arches, and box structures shall conform
to the requirements of AASHTO M 167M/M 167-09 (ASTM A761 / A761M - 04(2009)). Nuts and
bolts for aluminium structural plates shall consist of aluminium conforming to the requirements of
ASTM F468 - 10 or standard-strength steel conforming to ASTM A307 - 10.
31.4.4 Mixing of Materials

Unless the materials are adequately separated or protected to avoid galvanic reactions, the
Contractor shall not mix aluminium and steel materials in any installation. Hot-dipped galvanised
steel and stainless steel bolts and nuts are acceptable materials to connect aluminium structural
plates.
31.4.5 Fabrication
Bolts with the seams staggered so that no more than three places come together at any one point
shall connect the plates at longitudinal and circumferential seams.
31.4.6 Welding
If required, welding of the steel shall conform to the current AASHTO, American Welding Society
AASHTO/AWS D1.5M/D1.5:2010 Bridge Welding Code. All welding of steel plates, other than
fittings, shall be performed prior to galvanizing.
If required, welding of aluminium shall conform to the American Welding Society ANSI/AWS
D1.2/D1.2M:2003, Structural Welding Code—Aluminum.
31.4.7 Protective Coatings

When required in the Contract documents, the Contractor shall protect metal pipes and structural
metal plate culverts with a bituminous coating or shall pave the invert with bituminous materials.
Unless otherwise specified in the Contract documents, the Contractor shall apply bituminous
coatings as instructed in AASHTO M 190-04 (2012), Type A. If required, the Contractor shall apply
bituminous pavings over the bituminous coatings to the inside bottom portion of the pipe — as
provided in AASHTO M 190-04 (2012), Type C — unless otherwise specified in the Contract
documents. After installation, the Contractor shall coat the portions of all nuts and bolts used for the
assembly of coating structural plate pipes, arches, pipe arches, and box culverts that project outside
the pipe. Portions of the nuts and bolts projecting inside the pipe need not be coated.
When required in the Contract documents, polymeric coatings shall conform to the requirements of
AASHTO M 246-05 (R2011) (ASTM A742 / A742M - 03(2008)). Prior to corrugating, the Contractor
shall apply polymeric coatings to the galvanised sheet. Unless otherwise specified in the Contract
documents, the coating thickness shall not measure less than 0.25 mm. Any pinholes, blisters,
cracks, or lack of bond shall be a cause for rejection. Polymeric coatings are not permitted on
structural plates.
31.4.8 Bedding and Backfill Materials

31.4.8.1 General Specifications for Bedding and Backfill Materials
Bedding shall consist of loose native or granular material with a maximum particle size measuring
less than one-half the corrugation depth. Backfill for metal culverts shall consist of a granular
material, as specified in the Contract documents and specifications, and shall be free of organic
material and rock fragments larger than 75 mm in the greatest dimension. These materials shall
have moisture content within the limits required for compaction. As a minimum, backfill materials
shall meet the requirements of AASHTO M 145-91 (2008) for A-1, A-2, or A-3.
Page 31-4
31.4.8.2 Long-span Structural Plate Structures

Bedding and backfill materials shall meet the general requirements of Article 31.4.8.1, General
Specifications for Bedding and Backfill Materials. As a minimum, backfill materials for structures with
less than 3.6 m of cover shall meet the requirements of AASHTO M 145-91 (2008) for A-1, A-2-4, A-
2-5, or A-3. Minimum backfill requirements for structures with 3.6 m or more cover shall meet
AASHTO M 145-91 (2008) requirements for A-1 or A-3.

Bedding and backfill materials shall meet the general requirements of Section 31.4.8, Bedding and
Backfill Materials. As a minimum, backfill shall meet the requirements of AASHTO M 145-91 (2008)
for A-1, A-2-4, A-2-5, or A-3.
31.4.8.4 Deep Corrugated Structures

For deep corrugated structures, the selected backfill within the structural backfill zone shall meet the
requirements of AASHTO M 145-91 (2008) A-1, A-2-4, A-2-5, or A-3 (ASTM D2487 – 11
Classifications GW, GP, SW, SP, GM, SM, SC, GC) and the Manufacturer’s requirements.
31.4.8.5 Concrete Backfill

At locations where the Contractor will backfill the pipe with concrete, as shown in the Contract
documents, the concrete backfill shall consist of minor concrete conforming to the provisions in
Section 21.27 of Chapter 21, Concrete Structures — except that minor concrete shall contain not
less than 200 kg of cement per 1 cubic metre of concrete. Types of concrete to be used will be
designated in the Contract documents.
31.5 Assembly
31.5.1 General
Corrugated metal pipes and structural plate pipes shall be assembled in accordance with the
Manufacturer's instructions. All pipes shall be unloaded and handled with reasonable care. Pipes or
plates shall not be rolled or dragged over gravel or rock, and the Contractor shall prevent them from
striking rock or other hard objects during placement in the trench or on the bedding.
Starting at the downstream end, the Contractor shall place the corrugated metal pipes (CMPs) in the
bed. Pipes with circumferential seams shall be installed with their inside circumferential sheet laps
pointing downstream.
Bituminous-coated, polymer-coated, and paved-invert pipes shall be installed in a similar manner to
CMPs with special care in handling to avoid damage to coatings. Paved-invert pipes shall be installed
with the invert pavement placed and centred on the bottom.
Structural metal plate culverts and pipes shall be assembled and installed as specified in the
Contract documents and detailed erection instructions. Copies of the Manufacturer's assembly
instructions shall be furnished as specified in Section 31.3, Working Drawings. Bolted longitudinal
seams shall be well-fitted with the lapping plates parallel to each other. Applied bolt torques for 19-
mm-diameter (M20), high-strength steel bolts (ASTM A449 - 10) for the assembly of steel structural
plates shall be a minimum of 0.135 kN.m, and a maximum of 0.407 kN.m. Aluminium structural plates
shall be assembled using 19-mm-diameter (M20) aluminium bolts (ASTM F468 - 10) or standard
strength steel bolts (ASTM A307 - 10) that shall be torqued to a minimum of 0.135 kN.m, and a
maximum of 0.203 kN.m. When the Contractor uses a seam sealant tape or a shop-applied asphalt
coating, bolts shall be retightened no more than once and generally within 24 hours after initial
tightening.
Longitudinal seams in deep corrugated structures shall be staggered.
Page 31-5
31.5.2 Joints
Joints for corrugated metal culverts and drainage pipes shall meet the requirements described
herein.
31.5.2.1 Field Joints

Designs for transverse field joints shall permit the successive connection of pipe sections and form
a continuous line free from appreciable irregularities in the flow line. Additionally, the joints shall meet
the general performance requirements described in Articles 31.5.2.2 through 31.5.2.4.
Suitable transverse field joints that satisfy the requirements for one or more of the subsequently
defined joint performance categories can be obtained with the following types of connecting bands
when furnished with the suitable band-end fastening devices:
a. Corrugated bands;
b. Bands with projections;
c. Flat bands;
d. Bands of special design that engage factory reformed ends of corrugated pipe; or,
e. Other equally effective types of field joints may be used with the approval of the Engineer.
31.5.2.2 Joint Types

Standard or special joints shall be specified within the Contract documents, as appropriate for the
requirements at hand.
Standard joints are for pipes not subject to large soil movements or disjointing forces. These joints
are satisfactory for ordinary installations where simple slip-type joints are typically used. Special
joints are for more severe requirements, including the following:
a. A need to withstand soil movements or resist disjointing forces;
b. Poor foundation conditions; and,
c. Conditions producing longitudinal hydraulic forces requiring down drain joints, such as pipes
on steep slopes or sharp curves.
31.5.2.3 Soil Conditions

When poor soil conditions are encountered, the Contract documents should specify which special
joints the Contractor shall use.
31.5.2.4 Joint Properties

Joint property requirements shall be taken as specified in Table 31-3. A rational analysis or suitable
test may determine the values for various types of pipes.
When considering the design of, or selection of, pipe joints, the Contractor shall consider the
following design issues:
a. Joint Overlap: Standard joints that do not meet the moment strength alternatively shall have
a minimum sleeve width overlapping the abutting pipes. Minimum total sleeve widths shall
be as given in Table 31-3. Any joint meeting the requirements for a special joint may be used
in lieu of a standard joint.
b. Soil Tightness: Soil tightness refers to openings in the joint through which soil may infiltrate.
No opening may exceed 25 mm. Additionally, for all categories, if the size of the opening
exceeds 3 mm, the length of the channel shall be at least four times the size of the opening.
Page 31-6
Backfill that is not subject to piping action is classified as non-erodible. Such backfill typically
includes granular soil (with grain sizes equivalent to coarses and, small gravel, or larger) and
cohesive soils. Backfill that is subject to piping action and that tends to either infiltrate the
pipe or be easily washed by water exfiltration is classified as erodible. Such backfill typically
includes fine sands and silts.
For non-erodible or erodible soils, the ratio of D85 soil size to the size of the opening must be
greater than 0.3 for medium to fine sand or 0.2 for uniform sand. These ratios need not be
met for cohesive backfills where the plasticity index exceeds 12 percent. Alternatively, a joint
that withstands 14 kPa hydrostatic tests without leakage shall be considered soil tight. Joints
that do not meet these requirements may be made soil tight by wrapping them with a suitable
geotextile.
c. Water Tightness: The adjoining pipe ends in any joint shall not vary more than 13 mm in
diameter or more than 38 mm in circumference for watertight joints.
Water tightness may be specified for joints of any category, where needed, to satisfy other
criteria. Leakage rates shall be measured with the pipe in place or at an approved test facility.
Tolerances indicated may be attained by proper production controls or by match-marking
pipe ends.
Table 31-3: Categories of Pipe Joint
Soil Condition
Non-erodible Erodible
Joint Type Joint Type
Joint Property Standard Special Standard Special Down Drain
Shear Resistance 2% 5% 2% 5% 2%
Moment Resistance 5% 15% 5% 15% 15%
Tensile Resistance up
0 22.2 kN - 22.2 kN 22.2 kN
to 1,060 mm Diameter
Tensile Resistance
1,200 mm – 2130 mm - 44.5 kN - 44.5 kN 44.5 kN
Diameters
Joint Overlap,
265 mm NA 265 mm NA NA
Minimum
Soil Tightness NA NA 0.3 or 0.2 0.3 or 0.2 0.3 or 0.2
31.5.3 Assembly of Long-span Structures

Unless held in shape by cables, struts, or backfill, longitudinal seams shall be tightened when the
plates are hung. Prior to bolt tightening, the Contractor shall take care to align plates to ensure
properly fitted seams. Variations in structure dimensions before backfill shall comply with the
following provisions:
a. For horizontal elliptic shapes having a ratio of top to side radii of three or less, the span and
rise shall not deviate from the specified dimensions by more than 2 percent.
b. For arch shapes having a ratio of top to side radii of three or more, the rise shall not deviate
from the specified dimensions by more than 1 percent of the span.
c. For all other long-span structures, the span and rise shall not deviate from the specified
dimensions by more than 2 percent, or more than 125 mm, whichever is less.
When required by structural design, the Contractor shall attach reinforcing ribs to the structural plate
corrugation crown prior to backfilling, using a bolt spacing of not more than 300 mm. To designate
Page 31-7
its proper position in the finished structure, the Contractor shall place legible, identifying letters or
numbers on each rib.
When required for control of structure shape during installation, the Contractor shall space
reinforcing ribs and attach them to the corrugated plates at the discretion of the Manufacturer with
the approval of the Engineer.
Erection processes specified herein may require temporary shoring.
31.6 Installation
31.6.1 General
All culvert pipes shall be laid by the Contractor true to the lines and grades given in the Contract
documents, or as approved in the working drawings. Departure from and return to plan alignment
and grade that exceeds 5 mm per metre of nominal pipe length, with a total of not more than 25 mm
departure from the theoretical line and grade shall not be permitted by the Contractor. Any culvert
pipe that is not in true alignment or which shows any settlement after laying shall be taken up and
relayed by the Contractor at no additional expense to the Owner.
For trench conditions, the trench shall be excavated to the width, depth, and grade shown in the
Contract documents. Trenches shall be wide enough to allow the Contractor to prepare the
foundation, lay the culvert pipe, and place and compacting backfill as specified; except that the
trench width shall not exceed the culvert pipe's outside diameter by more than 915 mm.
All temporary drainage facilities necessary shall be provided by the Contractor to protect the work
and adjacent property. Temporary drainage shall be maintained in effective operating condition by
the Contractor, as the Engineer approves, until the permanent culvert pipe installations are
operational. Temporary culverts shall be removed and disposed by the Contractor after the
permanent culvert pipe installations are operational.
Proper preparation of foundations; placement of foundation materials, where required; and
placement of bedding materials shall precede the installation of all culvert pipe. This work shall
include necessary levelling of the native trench bottom or the top of the foundation material — as
well as placement and compaction of required bedding material to a uniform grade so that a uniform
base can support the entire length of pipe. Backfill materials shall be placed and compacted around
the pipe in a manner to meet the requirements specified.
Materials used for foundation improvements, bedding, and structure backfill must have gradations
compatible with adjacent soils to avoid migration. Where material gradations cannot be properly
controlled, adjacent materials must be separated with a suitable geotextile.
All pipes shall be protected by sufficient cover before permitting heavy construction equipment to
pass over them during construction.
31.6.2 Foundation
Foundations under the pipe and structure backfill shall be investigated for their adequacy to support
the loads. Foundations shall be provided, such that the structure backfill does not settle more than
the pipe to avoid down drag loads on the pipe.
Foundations must provide uniform support for the pipe invert. Boulders, rock, or soft spots in the
foundations shall be excavated to a suitable depth and backfilled with material compacted sufficiently
to provide uniform bearing, as shown in Figure 31-1.
Page 31-8
Figure 31-1: Pipe Installation Nomenclature.

Where the natural foundation is judged inadequate to support the pipe or structure backfill by the
Engineer, the Contractor shall excavate it to a suitable depth and backfill it with material compacted
sufficiently to control settlements — as shown in Figure 31-2 and Figure 31-3.
Foundation on Localised Soft Zone Foundation on Rock

Note: d = 40 mm per metre of fill over pipe, with 0.63 m maximum
Figure 31-2: Foundation Treatment for Localised Soft Spots or Rock
Page 31-9
Figure 31-3: Foundation Treatment for Settlement Control
Where relatively large-radius inverts adjoin small-radius corners or sides for sections such as pipe
arches, elliptic pipe or underpasses, the foundation shall be designed to support the radial pressures
exerted by the smaller radius portions of the pipe. Principal foundation support shall be provided in
the area extending radially outward from the smaller radius areas. These pressures may be two to
five times the loading pressures on top of the pipe, depending on the pipe shape. When corrective
measures are necessary, providing less support under the invert allows the pipe to maintain its shape
as minor settlements occur.
Where settlement of the pipe is expected to be so large that the required grade under high fills will
not be maintained, pipe may be cambered to prevent excessive sag. Camber amounts shall be
determined based on consideration of the flow line, gradient, fill height, the compressive
characteristics of the foundation material, and the depth to incompressible strata.
31.6.3 Bedding
Pipe bedding is a relatively thin layer of loosely placed material that cushions the pipe invert and
allows the corrugation to nest or seat into it, thus supporting the corrugation.
When, in the opinion of the Engineer, the natural soil does not provide a suitable bed, the Contractor
shall provide a bedding blanket with a minimum thickness of twice the corrugation depth.
Pipe arches and horizontal elliptic and underpass shapes with spans exceeding 3.6 m shall be
placed on a shaped bed. Shaped areas shall be centered beneath the pipe and shall have a minimum
width of one-half the span for pipe arch and underpass shapes, and one-third the span for horizontal
elliptic shapes. Preshaping may consist of a simple V-shape graded into the soil as shown in Figure
31-4.
Figure 31-4: Shaped Bedding for Large Pipe-Arch, Horizontal Elliptic, and Underpass
Structures
31.6.4 Structure Backfill

31.6.4.1 General
To ensure that the quality of the soil and the compactive effort obtained is as specified, the Contractor
shall undertake sufficient inspection and testing.
Backfill material shall meet the requirements of Section 31.4.8, Bedding and Backfill Materials, and
shall be placed in layers not exceeding 200-mm, loose lift thickness to a minimum 90 percent
standard density per AASHTO T 99-10. Equipment used to compact backfill within 900 mm from the
pipe sides — or from the edges of footings of arches and box culverts — shall be approved by the
Page 31-10
Engineer prior to use. Except as provided below for long-span structures, the equipment used for
compacting backfill beyond these limits may be the same as used for compacting embankment.
Backfill materials shall be placed and compacted with care under the haunches of the pipe and shall
be raised evenly on both sides of the pipe by working backfill operations from side to side. This
backfill differential shall not exceed 600 mm, or one-third, of the rise of the structure, whichever is
less. Backfill shall continue to not less than 300 mm above the top for the full length of the pipe. Fill
above this level shall become embankment fill or other materials, as specified to support the
pavement. Trenched shall be kept to the minimum width required for placing pipe, placing adequate
bedding and side fill, and creating safe working conditions. Ponding or jetting of backfill shall not be
permitted except upon written permission by the Engineer.
Structural integrity of the corrugated metal structure is vitally affected by the quality of construction
in the field; therefore, quality control is of extreme importance.
Where single or multiple structures are installed at a skew to the embankment, the Contractor shall
provide proper support for the pipe. This support may be achieved with a rigid, reinforced concrete
headwall or by warping the embankment till to provide the necessary balanced side support. Figure
31-5 provides guidelines for warping the embankment.
Figure 31-5: End Treatment of Skewed Flexible Culvert
31.6.4.2 Arches
Arches may require special shape control during the placement and compaction of structure backfill.
Prior to construction, the Manufacturer shall attend a preconstruction conference to advise the
Contractor and the Engineer of the critical functions to be performed during backfilling and to present
the intended quality control steps to be used to control loads, shapes, and movements.
Pin connections at the footing restrict uniform shape change. Arches may peak excessively or
experience curvature flattening in their upper quadrants during backfilling. Using lighter compaction
equipment, easily compacted structure backfill, or top loading by placing a small load of structure
backfill on the crown will aid installation.
31.6.4.3 Long-span Structural Plate Structures

Backfill requirements for long-span, structural-plate structures are similar to those for smaller
structures. Their size and flexibility require special control of backfill and continuous monitoring of
structure shape.
Page 31-11
Prior to construction, the Manufacturer shall attend a preconstruction conference to advise the
Contractor and the Engineer of the critical functions to be performed during backfilling and to present
the intended quality control steps to be used to control loads, shapes, and movements.
Equipment and construction procedures used to backfill long-span, structural-plate structures shall
be such that excessive structure distortion will not occur. Structure shape shall be checked regularly
while backfilling to verify acceptability of the construction methods used. Allowable shape changes
and their magnitudes will be specified by the Manufacturer, or the Fabricator, of the long-span
structures. A qualified shape-control inspector shall be provided by the Manufacturer to aid the
Engineer during the placement of all structure backfill to the minimum cover level over the structure.
This inspector shall advise the Engineer on the acceptability of all backfill material and methods and
the proper monitoring of the shape.
Structure backfill material shall be placed in horizontal, uniform layers not exceeding a 200-mm,
loose lift thickness and shall be brought up uniformly on both sides of the structure. Each layer shall
be compacted to a density not less than 90 percent modified density per AASHTO T 180-10.
Structure backfills shall be constructed to the minimum lines and grades shown in the Contract
documents, keeping them at or below the level of adjacent soil or embankment. Exceptions to the
required structure backfill density shall be as follows:
a. Areas under the invert;
b. 300-mm to 450-mm widths of soil immediately adjacent to the large radius side plates of high-
profile arches and inverted-pear shapes; and,
c. Lower portions of the first horizontal lift of overfill carried ahead of and under the small,
tracked vehicle initially crossing the structure.

When specified in the Contract document, or required by the Engineer, a preconstruction conference
on backfilling shall be required. Shape control considerations shall be similar to those needed for a
metal culvert. Metal box culverts are not long-span structures because they are relatively stiff, semi-
rigid frames.
Structure backfill materials shall be placed in uniform, horizontal layers not exceeding a 200-mm
maximum, loose lift thickness and compacted to a density not less than 90 percent modified density
per AASHTO T 180-10. Structure backfills shall be constructed to the minimum lines and grades
shown in the Contract documents, keeping them at or below the level of the adjacent soil or
embankment.
31.6.4.5 Concrete Backfill

Concrete backfill shall be placed in the trench against undisturbed material at the sides and bottom
of the trench and in a manner that will prevent floating or shifting of the pipe, and voids in, or
segregation of, the concrete. Foreign material that falls into the trench, prior to or during placing of
the concrete, shall be immediately removed. Where necessary, earth plugs shall be constructed and
compacted at the ends of the planned concrete backfill to contain the concrete within the trench.
Concrete backfill surfaces shall be broomed with a heavy broom to produce a uniform rough surface,
if asphalt concrete is to be placed directly thereon. No material shall be placed on top of the concrete
backfill until eight hours after placing the concrete backfill.
Lean concrete backfill levels around culverts shall be determined by the Engineer, according to the
nature of soil surrounding the culvert.
31.6.5 Bracing
When required, temporary bracing shall be installed and shall remain in place as long as necessary
to protect workers and to maintain structure shape during erection.
Page 31-12
For long-span structures that require temporary bracing or cabling to maintain their shapes, the
Contractor shall not remove supports until backfill reaches an elevation that provides the necessary
support. In no case shall internal braces be left in place when backfilling reaches the top quadrant
of the pipe or the top radius arch portion of a long-span structure.
31.6.6 Arch Substructures and Headwalls

If not detailed in the Contract plans, the Contractor shall design the substructures and headwalls in
accordance with the applicable requirements of AASHTO LRFD Bridge Design Specifications, and
Road Structures Design Manual ADQCC (TR-516)
Corrugated metal arch ends shall rest in a keyway formed into continuous concrete footings, or shall
rest on a metal bearing surface — usually an angle or channel shape — that is securely anchored
to or embedded in the concrete footing.
When specified, the metal bearing may be a hot-rolled or cold-formed galvanised steel angle or
channel. These shapes shall not measure less than 5 mm in thickness and shall be securely
anchored to the footing at a maximum spacing of 0.6 m. When the metal bearing member is not
completely embedded in a keyway in the footing, the Contractor shall punch one vertical leg to allow
the bolting of the end of the corrugated plates to this leg of the bearing member.
Where an invert slab is provided that is not integral with the arch footing, the invert slab shall be
continuously reinforced.
31.6.7 Inspection Requirements for CMP

31.6.7.1 Visual Inspection
Inspections at the appropriate times during installation allow corrections to be made in assembly and
backfill practices. Construction inspection during early Project stages will allow the Contractor to
evaluate and, if necessary, modify construction and quality control practices.
CMP shall be inspected after placement in the trench, as required during backfilling, and after
completion of installation to ensure that final installation conditions allow the pipe to perform as
designed. Bedding and backfill material installations — as well as their placement and compaction
— shall be determined to meet the requirements of this article.
During the initial phase of the installation process, inspections shall concentrate on detecting
improper practice and poor workmanship. Errors in line and grade — as well as any improper
assembly or backfill techniques — shall be corrected prior to placing significant backfill or trench fill.
Coupling bands shall be properly indexed with the corrugation and tightened, and bell and spigot
joints shall be properly seated to prevent the infiltration of soil fines. When used, gaskets shall not
bulge or hang into the pipe. If they are visible, gaskets shall appear uniformly oriented around the
pipe.
Racking or denting of the pipe shall be taken to indicate improper backfill placement and shall be
corrected by the Contractor. Wall sections damaged during installation shall be evaluated and then
repaired or the section of the pipe shall be replaced.
Coated pipes shall be inspected to ensure the coating has no cracks or scratches or locations of
peeling. Coatings shall be repaired in accordance with material specification requirements.
Final internal inspections shall be conducted on all buried CMP installations to evaluate issues that
may affect long-term performance. Final inspections shall be conducted no sooner than 30 days
after completion of installation and final fill. To ensure the minimum cover level is provided, the
Contractor shall check shallow cover installations.
These inspections will verify that bedding, backfill, and compaction requirements are followed during
installation. Pipes shall be checked for alignment, joint separation, cracking at bolt holes, localised
Page 31-13
distortions, bulging, flattening, or racking. Minimum or near-minimum cover installations shall be

inspected prior to and immediately after vehicular load is applied.
31.6.7.2 Installation Deflection

Pipes shall be evaluated to determine whether the internal diameter of the barrel has been reduced
more than the limits set forth in this specification when measured not less than 30 days following
completion of installation.
Because of their broad diameter tolerances, metal pipes measuring 600 mm in diameter and smaller
typically are not deflection tested. A visual inspection shall be performed to check for denting or other
damage using a video camera conforming to Article 31.6.7.3, Internal Inspection of Culverts. If
deflection testing is required by the Owner or the Engineer — or the visual inspection indicates
excessive deflection — the Contractor shall use a device conforming to Article 31.6.7.3, Internal
Inspection of Culverts, and approved by the Engineer, that can physically verify the dimensions of
the pipe and is not limited by poor lighting, water flow, pipe length, or other limiting conditions of the
installed environment. If deflection testing is performed, deflection for metal pipes measuring 600
mm in diameter and smaller shall not exceed 7.5 percent of the pipe’s nominal diameter plus a
manufacturing tolerance — as determined to be appropriate by the Owner or the Engineer.
Pipes measuring larger than 600 mm may be entered and deflection levels measured directly. In lieu
of direct measurements, the Contractor may use a calibrated video camera — or any other device
approved by the Engineer — that can physically verify the dimensions of the pipe and is not limited
by poor lighting, water flow, pipe length, or other limiting conditions of the installed environment.
In all installations of pipes measuring larger than 600 mm in diameter, at least 10 percent of the total
number of pipe runs representing at least 10 percent of the total pipe footage on the Project shall be
randomly selected by the Engineer and inspected for deflection. Also, as determined by the 100
percent visual inspection in Article 31.6.7.1, Visual Inspection, all areas in which deflection can be
visually detected shall be inspected for deflection.
Ten percent of each pipe installation shall be defined as 10 percent of the number of pipe runs, and
not less than 10 percent of the total length of installed pipe on the Project. Deflection testing
requirements are intended to serve as a minimum and do not limit the Owner from more stringent
requirements.
Where direct measurements are made, a measurement shall be taken once every 3 m for the length
of the pipe, and a minimum of four measurements per pipe installation is required.
Pipes measuring larger than 600 mm in diameter shall be evaluated by direct measurement.
Deflection shall be determined by comparing span and rise measurements with the nominal pipe
diameter. Vertical deflection, such as a percentage, shall be expressed as the following:
rise
100 x { − 1.0 }
diameter
Equation 31-1: Vertical deflection
Similarly, horizontal deflection shall be expressed as the following:
span
100 x { − 1.0 }
diameter
Equation 31-2: Horizontal deflection
For all round pipes measuring larger than 600 mm in diameter, including round and single radius
arch structural plates, deflections exceeding 7.5 percent the nominal diameter of the pipe plus the
manufacturing tolerance of either 1 percent of the nominal diameter or 12.5 mm, whichever is
greater, shall be considered as indicative of poor backfill materials, poor workmanship, or both.
These pipes shall require remediation or replacement. Passing deflection criterion shall not eliminate
the Contractor’s need to evaluate associated denting, racking, or other shape damage.
Page 31-14
For pipe arches, deflections resulting in a decrease in rise or increase in span exceeding 7.5 percent
shall be considered indicative of poor backfill materials, poor workmanship, or both. These pipes
shall require remediation or replacement. Passing deflection criterion shall not eliminate the
Contractor’s need to evaluate associated denting, racking, or other shape damage.
Structural plate structures shall be inspected by direct measurement. They shall be assembled in
accordance with the shape tolerances of Section 31.5.3, Assembly of long-span structures.
Immediately after backfilling, these structures shall be measured to check for any immediate
deflections that occurred during the backfilling operation. After 30 days, these structures shall be
measured again to check for any additional deflection. All deflection measurements shall be based
on design dimensions. For multiple radius structures, such as ellipses, pipe-arches, and low- and
high-profile arches, the crown (top) radius shall not increase by more than 10 percent of the design
radius — as calculated from the measured middle ordinate off a suitable length straight edge. If the
top radius exceeds the design value by more than 10 percent, or if the structure is racked or
unsymmetrical by more than 2 percent, it shall require remediation. Racking degrees or loss of
symmetry shall be determined by dropping a plumb line from the actual top centreline of the installed
structure and measuring the half spans that exist on each side of the plumb line to the maximum
span line. For a symmetrical structure, these measurements at each individual cross section shall
be equal. Racking degrees or loss of symmetry shall be expressed as a percentage, as follows:
half span A – half span B
100 x { }<2
span
Equation 31-3: Racking degrees or loss of symmetry
31.6.7.3 Internal Inspection of Culverts

It is recommended that inspection personnel not enter culverts measuring less than 600 mm in
diameter. Internal inspection of culverts in this size range is best conducted using video cameras.
Culverts should only be entered by inspection personnel trained in working within confined spaces
and using procedures in full compliance with applicable Owner’s EHS regulations and Occupational
Safety and Health Administration (OSHA) Regulations (Standards - 29 CFR).
For culvert pipes measuring 600 mm or less in diameter, or if requested by the Engineer for pipes
measuring up to 1,200 mm in diameter, the Contractor shall provide the Engineer a video DVD and
report using low-barrel distortion video equipment with laser profile technology, non-contact video
micrometer, and associated software that provides the following:
• Actual recorded length and width measurements of all cracks within the pipe;
• Actual recorded separation measurement of all pipe joints;
• Pipe ovality report;
• Deflection measurements and graphical diameter analysis report in terms of x and y axis;
• Flat analysis report;
• Representative diameter of pipe;
• Pipe deformation measurements, leaks, debris, or other damage or defects; and,
• Deviation in pipe line and grade, joint gaps, and joint misalignment.
Laser profiling and measurement technology must be certified by the company performing the work
and must be in compliance with the calibration criteria approved by the Engineer. Reports may be
submitted in electronic media, if approved by the Engineer.
For video recorded, laser-profiled pipes that indicate deflection and appears to be in excess of that
allowed by specification, the Engineer may require further testing. If directed by the Engineer, the
Contractor shall test pipes using a mandrel, which shall be pulled by hand and be approved by the
Engineer prior to use. If use of a mandrel is selected as the means of further testing, the mandrel’s
Page 31-15
diameter, length, and other requirements shall conform to Sub-article b of Article 31.6.7.3. The
Contractor shall remove, replace, and retest pipe failing to meet the specific deflection requirements
for the type of pipe installed, at no cost to the Owner.
a. Video Report
The Contractor shall provide a high quality DVD in a MPEG2 format with a standard resolution of
720 by 480. The Contractor shall use a camera with lighting suitable to allow a clear picture of the
entire periphery of the pipe. Cameras shall be centred in the pipe both vertically and horizontally and
be able to pan and tilt to a 90-degree angle with the axis of the pipe and rotating 360 degrees. The
Contractor shall use equipment to move the camera through the pipe that will not obstruct the
camera’s view or interfere with proper documentation of the pipe’s condition.
Video images shall be clear, focused, and relatively free from roll, static, or other image distortion
qualities that prevent the reviewer from evaluating the condition of the pipe. Videos will include
identification before each section of pipe filmed, which will include the Project number, the structure
number corresponding to the structure number on the set of the Contract plans for the Project, size
of pipe, the date and time, and indicate which pipe is being filmed if multiple pipes are connected to
the structure. Notes shall be taken during the video recording process. Copies of the video and
corresponding notes shall be provided by the Contractor to the Engineer.
Cameras shall move through the pipe at a speed not greater than 9 m per minute. Videos shall be
marked with the distance down the pipe. These distances shall have an accuracy of 300 mm per 30
m. The Contractor shall film the entire circumference at each joint and shall stop the camera and
pan when necessary to document defects.
b. Mandrels
The Contractor shall use mandrels that are rigid; nonadjustable; have an odd number of legs with a
minimum nine legs; and have a length not less than its nominal diameter. Diameters at any point
shall not be less than the allowed percent deflection of the certified actual mean diameter of the pipe
being tested. Mandrels shall be fabricated of metal, fitted with pulling rings at each end, and stamped
or engraved on some segment other than a runner with the nominal pipe size and mandrel outside
diameter.
31.7 Construction Precautions

Structures covered by this section shall be investigated for all critical stages in their installation and
in the final intended purpose. For construction loads, additional cover may be required beyond that
required in the final condition to which the design loads apply. In the absence of more specific
information, the cover depths in Table 31-4 may be considered for the smaller structures indicated.
Minimum covers indicated shall be increased when site conditions so indicate. Guidance for structure
spans or axle loads not listed shall be provided by the Manufacturer and approved by the Engineer.
Table 31-4: Minimum Cover for Construction Loads on Circular, Pipe-Arch, Elliptic, and
Underpass Shapes
Minimum Cover, m, for Indicated Axle Loads
Pipe Span (80 – 222) kN (222 – 333) kN (333 – 490) kN (490 – 667) kN
(0.3 – 1.0) m 0.6 0.75 0.9 0.9
(1.2 – 1.8) m 0.9 0.9 1 1.2
(2.0 – 3.0) m 0.9 1 1.2 1.2
(3.2 – 3.65) m 1 1.2 1.4 1.4
Page 31-16
Any additional cover required to avoid damage to the pipe shall be provided by the Contractor.
Minimum cover shall be measured from the top of the pipe to the top of the maintained construction
roadway surface.
Surfaces shall be maintained to provide adequate cover until paving is completed, or until the Project
is accepted by the Owner, if paving is not required.
31.8 Salvaged Metal Culverts

31.8.1 Description
This section describes excavating and removing existing metal culverts and transporting, cleaning,
and reinstalling at new locations as per the Contract plans or the Engineer directions.
31.8.2 Construction
If existing culvert pipes are designated for salvage and use in the new work, the Contractor shall
remove them from the existing location and then clean, handle, transport, and install them at the new
location without damaging the culvert pipes. Any material damaged by this process shall be replaced
by the Contractor at no expense to the Owner.
Culvert pipes shall be constructed by the Contractor at the new location as specified in this chapter.
Page 31-17
INDEX
additional cover, 16, 17 installation, 5, 6, 9, 12, 14, 16

aluminium, 5, 6, 7 internal diameter, 14
apron end walls, 4, 5 invert slab, 3, 13
arches, 3, 5, 6, 11, 13, 15 inverted pear, 3
Backfill material, 11 Joint Overlap, 8
backfill materials, 6, 11, 13, 15 Joints, 7, 8
Bedding, 6, 11, 14 large-radius, 11
bituminous coating, 6 long-span structures, 3, 9, 11, 12, 13, 15
box structures, 3, 5 mandrels, 16
camera, 14, 16 metal pipes, 3, 6, 7, 14
circular, 3 multiple radius arch, 3
compaction, 6, 9, 12, 14 paving, 17
Concrete backfill, 13 pipe arches, 3, 5, 6
conduits, 3 prestressing, 4
corners, 11 rational analysis, 8
corrections, 14 salvage, 17
Corrugated, 4, 5, 6, 7, 13 settlement, 9, 11
corrugation depth, 6, 11 soil conditions, 8
culvert, 3, 4, 9, 13, 15, 17 Soil Tightness, 8
deep corrugated structures, 3, 6, 7 steel sheets, 5
Department of Transport, 31-2 structural plate metal pipes, 3
downstream end, 7 substructures, 3, 13
existing metal culverts, 17 temporary bracing, 13
footings, 3, 11, 13 temporary drainage facilities, 9
foundations, 9 trench conditions, 9
galvanised, 5, 6, 13 underpass, 3, 11
geotextile, 8, 9 Vertical deflection, 15
granular material, 6 Video images, 16
headwalls, 3, 13 Water Tightness, 8
horizontal deflection, 15 welding, 6
horizontal elliptic, 3, 8, 11 workmanship, 14, 15
inspection personnel, 15 Zinc-coated, 5
Page 31-18
PART 2
ROAD STRUCTURES
CHAPTER 32 - PRECAST CONCRETE CULVERTS
DOCUMENT NO: TR-

FIRST EDITION
JANUARY 2018
Chapter 32: Precast Concrete Culverts

TABLE OF CONTENTS
List of Tables .................................................................................................................................. ii
32 Precast Concrete Culverts............................................................................................... 32-1
32.1 General ........................................................................................................................ 32-1
32.4 Materials ...................................................................................................................... 32-2
32.4.1 Reinforced Concrete Culverts ............................................................................... 32-2
32.4.2 Joint Sealants ....................................................................................................... 32-3
32.4.2.1 General.......................................................................................................... 32-3
32.4.2.2 Cement Mortar ............................................................................................... 32-3
32.4.2.3 Bituminous Plastic Cement ............................................................................ 32-4
32.4.2.4 Flexible Watertight Gaskets ........................................................................... 32-4
32.4.2.5 Other Joint Sealant Materials ......................................................................... 32-4
32.4.3 Bedding and Backfill Materials .............................................................................. 32-5
32.5 Fabrication and Assembly ............................................................................................ 32-5
32.5.1 General................................................................................................................. 32-5
32.5.2 Testing .................................................................................................................. 32-5
32.5.3 Lifting Holes .......................................................................................................... 32-5
32.5.4 Marking ................................................................................................................. 32-5
32.5.5 Tolerances ............................................................................................................ 32-5
32.5.6 Defects and Repair ............................................................................................... 32-6
32.5.7 Storage and Shipment .......................................................................................... 32-6
32.6 Installation ................................................................................................................... 32-6
32.6.1 General................................................................................................................. 32-6
32.6.2 Joints .................................................................................................................... 32-6
32.6.3 Foundation Bedding and Backfill ........................................................................... 32-7
32.6.3.1 General.......................................................................................................... 32-7
32.6.3.2 Precast Reinforced Concrete Circular, Arch, and Elliptical Pipe ..................... 32-7
32.6.3.3 Precast Reinforced Concrete Box Sections ................................................. 32-13
32.6.4 Placing Culvert Sections ..................................................................................... 32-14
32.6.5 Haunch, Lower Side, and Backfill or Overfill ....................................................... 32-15
32.6.5.1 Precast Reinforced Concrete Circular Arch and Elliptical Pipe ..................... 32-15
32.6.5.2 Precast Reinforced Concrete Box Sections ................................................. 32-15
32.6.5.3 Placing of Haunch, Lower Side, and Backfill or Overfill ................................ 32-15
32.6.5.4 Cover Over Culvert During Construction ...................................................... 32-16
32.7 Field Inspection.......................................................................................................... 32-16
32.7.1 General............................................................................................................... 32-16
32.7.2 Misalignment ...................................................................................................... 32-16
32.7.3 Joint Defects ....................................................................................................... 32-17
32.7.4 Longitudinal Cracks ............................................................................................ 32-17
32.7.5 Transverse Cracks .............................................................................................. 32-17
32.7.6 Spalls .................................................................................................................. 32-17
32.7.7 Slabbing ............................................................................................................. 32-18
32.7.8 End Section Drop-off .......................................................................................... 32-18
32.7.9 Follow-up ............................................................................................................ 32-18
32.8 Surface Finish ............................................................................................................ 32-18
32.9 Waterproofing ............................................................................................................ 32-18
32.10 Removing and Replacing Culverts ............................................................................. 32-18
Index 32-19
Page i
CHAPTER 32: PRECAST CONCRETE CULVERTS First Edition -January 2018
LIST OF FIGURES
Figure 32-1: Standard Embankment Installation for Round Pipe ................................................ 32-7
Figure 32-2: Standard Trench Installation for Round Pipe .......................................................... 32-8
Figure 32-3: Embankment Beddings for Horizontal Elliptical Pipe .............................................. 32-8
Figure 32-4: Embankment Beddings for Vertical Elliptical Pipe .................................................. 32-9
Figure 32-5: Embankment Beddings for Arch Pipe..................................................................... 32-9
Figure 32-6: Trench Beddings for Horizontal Elliptical Pipe ...................................................... 32-10
Figure 32-7: Trench Beddings for Arch Pipe ............................................................................ 32-10
Figure 32-8: Trench Beddings for Vertical Elliptical Pipe .......................................................... 32-11
Figure 32-9: Bedding and Backfill Requirements ..................................................................... 32-14
Figure 32-10: Excavation of Bell Holes for Uniform Support ..................................................... 32-14
LIST OF TABLES
Table 32-1: Designations and titles for AASHTO and ASTM standards that apply to precast concrete
culverts construction works ........................................................................................................ 32-1
Table 32-2: Reinforced Concrete Culvert Specification Requirements ....................................... 32-3
Table 32-3: The Annular Space Range and the Type Sealer ..................................................... 32-3
Table 32-4: Bituminous Plastic Cement Material Requirements ................................................. 32-4
Table 32-5: Standard Embankment Installation Soils & Minimum Compaction Requirements .. 32-11
Table 32-6: Standard Trench Installation Soils and Minimum Compaction Requirements ........ 32-11
Table 32-7: Equivalent USCS and AASHTO Soil Classifications for SIDD Soil Designations ... 32-13
Page ii
32 PRECAST CONCRETE CULVERTS

32.1 General
This work shall consist of fabricating, furnishing, installing, and inspecting buried precast concrete
culverts conforming to these specifications, Road Structures Design Manual (ADQCC TR-516),
Section 12 of the American Association of State Highway and Transportation Officials (AASHTO)
Load and Resistance Factor Design (LRFD) Bridge Design Specifications, and the details shown in
the Contract documents. Precast, reinforced concrete pipe shall be circular, arch, or elliptical, as
specified in the Contract documents. Precast, reinforced concrete box sections shall be of the
dimensions specified in the Contract documents.

Standards and codes for precast concrete culverts shall be as specified in these specifications, in
the Contract documents, if any, and the following, in their latest edition:
and Testing;
AASHTO Soil Classification System;
Standards - 29 CFR OSHA Regulations;
USCS Unified Soil Classification System.
precast concrete culverts. It also includes designations and titles.
Table 32-1: Designations and titles for AASHTO and ASTM standards that apply to precast
concrete culverts construction works
AASHTO ASTM
Title
AASHTO M Standard Specification for Reinforced Concrete Culvert,
ASTM C76 - 12
170-12 Storm Drain, and Sewer Pipe
AASHTO M Standard Specification for Reinforced Concrete D-Load
ASTM C655 - 12
242M/M 242-12 Culvert, Storm Drain, and Sewer Pipe
AASHTO M Standard Specification for Reinforced Concrete Arch
ASTM C506 - 12
AASHTO M Standard Specification for Reinforced Concrete Elliptical
ASTM C507 - 12
Page 32-1
AASHTO ASTM
Title
Standard Specification for Joints for Concrete Pipe,
AASHTO M
ASTM C990 - 09 Manholes, and Precast Box Sections Using Preformed
198-10
Flexible Joint Sealants
AASHTO M Standard Specification for Joints for Concrete Pipe and
ASTM C443 - 12
315-06 Manholes, Using Rubber Gaskets
Standard Specification for Precast Reinforced Concrete
AASHTO M ASTM C1433 -
Monolithic Box Sections for Culverts, Storm Drains, and
273-11 10
Sewers
Standard Test Methods for Emulsified Bitumens Used as
ASTM D2939-03
Protective Coatings (Withdrawn 2012)
ASTM D128 - Standard Test Methods for Analysis of Lubricating
98(2008) Grease
Standard Practice for Classification of Soils for
ASTM D2487 -
Engineering Purposes (Unified Soil Classification
11
System)
Standard Specification for Precast Reinforced Concrete
AASHTO M ASTM C1433 -
Monolithic Box Sections for Culverts, Storm Drains, and
259-11 10
Sewers
AASHTO T187-
Standard Method of Test For Concrete Joint Sealers
1992
AASHTO M ASTM D3282 - Standard Practice for Classification of Soils and Soil-
145-91 (2008) 09 Aggregate Mixtures for Highway Construction Purposes

When complete details are not provided in the Contract plans or Contract documents, the Contractor
shall submit working drawings and substantiating calculations of the proposed structure or
installation system. Fabrication or installation of the structure shall not begin until the Engineer has
approved the drawings. Working drawings shall show complete details and substantiating
calculations of the structure, the materials, equipment, and installation methods proposed.
Working drawings shall be submitted in advance of the start of the work to allow for their review,
revision, and approval without delay to the work. Approval by the Engineer shall not relieve the
Contractor of any contractual responsibility.
32.4 Materials
Materials for precast concrete culverts shall comply with the requirements outlined in this section.
32.4.1 Reinforced Concrete Culverts

Reinforced concrete culvert materials shall meet the requirements of the classes and sizes specified
in Table 32-2.
Page 32-2
Table 32-2: Reinforced Concrete Culvert Specification Requirements
Type Specification
AASHTO M 170-12 (ASTM C76 - 12) or

Circular pipe
AASHTO M 242M/M 242-12 (ASTM C655 - 12)
Arch pipe AASHTO M 206M/M 206-12 (ASTM C506 - 12)
Elliptical pipe AASHTO M 207M/M 207-10 (ASTM C507 - 12)
AASHTO M 259-11 and AASHTO M 273-11 or

Box sections
ASTM C1433 - 10
32.4.2 Joint Sealants

32.4.2.1 General
A certificate of compliance shall be submitted by the Contractor to the Engineer stating that the
furnished material conforms to the joint property requirements.
Design and production tolerances for the annular space within the manufactured joint will determine
the type of joint required when sealing the joints, per the manufacturer.
When the annular space within the pipe joints, also known as the algebraic difference in diameters
measured between the exterior edges of the pipe at the spigot end and the interior faces of the hub
at the shoulder of the joint, falls within the following ranges shown in Table 32-3, the type sealer
noted thereafter will be used.
Table 32-3: The Annular Space Range and the Type Sealer
Total Annular Space Type Sealer
6 mm or less Bituminous plastic cement

Mortar or bituminous plastic cement as elected by
6 mm to 13 mm
the Contractor
13 mm or more Mortar
32.4.2.2 Cement Mortar

Mortar shall be composed of one part cementitious material as defined in Section 4.3.1 of Chapter
4, Concrete Works, of these standard specifications, and two parts sand by volume. Sand shall be
well graded and of such size that all will pass sieve No. 8, which shall measure 2.4 mm. These
materials shall be mixed to a consistency suitable for the purpose intended and used within 30
minutes after the water mixture has been added. Admixtures, if any, shall be approved by the
Engineer prior to use.
a. Placing Cement Mortar

When placing cement mortar, the Contractor shall clean the lower portion of the receiving end of the
pipe and shall plaster the inside with sufficient joint mortar to bring the inner surfaces of the abutting
pipe sections flush and even. These sections shall be fitted by the Contractor as close as the
construction of the culvert permits. Joints shall be filled and sealed with mortar inside and out. Excess
mortar shall be cleaned from the inside of the joint by the Contractor.
Mortar shall be cured outside of joints by covering with polyethylene sheeting or spraying with a
curing compound. The Contractor shall backfill while mortar is plastic. If mortar sets before backfilling
operations occur, the Contractor shall wait at least 24 hours before backfilling.
Page 32-3
32.4.2.3 Bituminous Plastic Cement

Bituminous plastic cement meeting the specifications noted in this article, or other kinds of mastic
joint sealer that the Engineer has approved, shall be used on joints whose design or manufacturing
process produces an annular space within the limits noted in Table 32-3.
Bituminous joint sealing compounds may be applied cold for sealing the joints of bell and spigot or
tongue and groove culvert pipe. Material furnished shall be composed of a steam-refined petroleum
asphalt dissolved in a suitable solvent and stiffened with a mineral filler.
a. Properties of Bituminous Plastic Cement

Bituminous plastic cement shall consist of a smooth uniform mixture, not thickened or livered, and it
shall show no separation that cannot be easily overcome by stirring. Consistencies and properties
of these materials shall permit their application by the Contractor with a trowel, putty knife, or caulking
compound gun without pulling or drawing. When applied to the joint surfaces, these materials shall
exhibit good adhesive and cohesive properties. The material shall meet the requirements specified
in Table 32-4.
Bituminous plastic cement shall set to a rough, plastic coating, free from blisters, when applied in a
layer 1.5 mm to 3 mm thick on a tinned metal panel and cured at room temperature for 24 hours.
Table 32-4: Bituminous Plastic Cement Material Requirements
Minimum Maximum
Grease cone penetration 175 250
Unit weight in kilograms per litre 1.17 -
Non-volatile 70 -
Ash, by ignition, by weights or masses 15 45
Methods of tests shall be in accordance with the following:
Grease cone penetration AASHTO T187-1992
Non-volatile ASTM D2939-03
Ash ASTM D128 - 98(2008)
32.4.2.4 Flexible Watertight Gaskets

Flexible watertight, gasketed joints shall conform to the requirements of AASHTO M 198-10 (ASTM
C990 - 09) or AASHTO M 315-06 (ASTM C443-12) and shall be flexible and capable of withstanding
expansion, contraction, and settlement of the pipeline.
All rubber gaskets shall be stored in as cool a place as practicable, preferably at 21 degrees Celsius
or less.
Rubber gaskets that require lubrication shall be lubricated with the lubricant recommended and
supplied by the pipe manufacturer.
32.4.2.5 Other Joint Sealant Materials

Other joint sealant materials shall be submitted for testing in advance of their use and shall not be
used prior to receiving approval from the Engineer.
Other materials for joint sealant may include the following:
a. Oakum and mortar;
b. Oakum and joint compound;
c. Coupling bands; and,
Page 32-4
d. Preformed plastic sealing compound.
32.4.3 Bedding and Backfill Materials

Bedding and backfill materials shall conform to the provisions of Section 32.6, "Installation."
32.5 Fabrication and Assembly

32.5.1 General
Precast concrete units or elements shall be fabricated in accordance with the applicable
requirements of Section 21.17 of Chapter 21, Concrete Structures, of these standard specifications,
and assembled in accordance with the manufacturer's instructions. All units or elements shall be
handled with reasonable care and shall not be rolled or dragged over gravel or rock. Care shall be
taken to prevent the units from striking rock or other hard objects during placement.
32.5.2 Testing
Test specimens shall be produced by the Contractor in accordance with Sections 21.3.3 and 21.5.2
of Chapter 21, Concrete Structures, of these standard specifications. All equipment required for
testing concrete for boxes produced in a precasting plant shall be furnished by the producer.
32.5.3 Lifting Holes

For precast boxes, the Contractor shall provide no more than four lifting holes in each section. Lifting
holes may be cast, cut into fresh concrete after form removal, or drilled and shall be of a sufficient
size for adequate lifting devices based on the size and weight of the box selection. Lifting holes
measuring larger than 75 mm in diameter shall not be used. When locating lift holes, the Contractor
shall not cut more than one longitudinal wire or two circumferential wires per layer of reinforcing
steel. Spalled areas around lifting holes shall be repaired by the Contractor.
32.5.4 Marking
Precast boxes shall be marked by the Contractor with the following:
• Name or trademark of the producer;
• Date of manufacture;
• Box size;
• Minimum and maximum fill heights; and,
• Match marks for proper installation, when required, under Section 32.5.5, Tolerances.
For boxes without lifting holes, the Contractor shall mark one end of each box section on the inside
and outside walls to indicate the top or bottom — as it will be installed. Markings shall also be
indented into the box section, or the Contractor shall paint them on each box with waterproof paint.
32.5.5 Tolerances
Precast sections, of either type, shall meet the following requirements:
a. The inside vertical and horizontal dimensions shall not vary from the Contract plan
requirements by more than 12.5 mm, or 1 percent, whichever is greater.
b. The horizontal or vertical plane at each end of the box section shall not vary from the
perpendicular by more than 12.5 mm, or 1 percent, whichever is greater, when measured on
the inside faces of the section.
c. The sides of a section at each end shall not vary from being perpendicular to the top and
bottom by more than 12.5 mm, or 1 percent, whichever is greater, when measured diagonally
between opposite interior corners.
Page 32-5
Wall and slab thicknesses shall not measure less than what is shown in the Contract plans and in
the approved working drawings — except for occasional deficiencies not greater than 6 mm, or 5
percent, whichever is greater. If proper jointing is not affected, the Contractor may use thicknesses
in excess of plan requirements.
Deviations from the above tolerances will be acceptable if the sections can be fitted at the plant, or
jobsite, and the joint opening at any point does not exceed 25 mm. Match marks shall be used by
the Contractor for proper installation on sections that have been accepted in this manner.
32.5.6 Defects and Repair

Fine cracks along surfaces that do not extend to the plane of the nearest reinforcement are
acceptable — unless the cracks are numerous and extensive. Cracks that extend into the plane of
the reinforcing steel shall be repaired by the Contractor in an approved manner. Excessive damage,
honeycombs, or cracking will be subject to structural review. Repaired boxes that are sound, properly
finished, and cured in conformance with pertinent specifications may be accepted by the Engineer.
When fine cracks on the surface indicate poor curing practices, the Contractor shall discontinue
further production of precast sections until corrections are made and proper curing is provided.
32.5.7 Storage and Shipment

Precast sections shall be stored on a level surface by the Contractor. These sections shall not hold
any load until design strength is reached and curing is complete. Shipment of sections shall occur
when the design strength and curing requirements have been met.
32.6 Installation
32.6.1 General
Cracks in an installed precast concrete culvert that exceed 0.25 mm in width shall be appraised by
the Engineer and assessed for structural integrity, environmental conditions, and the design service
life of the culvert. Cracks having greater widths, or otherwise determined to be detrimental, shall be
sealed by a method approved by the Engineer.
For trench conditions, the trench shall be excavated to the dimensions and grade specified in the
Contract documents — or as directed by the Engineer. Provisions shall be made by the Contractor
as required to insure adequate drainage of the trench to protect the bedding during construction
operations.
Proper preparation of foundations; placement of foundation materials, where required; and
placement of bedding materials shall precede the installation of the culvert. This work shall include
necessary levelling of the native trench bottom, or the top of foundation materials; as well as the
placement and compaction of required bedding material to a uniform grade so that the entire length
of pipe shall be supported on a uniformly, slightly yield of bedding. Backfill materials shall be placed
and compacted around the culvert in a manner to meet the requirements specified.
Materials used for foundation improvements, bedding, and structure backfill shall have gradations
compatible with adjacent soils to avoid migration. Where material gradations cannot be properly
controlled, adjacent materials shall be separated with a suitable geotextile.
32.6.2 Joints
Joints for reinforced concrete pipe and precast reinforced concrete box sections shall comply with
the details shown in the Contract documents and in the approved working drawings. Each joint shall
be sealed to prevent infiltration of soil fines or water, as required by the Contract documents. Field
tests may be required by the Engineer whenever there is a question regarding compliance with the
Contract requirements.
Page 32-6
32.6.3 Foundation Bedding and Backfill

32.6.3.1 General
If rock strata or boulders are encountered under the culvert within the limits of the required bedding,
the rock or boulders shall be removed and replaced with bedding material. Foundations shall be
comprised of stiff to hard in situ soil, stabilized soil, or compacted fill material. If the foundation is
rock or other unyielding soil, then a minimum bedding thickness of 150 mm, or 2 percent of the fill
height — whichever is greater — shall be considered. Where, in the opinion of the Engineer, the
natural foundation soil is such as to require stabilization, such material shall be replaced by a layer
of bedding material. Where unstable or unsuitable material, such as peat or muck, is encountered at
or below invert elevation during excavation, the necessary subsurface exploration and analysis shall
be made and corrective treatment shall be as directed by the Engineer.
Where rock or other unyielding foundations exist and blasting is anticipated, the Engineer may
require that suitable steps be taken to protect the pipe.
32.6.3.2 Precast Reinforced Concrete Circular, Arch, and Elliptical Pipe

The bedding of the class, specified in the Contract documents or in the working drawings, shall be
provided. Installation types specified shall conform to one of the types of installation given in Table
32-5 and Table 32-6 and the details shown in Figure 32-1 through Figure 32-8, which define soil
areas and critical dimensions for circular, arch, and elliptical pipes.
Table 32-5 and Table 32-6 list general soil types, minimum compaction requirements, and minimum
bedding thicknesses for the four standard installation types for embankment and trench installations,
respectively.
Figure 32-1: Standard Embankment Installation for Round Pipe
Page 32-7
Figure 32-2: Standard Trench Installation for Round Pipe
Figure 32-3: Embankment Beddings for Horizontal Elliptical Pipe
Page 32-8
Figure 32-4: Embankment Beddings for Vertical Elliptical Pipe
Figure 32-5: Embankment Beddings for Arch Pipe
Page 32-9
Figure 32-6: Trench Beddings for Horizontal Elliptical Pipe
Figure 32-7: Trench Beddings for Arch Pipe
Page 32-10
Figure 32-8: Trench Beddings for Vertical Elliptical Pipe
Table 32-5: Standard Embankment Installation Soils & Minimum Compaction Requirements
Installation Bedding Haunch and outer Lower
type thickness bedding side
For soil foundations, BC /24
90% (A1, A3 or SW),
minimum, not less than 75 mm.
95% (A1, A3 or 95% (A2, A4 or ML),
Type 1 For rock foundations, use BC/12 SW) or 100% (A5, A6 or
minimum, not less than 150
CL)
mm.
Type 2 – installations For soil foundations, BC /24
minimum, not less than 75 mm. 85% (A1, A3 or SW),
are available for 90% (A1, A3 or
90% (A2, A4 or ML),
horizontal elliptical, For rock foundations, use BC SW), or 95% (A2,
or 95% (A5, A6 or
vertical elliptical, and /12 minimum, not less than 150 A4 or ML)
CL)
arch pipe mm.
Type 3 – installations For soil foundations, BC /24
minimum, not less than 75 mm. 85% (A1, A3 or 85% (A1, A3 or SW),
are available for
SW), 90% (A2, A4 90% (A2, A4 or ML),
horizontal elliptical, For rock foundations, use BC or ML), or 95% or 95% (A5, A6 or
vertical elliptical, and /12 minimum, not less than 150 (A5, A6 or CL) CL)
arch pipe mm.
For soil foundations, no No compaction
bedding required. No compaction
required, except if
required, except if
Type 4 For rock foundations, use BC (A5, A6 or CL),
(A5, A6 or CL), use
/12 minimum, not less than 150 use 85% (A5, A6
85% (A5, A6 or CL)
mm. or CL)
The following interpretations apply to Table 32-5:

a. Compaction and soil symbols, such as 95 percent (A1, A3, or SW), shall be taken to refer to
(A1, A3, or SW) soil material with minimum standard proctor compaction of 95 percent.
Equivalent modified proctor values shall be as given in Table 32-7.
b. Soil in the outer bedding, haunch, and lower side zones, except within Bc/3 from the pipe
spring line, shall be compacted to at least the same compaction as the majority of soil in the
overfill zones.
c. The minimum width of a subtrench for Type 1 through Type 3 installation shall be Bc+0.6 m
or 1.33 Bc , whichever is greater or wider — if required for adequate space to attain the
specified compaction in the haunch and bedding zones.
d. A subtrench is defined as a trench in the natural material under an embankment used to
retain bedding material with its top below finished grade by more than 10 percent of the depth
of soil cover on the top of the culvert or pipe, or, for roadways, its top is at an elevation lower
than 300 mm below the bottom of the pavement base material.
e. For subtrenches with walls of natural soil, any portion of the lower side zone in the subtrench
wall shall be at least as firm as an equivalent soil placed to the compaction requirements
specified for the lower side zone and as firm as the majority of soil in the overfill zone, or shall
be removed and replaced with soil compacted to the specified level.
f. Only Type 2 and 3 installations are available for horizontal elliptical, vertical elliptical, and
arch pipe.
g. The required bedding thickness is the thickness of the bedding after placement of the pipe
on the bedding and is prior to placement of the backfill.
Table 32-6: Standard Trench Installation Soils and Minimum Compaction Requirements
Page 32-11
Installation Bedding Haunch and Lower

type thickness outer bedding side
For soil foundations, BC /24 90% (A1, A3 or
minimum, not less than 75 SW),
mm. 95% (A1, A3 or 95% (A2, A4 or ML),
Type 1
For rock foundations, use SW) 100% (A5, A6 or
BC/12 minimum, not less CL), or natural soils
than 150 mm. of equal firmness
Type 2 – For soil foundations, BC /24 85% (A1, A3 or
installations are minimum, not less than 75 90% (A1, A3 or SW),
available for mm. SW), 90% (A2, A4 or ML),
horizontal elliptical, For rock foundations, use BC or 95% (A2, A4 95% (A5, A6 or CL),
vertical elliptical, /12 minimum, not less than or ML) or natural soils of
and arch pipe 150 mm. equal firmness
Type 3 – For soil foundations, BC /24 85% (A1, A3 or 85% (A1, A3 or
installations are minimum, not less than 75 SW), SW),
available for mm. 90% (A2, A4 or 90% (A2, A4 or ML),
horizontal elliptical, For rock foundations, use BC ML), or 95% (A5, A6 or CL),
vertical elliptical, /12 minimum, not less than 95% (A5, A6 or or natural soils of
and arch pipe 150 mm. CL) equal firmness
For soil foundations, no No compaction 85% (A1, A3 or

bedding required. required, except if SW),
90% (A2, A4 or ML),
Type 4 For rock foundations, use BC (A5, A6 or CL), 95% (A5, A6 or CL),
/12 minimum, not less than use 85% (A5, A6 or natural soils of
150 mm. or CL) equal firmness
The following interpretations apply to Table 32-6:
a. Compaction and soil symbols, such as 95 percent (A1, A3, or SW), shall be taken to refer to
(A1, A3, or SW) soil material with minimum standard proctor compaction of 95 percent.
Equivalent modified proctor values shall be as given in Table 32-7.
b. Trench top elevation shall be no lower than 0.1H below finish grade, or for roadways, its top
shall be no lower than an elevation of 300 mm below bottom of pavement base material.
c. Soil in bedding and haunch zones shall be compacted to at least the same compaction as
specified for the majority of soil in the backfill zone.
d. The minimum trench width for Type1 through Type 3 installation shall be Bc+0.6 m or 1.33
Bc, whichever is greater, or wider, if required for adequate space to attain the specified
compaction in the haunch and bedding zones.
e. For trench walls that are within 10 degrees of vertical, the compaction or firmness of the soil
in the trench walls and lower side zone need not be considered.
f. For trench walls with greater than 10-degree slopes that consist of embankment, the lower
side shall be compacted to at least the same compaction as specified for the soil in the backfill
zone.
g. Only Type 2 and 3 installations are available for horizontal elliptical, vertical elliptical, and
arch pipe.
h. The required bedding thickness is the thickness of the bedding after placement of the pipe
on the bedding and is prior to placement of the backfill.
AASHTO M 145-91 (2008) (ASTM D3282 – 09), ASTM D2487 - 11, and Unified Soil Classification
System (USCS) soil classifications equivalent to the generic soil types in the standard installations
may be taken from Table 32-7.
Page 32-12
Table 32-7: Equivalent USCS and AASHTO Soil Classifications for SIDD Soil Designations
Representative Soil Types Percent Compaction
*SIDD Soil
USCS AASHTO Modified Proctor
95
90
85
Gravelly Sand SW, SP, GW, GP A1, A3
80
75
59
95
GM, SM, ML 90
Also GC, SC with than 20 85

Sandy Silt A2, A4
percent passing a No. 200 80
sieve
75
46
90
85
80
GL, MH, GC, SC A5, A6
75
70
Silty Clay
40
90
CH
85
Not allowed for haunch or A7
bedding 80
40
*Standard Installation Direct Design Soil
32.6.3.3 Precast Reinforced Concrete Box Sections

Unless otherwise permitted herein, a bedding shall be provided for the type of installation specified
conforming to Figure 32-9, unless in the opinion of the Engineer, the natural soil provides a suitable
bedding.
Bedding material may be granular material, all of which passes a 9.5-mm sieve and not more than
10 percent of which passes sieve No. 200, measuring 75 μm. Backfill shall be selected material and
shall be free of organic material, rock fragments larger than 75 mm in the greatest dimension, and
shall have moisture content within the units required for compaction.
Page 32-13
Figure 32-9: Bedding and Backfill Requirements
32.6.4 Placing Culvert Sections

Unless otherwise authorized by the Engineer, the laying of culvert sections on the prepared bedding
shall be started at the outlet and with the bell end pointing upstream and the spigot or tongue end
pointing downstream and shall proceed toward the inlet end with the abutting sections properly
matched, true to the established lines and grades. Where pipe with bells is installed, bell holes shall
be excavated in the bedding to such dimensions that the entire length of the barrel of the pipe will
be supported when properly installed — as shown in Figure 32-10. Proper facilities shall be provided
for hoisting and lowering the sections of culvert into the trench without disturbing the prepared
bedding and the sides of the trench. Section ends shall be carefully cleaned before the section is
jointed. Sections shall be fitted and matched so that when laid in the bed they shall form a smooth,
uniform conduit. When elliptical pipe with circular reinforcing or circular pipe with elliptical reinforcing
is used, the pipe shall be laid in the trench in such position that the markings "Top" or "Bottom," shall
not be more than five degrees from the vertical plane through the pipe’s longitudinal axis.
Adjustments in grade by exerting force on the culvert with excavating equipment or by lifting and
dropping the culvert shall be prohibited. If the installed culvert section is not on grade after joining,
the section shall be completely un-joined, the grade corrected, and the section rejoined.
Figure 32-10: Excavation of Bell Holes for Uniform Support

Multiple installations of reinforced concrete culverts shall be laid with the centre lines of individual
barrels parallel at the spacing shown in the Contract documents. Pipe and box sections used in
parallel installations require positive lateral bearing between the sides of adjacent pipe or box
sections. Compacted earth fill, granular backfill, or grouting between the units is considered means
of providing positive bearing.
The joint ends, when using rubber gaskets, shall be protected from mud, silt, gravel, or other
unwanted material. The pipe sections with gaskets attached shall be laid, removed, cleaned, and
relubricated. Gaskets disturbed or contaminated shall be reseated.
The joints shall be forced-home using the pipe manufacturer‘s recommended procedure. Driving or
ramming by hand or machinery shall not be done. The last section of each day's run shall be blocked
to prevent creep.
Page 32-14
A dike or plug of impervious material shall be placed near the intake end of the culvert to prevent
piping. The dike shall measure 0.6 m long and adequately surround the pipe to form an impervious
barrier.
The ends of the pipe or pipe arch shall be rigidly supported to prevent movement before and during
the construction of end walls or headers.
Culverts shall not be left extending beyond the staked limits, unless approved by the Engineer.
32.6.5 Haunch, Lower Side, and Backfill or Overfill

32.6.5.1 Precast Reinforced Concrete Circular Arch and Elliptical Pipe
Haunch, low side, and overfill materials shall be installed to the limits shown in Figure 32-1 through
Figure 32-8.
32.6.5.2 Precast Reinforced Concrete Box Sections

Backfill material shall be installed to the limits shown in Figure 32-9 for the embankment or trench
condition.
32.6.5.3 Placing of Haunch, Lower Side, and Backfill or Overfill

Fill material shall be placed in layers with a maximum loose thickness of 200 mm and compacted to
obtain the required density. These materials shall be placed and compacted with care under the
haunches of the culvert and shall be raised evenly and simultaneously on both sides of the culvert.
For the lower haunch areas of Type 1, 2, and 3 standard installations, soils requiring 90 percent or
greater standard proctor densities shall be placed in layers with a maximum thickness of 200 mm
and compacted to obtain the required density. Trench widths shall be kept to the minimum required
for installation of the culvert. Ponding or jetting will be only by the permission of the Engineer.
Backfill shall be placed in horizontal layers, and shall not be placed against concrete less than seven
days old or until 80 percent of the design strength is achieved.
Backfill for the most shapes of culverts is explicated in the following:
a. Pipe Culverts
Material shall be placed and compacted in evenly balanced layers on each side of each pipe culvert.
The Contractor shall backfill according to one of the following:
1. Pipe Culverts with Compacted Backfill
Backfill material shall be placed and compacted to a height of 0.3 m above the top of the
pipe. Backfilling the trench shall be completed by the Contractor with suitable roadway
excavation or unclassified borrow.
2. Pipe Culverts with Lean Concrete Backfill
Pipe shall be placed and staked to prevent floating and movement.
Lean concrete backfill shall be mixed and placed by pug-mill, rotary drum, or other approved
mixer to obtain a uniform mix. Lean concrete backfill shall be placed in a uniform manner that
prevents voids in, or segregation of the backfill.
When backfilling around culverts and other structures, lean concrete backfill shall be placed
in a manner that does not float or shift the structure. Backfill shall be brought up evenly on all
sides of the structure.
Lean concrete backfill levels around culverts shall be determined by the Engineer, according
to the nature of the soil in which the culverts will be placed.
Page 32-15
b. Arch Culverts with Headwalls

When backfilling culverts with headwalls, the Contractor shall backfill according to one of the
following:
1. Before Headwalls Placement
Material backfilled first shall be placed and compacted midway between the ends of the arch.
Backfill material shall be placed and compacted in layers on both sides of the arch to form as
narrow a ramp as possible.
Ramps shall be built evenly on both sides until reaching the top of the arch.
Backfill materials remaining shall be placed from the top of the ramp working both ways to
the ends.
Backfill materials shall be compacted evenly in layers on both sides of the arch.
2. After Headwalls Placement
Materials backfilled first shall be placed and compacted adjacent to one headwall.
Backfill materials shall be placed and compacted evenly in layers on both sides of the arch
adjacent to the headwall until reaching the top of the arch.
Backfill materials remaining shall be placed from the top of the arch working toward the other
headwall.
Backfill materials shall be compacted evenly in layers on both sides of the arch.
32.6.5.4 Cover Over Culvert During Construction

If the passage of construction equipment over an installed culvert is necessary during the Project
construction, compacted overfill in the form of a ramp shall be constructed to a minimum elevation
of 0.9 m over the top of the culvert or to a height such that the equipment loads on the culvert do not
exceed the culvert design strength. In an embankment installation, the overfill shall extend a
minimum of one culvert diameter width or 0.9 m, whichever is greater, beyond each side of the
culvert to prevent possible lateral displacement of the culvert. If a large volume of construction traffic
must cross an installed culvert, the point of crossing shall be changed occasionally to minimize the
possibility of lateral displacement.
32.7 Field Inspection

32.7.1 General
Internal inspections shall be conducted on all buried rigid pipe installations to evaluate issues that
may affect long-term performance, such as cracks, joint quality, and alignment. Inspections shall be
conducted no sooner than 30 days after completion of installation and final fill.
It is recommended that inspection personnel not enter culverts less than 600 mm in diameter.
Internal inspection of rigid culverts in this size range is best conducted using video cameras. Culverts
shall only be entered by inspection personnel trained in working within confined spaces and using
procedures in full compliance with applicable Abu Dhabi Road Regulations and Occupational Safety
and Health Administration (OSHA) Regulations (Standards - 29 CFR).
32.7.2 Misalignment
Misalignment may be taken to indicate the presence of problems in the supporting soil or the
Contractor grade control. Culvert barrel’s vertical and horizontal alignments shall be checked by the
Contractor by sighting along the crown, invert, and sides of the culvert, and by checking for
differential movement or settlement at joints between pipe sections. Vertical alignments shall be
checked for sagging, faulting, and invert heaving. Pipes laid with camber or a grade change shall be
Page 32-16
accounted for by the Contractor. Horizontal alignments shall be checked for straightness or smooth
curvature.
32.7.3 Joint Defects

Leaking joints may be detected during low flows by visual observation of the joints, by checking
around the ends of the culvert for evidence of piping, and if required in the Contract documents, by
special testing methods typically employed for sanitary sewers.
Differential movement, cracks, spalling, improper gasket placement, movement or settlement of pipe
sections, and leakage shall be noted in the inspection report. Severe joint cracks are similar in
significance to separated joints.
Joint separations greater than the pipe manufacturer's maximum limit shall be considered significant
because they can accelerate damage caused by exfiltration and infiltration, resulting in the erosion
of the backfill material. Exfiltration occurs when leaking joints allow water flowing through the pipe to
leak into the supporting material. Infiltration is the reverse of exfiltration. Open joints, staining at the
joints on the sides and top of the culvert, deposits of soil in the culvert, or depressions over the
culvert are indicative of infiltration.
Evidence of any soil migration through the joint warrants further investigation by the Contractor to
determine the source, and if repair or replacement is required.
32.7.4 Longitudinal Cracks

Hairline longitudinal cracks in the crown or invert indicate that the steel has accepted part of the load.
Cracks equal to or less than 0.25 mm in width are considered minor and only need to be noted in
the inspection report.
Other signs of distress, such as differential movement, efflorescence, spalling, or rust stains shall
also be noted. When cracks are wider than 0.25 mm, measurements shall be taken of the width,
length, and locations of the cracks and diameter of the pipe, both horizontally and vertically. An
evaluation shall be conducted by the Contractor and shall be submitted to the Engineer for review
and approval considering the structural integrity, environmental conditions, and the design service
life of the culvert.
Cracks having widths equal to or greater than 0.25 mm and determined to be detrimental shall be
sealed by a method approved by the Engineer. Pipes with cracks having widths greater than 2.5 mm
and determined by the Engineer to be beyond satisfactory structural repair shall be remediated or
replaced. Pipes having displacement across the crack shall be repaired or replaced.
Inspection records for pipes with crack widths exceeding 0.25 mm, shall be kept on file for monitoring
conditions during subsequent inspections. Crack measurements and photographs shall be taken for
monitoring conditions during subsequent inspections.
32.7.5 Transverse Cracks

Poor bedding may cause transverse or circumferential cracks and is a result of poor installation
practices, such as not providing indentations, or bell holes, in hard foundation material for the end of
the bell- and spigot-type pipe; or, not providing a sufficient depth of suitable bedding material.
Where transverse cracks are observed, the Contractor shall monitor them as described in Section
32.7.4, Longitudinal Cracks.
32.7.6 Spalls
Spalling is a fracture of the concrete parallel or inclined to the surface of the concrete. In precast
concrete pipe, spalls often occur along the edges of either longitudinal or transverse cracks when
the crack is due to overloading or poor support rather than simple tension cracking.
Spalling may be detected by visual examination of the concrete along the edges of cracks. Tapping
with a hammer shall be performed along the cracks to check for areas that have fractured but are
Page 32-17
not visibly separated. Such areas will produce a hollow sound when tapped. These areas may be
referred to as delaminations or incipient spalls. Pipe experiencing this type of problem shall be
repaired or replaced.
32.7.7 Slabbing
Slabbing is a serious problem that can occur under high fills. It is a radial failure of the concrete that
occurs from straightening of the reinforcement cage due to excessive tension. Slabbing is
characterized by large slabs of concrete peeling away from the sides of the pipe and a straightening
of the reinforcing steel.
Any pipe experiencing slabbing shall be repaired or replaced.
32.7.8 End Section Drop-off

End drop-offs are caused by erosion of the material supporting the pipe sections on the outlet end
of the culvert barrel. If a drop-off occurs, the end section shall be reset.
32.7.9 Follow-up
If any repairs or remedial action is performed on the pipe, a follow-up inspection following the same
guidelines as outlined in Section 32.7, Field Inspection, shall be performed between one and two
years' time.
32.8 Surface Finish

Defects that indicate proportioning, mixing, and moulding not in compliance with the specification, or
surface defects indicating honeycombed or open texture that would adversely affect the function of
the pipe, shall be repaired or the pipe replaced.
32.9 Waterproofing
Waterproofing of culverts shall be as specified in the particular specifications, as approved by the
Engineer, and in compliance with the applicable requirements of Chapter 28, Waterproofing, of these
32.10 Removing and Replacing Culverts

Where shown in the plans, or where designated by the Engineer, existing culverts shall be removed
and relaid in accordance with these specifications. Any culvert damaged by the Contractor‘s
operations shall be replaced at the Contractor’s expense. All joints of the pipe before being relaid
shall be cleaned so as to be free from all adhering material, including old mortar placed as a collar
or seal in the original construction. All culvert sections removed and not relaid shall become the
property of the Contractor.
Page 32-18
INDEX
annular space, 32-3, 32-4 installation, 32-2, 32-5, 32-6, 32-7, 32-11, 32-
arch, 32-1, 32-7, 32-11, 32-12, 32-13, 32-15, 13, 32-14, 32-15, 32-17, 32-18
32-16 Internal inspections, 32-17
Backfill material, 32-15, 32-16 interpretations, 32-11, 32-12
backfill materials, 32-5 jetting, 32-15
Bedding, 32-5, 32-7, 32-11, 32-12, 32-14 Joint separations, 32-17
bell end, 32-14 Leaking joints, 32-17
bell holes, 32-14, 32-18 Lean concrete, 32-16
Bituminous plastic cement, 32-3, 32-4 levelling, 32-7
blasting, 32-7 lifting holes, 32-5, 32-6
boulders, 32-7 Match marks, 32-5, 32-6
box sections, 32-1, 32-7, 32-15 migration, 32-7, 32-17
calculations, 32-2 Misalignment, 32-17
cementitious, 32-3 Mortar, 32-3, 32-4
certificate of compliance, 32-3 movement, 32-15, 32-16, 32-17, 32-18
circular, 32-1, 32-7, 32-14 overfill materials, 32-15
Compaction, 32-11, 32-12, 32-13 pipe, 32-1, 32-3, 32-4, 32-7, 32-11, 32-12, 32-
construction equipment, 32-16 13, 32-14, 32-15, 32-16, 32-17, 32-18, 32-
construction traffic, 32-17 19
curing, 32-4, 32-6 Poor bedding, 32-18
delaminations, 32-18 Precast, i, 32-1, 32-2, 32-5, 32-6, 32-7, 32-14,
Department of Transport, ii 32-15
design strength, 32-6, 32-15, 32-17 precasting plant, 32-5
Deviations, 32-6 prestressing, 32-2
downstream, 32-14 Ramps, 32-16
efflorescence, 32-18 reinforced concrete, 32-1, 32-7, 32-15
elliptical, 32-1, 32-7, 32-11, 32-12, 32-13, 32- reinforcement cage, 32-18
14 remedial action, 32-19
End drop-offs, 32-18 rock, 32-5, 32-7, 32-11, 32-12, 32-14
erosion, 32-17, 32-18 Rubber, 32-2, 32-4
Excessive damage, 32-6 Sand, 32-3, 32-13
exfiltration, 32-17 sealant materials, 32-5
existing culverts, 32-19 settlement, 32-4, 32-17
Fine cracks, 32-6 Slabbing, 32-18
floating, 32-16 Soil, 32-1, 32-2, 32-11, 32-13, 32-14
follow-up inspection, 32-19 soil fines, 32-7
foundations, 32-7, 32-11, 32-12 soil symbols, 32-11, 32-12
gasketed joints, 32-4 Spalled areas, 32-5
geotextile, 32-7 Spalling, 32-18
gradations, 32-7 structure backfill, 32-7
gravel, 32-5, 32-15 subtrench, 32-11, 32-12
Hairline longitudinal cracks, 32-18 Test specimens, 32-5
hammer, 32-18 thickness, 32-7, 32-11, 32-12, 32-13, 32-15
Haunch, 32-11, 32-12, 32-15 thicknesses, 32-6, 32-7
headwalls, 32-16 tolerances, 32-3, 32-6
high fills, 32-18 tongue end, 32-14
honeycombs, 32-6 trademark, 32-5
incipient spalls, 32-18 trench conditions, 32-6
indentations, 32-18 upstream, 32-14
infiltration, 32-7, 32-17 visual examination, 32-18
inlet end, 32-14 visual observation, 32-17
inspection personnel, 32-17 Waterproofing, 32-19
Inspection records, 32-18 watertight, 32-4
Page 32-19
PART 2
ROAD STRUCTURES
CHAPTER 33 - BRIDGE ACCESS SYSTEMS
DOCUMENT NO: TR-

FIRST EDITION
JANUARY 2018
Chapter 33: Bridge Access Systems

TABLE OF CONTENTS
Table of Contents............................................................................................................................ 2
33 Bridge Access Systems ........................................................................................................ 3
33.1 General ............................................................................................................................. 3
33.2 Reference Standards and Codes ...................................................................................... 3
33.3 Overall Requirements ....................................................................................................... 3
33.4 Outline Specifications ....................................................................................................... 3
33.4.1 Outline Specifications for Bucket Type Unit (BTU) ..................................................... 3
33.4.1.1 Stability ............................................................................................................... 4
33.4.1.2 Controls .............................................................................................................. 4
33.4.1.3 Standard Equipment ........................................................................................... 4
33.4.1.4 Safety Features .................................................................................................. 4
33.4.1.5 Operational Features .......................................................................................... 5
33.4.2 Outline Specification for Under-deck Type Unit (UTU) ............................................... 5
33.4.2.1 System ............................................................................................................... 5
33.4.2.2 Stability ............................................................................................................... 6
33.4.2.3 Control Stations .................................................................................................. 6
33.4.2.4 Standard Equipment ........................................................................................... 6
33.4.2.5 Safety Features .................................................................................................. 6
33.4.2.6 Operational Features .......................................................................................... 7
33.4.2.7 Other Features ................................................................................................... 7
33.5 Method of Procurement .................................................................................................... 7
33.6 Use of the Bridge Access System in the Work .................................................................. 8
33.7 Additional Quality Standards ............................................................................................. 8
33.7.1 Durability/Design Life ................................................................................................. 8
33.7.2 Spares and Replacement Parts ................................................................................. 8
33.7.3 Operating and Maintenance Documentation .............................................................. 8
33.7.4 Support Services, Repairs, and Facilities for Same ................................................... 8
33.7.5 Commissioning and Testing of Equipment ................................................................. 8
33.7.6 Safety ........................................................................................................................ 8
33.8 Warranties ........................................................................................................................ 8
33.9 Material to be Provided by the Engineer ........................................................................... 8
33.10 Programme ....................................................................................................................... 8
Index . ............................................................................................................................................ 9
Page 33-2
CHAPTER 33: BRIDGE ACCESS SYSTEMS First Edition -January 2018
33 BRIDGE ACCESS SYSTEMS

33.1 General
This work shall consist of procuring a comprehensive access system for the long-term inspection,
operation, and maintenance of bridges, which shall conform to the requirements of the Contract
documents and these standard specifications.
If required by the Contract documents, the bridge access system shall include the following units, at
a minimum:
1. One vehicle-mounted mobile access platform, a Bucket Type Unit (BTU), for all surfaces
above deck level.
2. One vehicle-mounted mobile access platform, an Under-deck Type Unit (UTU), for all under-
deck surfaces.
3. All other supplementary equipment needed to meet the requirements for safe access to all
surfaces.

Standards and codes for bridge access systems shall be as specified in these specifications, in the
OSHA Occupational Safety and Health Administration.
33.3 Overall Requirements

This system’s purpose is to enable the Owner to conveniently and safely access all external surfaces,
components of the bridge, and all openings into the interior of the bridge for long-term inspection,
maintenance, and repair. This system shall be suitable for the complete repainting of the bridge,
except in areas where it can be shown to be more economical to use temporary scaffolding.
This system shall include all necessary documentation, spares, support facilities for the storage and
maintenance of the access system, and where specified by the Contract documents, garaging
facilities off-site.
Suppliers shall provide training services for operation and maintenance of the system and
maintenance support services.
33.4 Outline Specifications

Features described in this section are indicative of the facilities to be included and the performance
required of the units. Suppliers shall provide details of any alternatives or variations to these and the
advantages or limitations of its proposal. In all cases, suppliers shall remain responsible for ensuring
that the overall performance requirements for the complete system are satisfied.
33.4.1 Outline Specifications for Bucket Type Unit (BTU)

Vehicle-mounted mobile access platform for all surfaces above deck level shall be a bucket-type
system with a minimum load capacity of 250 kg and a minimum working area of 1.2 m by 1 m. The
BTU shall:
a. Be used primarily to gain access to all parts of the bridge above deck level (e.g., visual
inspection, routine maintenance of paint, access to feature lighting for routine maintenance),
as well as the feature lighting systems on the outside of the deck
b. Provide access to the piers below deck level from the ground or from a barge
c. Reach adequate height above the bridge deck level to serve its purpose
Page 33-3
Turntable base shall be rigidly mounted on the chassis main frame, and shall be rotatable by 270
degrees, configured to allow the unit to be lowered from either side of the vehicle and provide
maximum operational flexibility of use on the bridge. Main boom shall rotate approximately 45
degrees up and 20 degrees down, and shall be designed to bridge barriers and other obstacles of
up to 3 m height.
By means of a second rotation track, a second boom shall be fixed to the outer end of the main
boom. This boom shall telescopically extend with a vertical clearance of up to 4.5 m measured from
the bridge deck. It shall be capable of being placed alongside the bridge in a vertical position. By
means of irreversible worm gear, the second rotation track shall be capable of rotating 180 degrees.
Vertical position of boom shall be actuated by two parallel arms (tubes) in combination with two
double-acting hydraulic cylinders to ensure that the parallel arms can be extended or returned. This
shall be sufficient to compensate for the transverse slope of the bridge deck.
Third boom shall be a telescoping boom with a maximum reach of 12 m under the bridge when the
second boom is in vertical position from the centre of the second rotation track. This boom shall be
actuated by a double-acting hydraulic cylinder.
Equipped with an access door, the personnel working bucket shall be attached to the third boom,
and shall be automatically maintained in a level position.
33.4.1.1 Stability
Stability of the BTU in operation with the unit lowered on either side of the vehicle shall be provided
by appropriate counterweights mounted on the turntable of the vehicle.
To minimize the concentrated load on the deck surface, a system of additional support wheels shall
evenly distribute the full vehicle weight on all axles. Air spring suspension shall be used to facilitate
movement of the vehicle on the bridge and absorb shocks when the machine is travelling on bumpy
roads.
Movements of the vehicle on the bridge during operation shall be self-propelled. Movements shall
be slow and well-controlled.
33.4.1.2 Controls
Complete set of controls shall be provided at the bucket. All the phases of deploying and retracting
the platform shall be easily surveyed. Auxiliary manual controls shall be located at the rotation frame
on the carrying vehicle, and shall rotate together with the rotation frame. Controls at the bucket shall
override the auxiliary controls on the vehicle.
33.4.1.3 Standard Equipment

Facilities shall include a hydraulic pump driven by the power take-off of the engine, a generator for
the power supply on the platform, a two-way intercom between the carrying vehicle and the work
platform, and an independent emergency hydraulic pump actuated by a 7 hp gas engine with
attached pump for returning the aerial device into the stowed position.
33.4.1.4 Safety Features

All functional elements of the aerial device shall be designed and constructed for structural and
operational safety for the operating crew and surroundings. BTU shall be designed, built, and tested
in accordance with the stringent international safety standards.
Safety features shall include, but shall not be limited to:
a. Overload protection by an automatic OFF-switch and acoustic signal
b. Emergency OFF-switches on the vehicle and at the work platform
c. Holding valves to prevent undesired movements of booms in case of hydraulic failure
Page 33-4
d. Independent, engine-powered emergency hydraulic pump to return the aerial device into the
stowed position on the vehicle
e. Warning placards to remind personnel of operational hazards and limits
f. Access steps and a platform bottom with anti-skid flooring and minimum 1.1 m-high safety
rails on the platform
g. Flashing lights on the vehicle
33.4.1.5 Operational Features

BTU shall be designed and built for safe, time-saving, and problem-free operations based on proven
designs with many years of service. It shall require the vehicle width only on one traffic lane or side
strip on the bridge, with a minimum obstruction of traffic flow, and it shall be rapidly erected or
removed on site without external assistance. At least one socket for single-phase power shall be
provided at the working platform for the use of inspection and maintenance tools and equipment.
33.4.2 Outline Specification for Under-deck Type Unit (UTU)

One vehicle-mounted mobile access platform for all under-deck surfaces shall be of an underbridge
type and shall have a platform (rather than bucket type). It shall be capable of being positioned on
either side of the bridge roadway and overreaching the roadway edge parapets and footways. It is
envisaged that the underbridge unit shall not be capable of providing inspection access to the entire
underside of the deck from one side only. It is therefore assumed that the platform area will be a
minimum of half bridge width by 1.4 m, and have a minimum working load of 250 kg.
33.4.2.1 System
Underbridge Type Unit (UTU) access equipment shall be mounted on a road vehicle equipped with
air-suspension rear axles to prevent shock and damage to the machine while travelling on uneven
roads.
Turntable base shall be rigidly mounted on the chassis main frame, and shall be rotatable by 90
degrees either way, configured to allow the unit to be lowered from either side of the vehicle and
provide maximum operational flexibility of use on the bridge. Main boom shall rotate approximately
45 degrees up and 20 degrees down, and shall be designed to bridge barriers and other obstacles
of up to 3 m height.
One vertical frame with a horizontal point of rotation for erection to approximately 95 degrees shall
be fixed to the rotation frame. Pivoting shall be achieved by means of two hydraulic cylinders to allow
a tolerance to compensate transverse sloping of the bridge deck.
Two parallel arms or another arrangement shall allow the unit to cross high barriers at deck edges.
Unhindered access from the vehicle to the lifting tower and platform shall be possible in any position
of the supports. Design shall ensure that the unit in the transport position remains within the
maximum allowable vehicle heights.
One second rotation track shall be mounted between the end of the lifting tower and the tower lower
part to allow rotation of the platform by 90 degrees to either side. Rotation motion shall be achieved
by means of irreversible worm gear.
For long platforms only, the work platform shall be divided into two or three sections. Second and
third segments shall be telescopically extendable until full platform length is obtained. To allow the
bridge piers to be circumnavigated without problems when the platform is fully-loaded, the work
platform shall be rotatable by two times 90 degrees. Sockets for single-phase electrical power shall
be provided on the platform.
Additional equipment such as work scaffolds or electrically operated inspection lifts shall be provided
for installation on the platform to make it possible to inspect hard-to-reach areas underneath the
bridge deck or between girders. Such scaffolds or lifts shall be of the folding type; therefore, do not
have to be dismounting for the road transport position of the UTU. Work platforms shall lie in parallel
Page 33-5
with the lifting tower when the UTU travels on the road. Inspection of bridge piers on their full length
shall be achieved by means of a pier inspection platform that can be lowered from the main platform.
All additional equipment required to meet the standard specifications shall be supplied.
33.4.2.2 Stability
Appropriate counterweights shall be mounted on the turntable of the vehicle to increase the stability
of the UTU in operation with the unit lowered on either side of the vehicle.
To minimize the concentrated load on the deck surface, a system of additional support wheels shall
evenly distribute the full vehicle weight on all axles. Air spring suspension shall be used to facilitate
movement of the vehicle on bridges and absorb shocks when the machine is travelling on bumpy
roads.
Movements of the vehicle on the bridge during operation shall be self-propelled. Movements shall
be slow and well controlled.
33.4.2.3 Control Stations

Control elements shall be suitably arranged and easily understandable, positioned in such a way
that all phases of deploying and retracting the platform can be easily surveyed. Standard control
units shall be located at the following locations on the UTU:
a. At the rear part of the vehicle for erection and removal
b. At the lower end of the lifting tower, for the movements of the platform:
• Lifting and lowering
• Rotation telescopic extension and retraction
c. In the driver’s cabin, for vehicle movements on the bridge and for steering
33.4.2.4 Standard Equipment

Equipment shall include:
a. Power take-off
b. Hydraulic pump driven by the power take-off
c. Generator for the power supply on the platform
d. Two-way intercom system for undisturbed dialogue between the bridge deck and the platform
e. Independent emergency hydraulic pump actuated by a 7 hp gas engine with attached pump
for returning the aerial device into the stowed position
33.4.2.5 Safety Features

All functional elements of the UTU shall be designed for structural and operational safety for the
operating crew and surroundings. UTU shall be designed and built in accordance with the stringent
international safety standards.
Safety features shall include, but shall not be limited to:
a. Overload protection by an automatic OFF-switch and acoustic signal
b. Emergency OFF- switches on the chassis, in the lifting tower, and on the platform
c. Independent emergency hydraulic pump allowing for folding up of the platform into the
transport position
d. Access route from the vehicle to the lifting tower, and a work platform secured by hand rails
and lifting tower construction
e. Platform with anti-skid flooring and a minimum 1.1 m-high safety rails
Page 33-6
f. Flashing lights on the vehicle
33.4.2.6 Operational Features

Design of the UTU shall be the result of many years of experience and practice-guided development.
It shall be designed and built for safe, time-saving, and problem-free operation.
Its operational features shall include, but shall not be limited to:
a. Dimensioning of the platform shall allow unencumbered inspection or maintenance work by
several persons simultaneously.
b. UTU shall require the vehicle width only on one traffic lane or side strip on the bridge, with
minimum obstruction of traffic flow.
c. Erection or removal times required shall be extremely short. On-site erection or removal of
UTU shall not require external assistance.
d. Tractors shall be removable from trailer-mounted units during operation on the bridge, for
use elsewhere.
e. Sockets for single-phase power shall be provided on the platform for the use of inspection
and maintenance tools and equipment.
f. Additional equipment, such as work scaffolds or lifts (optional), shall be capable of being
positioned along the full length of the platform.
33.4.2.7 Other Features

Other features of the UTU shall include, but shall not be limited to:
a. Outrigger stabilizers shall not be required.
b. Platform shall be capable of being lowered on both the left-hand side and the right-hand side
of the truck chassis.
c. Wide platform shall allow comfortable working conditions for the inspection crew. Platform
shall be capable of being raised under the bridge up to approximately 1.5 m from the bridge
deck.
d. Access shall be fully-protected from the bridge deck to the platform in all operating positions
of the platform.
e. Ladders, work scaffolds, or lifts used on the platform shall remain assembled for road
transportation. They shall be pivoted into the horizontal position on the platform floor and
remain embedded in the platform when in the stowed position on the truck chassis.
33.5 Method of Procurement

The Contractor shall prepare a list of suppliers able to provide the access system and technical and
contract documentation needed to request for proposals from suppliers. Proposals from single-
source suppliers shall be preferred, but proposals from two suppliers in a joint venture with joint and
several liabilities shall also be considered. On approval of a shortlist by the Engineer, the Contractor
shall obtain detailed technical and firm-priced proposals for the system, and shall prepare a report
on the proposals to the Engineer and obtain such supplementary information and proposals as may
be necessary for the proposals to be evaluated. This information should include drawings showing
the proposals for access to every surface and component.
Acting on instructions from the Owner, the Engineer shall select the supplier and impose such
additional requirements as deemed necessary for the systems.
The Contractor shall then procure the systems and supervise their manufacture, transportation,
receipt, storage, commissioning, testing, training, and acceptance by the Owner.
Page 33-7
33.6 Use of the Bridge Access System in the Work

Except by prior written agreement of the Engineer or as required for commissioning and testing of
the access system, the system shall not be used in any part of the work. Permission to use the
system for other purposes will only be granted in exceptional circumstances and will be subject to
guarantees, assurances, and payments to the Owner regarding such use.
33.7 Additional Quality Standards

33.7.1 Durability/Design Life
Design life of the system shall be 20 years with minimal maintenance in this period, except for repair
of normal wear and tear, all in accordance with current best industry practices for such systems.
33.7.2 Spares and Replacement Parts

Supplier shall provide a comprehensive list of spares and replacement parts, which shall fully identify
the item, its specifications, durability, and alternative sources of supply. This list shall identify whether
each component is of limited life (consumable or subject to wear), if an essential spare is needed for
contingency, or if the component does not require spares in stock.
33.7.3 Operating and Maintenance Documentation

Comprehensive training, operation, and maintenance manuals in both hard copy and digital format
are required in English and Arabic.
33.7.4 Support Services, Repairs, and Facilities for Same

Supplier shall provide all necessary support services on a scheduled and on-call basis for a minimum
period of 20 years.
33.7.5 Commissioning and Testing of Equipment

Before acceptance of the system by the Engineer, the system shall complete an agreed programme
of commissioning and testing.
33.7.6 Safety
All parts of the system and services shall comply with the requirements of current international safety
standards for operation and maintenance.
33.8 Warranties
Warranties and guarantees required in the supply contract shall be in accordance with the Owner’s
instructions.
33.9 Material to be Provided by the Engineer

The Engineer shall provide existing computer-based drawings of the bridge and supplementary
information to establish the requirements for access and other information specified by the Owner,
which shall include terms to be included in the supply contract.
33.10 Programme
The Contractor shall prepare a programme for the procurement of the system in accordance with
the further instructions of the Owner.
Page 33-8
INDEX
advantages, 2 shocks, 3, 5
Air spring suspension, 3, 5 Sockets, 5, 6
barge, 3 spares, 2, 7
bridges, 2, 5 Stability, 3, 5
bucket, 2, 3, 4 static load testing, 2
bumpy roads, 3, 5 storage, 2, 7
commissioning, 7, 8 supplementary information, 7, 8
concentrated load, 3, 5 suppliers, 2, 7
Control elements, 5 support facilities, 2
counterweights, 3, 5 temporary scaffolding, 2
deck level, 2, 3 testing, 7, 8
Department of Transport, 2 Third boom, 3
Design life, 7 training services, 2
documentation, 2, 7 transportation, 7
engine, 3, 4, 6 Turntable base, 3, 4
equipment, 2, 4, 5, 6 underbridge, 4
Erection, 6 under-deck surfaces, 2, 4
external surfaces, 2 vertical clearance, 3
feature lighting, 3 Vertical position, 3
Flashing lights, 4, 6 visual inspection, 3
footways, 4 Warning placards, 4
generator, 3 Warranties, 8
guarantees, 7, 8 wheels, 3, 5
Holding valves, 4 work scaffolds, 5, 6, 7
hydraulic cylinders, 3, 5 working area, 3
hydraulic pump, 3, 4, 6 written agreement, 7
independent emergency hydraulic pump, 4
irreversible worm gear, 3, 5
Ladders, 7
lifts, 5, 6, 7
limitations, 2
load capacity, 2
long-term inspection, 2
Main boom, 3, 4
maintenance, 2, 3, 4, 6, 7, 8
Movements, 3, 5
openings, 2
operation, 2, 3, 5, 6, 7, 8
operational hazards, 4
operational safety, 4, 6
performance requirements, 2
Permission, 7
piers, 3, 5
platform, 2, 3, 4, 5, 6, 7
power supply, 3, 6
procurement, 8
removal times, 6
repainting, 2
repair, 2, 7
routine maintenance, 3
safe access, 2
second boom, 3
self-propelled, 3, 5
Page 33-9
PART 2
ROAD STRUCTURES
CHAPTER 34 - ROAD TUNNELS
DOCUMENT NO: TR-

FIRST EDITION
JANUARY 2018
Chapter 34: Road Tunnels

TABLE OF CONTENTS
List of Figures ................................................................................................................................. iii
34 Road Tunnels .................................................................................................................. 34-1
34.1 General ........................................................................................................................ 34-1
34.1.2 Working Drawings................................................................................................. 34-2
34.1.3 Materials ............................................................................................................... 34-2
34.1.4 Tunnel Shape and Internal Elements .................................................................... 34-2
34.1.5 Additional Investigations during Construction ........................................................ 34-3
34.1.5.1 Geologic Face Mapping ................................................................................. 34-4
34.1.5.2 Geotechnical Instrumentation ........................................................................ 34-4
34.1.5.3 Probing .......................................................................................................... 34-5
34.1.5.4 Pilot Tunnels .................................................................................................. 34-5
34.1.6 Waterproofing ....................................................................................................... 34-5
34.1.7 Expansion and Contraction Joints ......................................................................... 34-6
34.2 Cut-and-Cover Tunnels................................................................................................ 34-6
34.2.1 Introduction ........................................................................................................... 34-6
34.2.2 Support of Excavation ........................................................................................... 34-6
34.2.2.1 General.......................................................................................................... 34-6
34.2.2.2 Monitoring of Ground Movement & Impact on Adjoining Structures ............... 34-6
34.2.2.3 Base Stability ................................................................................................. 34-7
34.2.3 Groundwater Control ............................................................................................ 34-7
34.2.3.1 Construction Dewatering................................................................................ 34-7
34.2.3.2 Methods of Dewatering and Their Typical Applications .................................. 34-8
34.2.3.3 Piping and Base Stability ............................................................................... 34-8
34.2.3.4 Potential Impact of Area Dewatering .............................................................. 34-8
34.2.3.5 Groundwater Discharge and Environmental Issues ....................................... 34-8
34.2.4 Maintenance and Protection of Traffic ................................................................... 34-8
34.2.5 Utility Relocation and Support ............................................................................... 34-9
34.2.5.1 Types of Utilities ............................................................................................ 34-9
34.2.5.2 General Approach to Utilities during Construction .......................................... 34-9
34.2.6 Waterproofing of Cut-and-Cover Tunnels.............................................................. 34-9
34.3 Rock Tunnelling ........................................................................................................... 34-9
34.3.1 Introduction ........................................................................................................... 34-9
34.3.2 Rock Tunnelling Methods ................................................................................... 34-10
34.3.2.1 Drill-and-Blast .............................................................................................. 34-10
34.3.2.2 Tunnel Boring Machines .............................................................................. 34-11
34.3.2.3 Road Headers ............................................................................................. 34-12
34.3.2.4 Other Mechanised Excavation Methods ....................................................... 34-13
34.3.2.5 Sequential Excavation Method/New Austrian Tunnelling Method ................. 34-13
34.3.3 Types of Rock Reinforcement and Excavation Support ...................................... 34-14
34.3.3.1 Excavation Support Options ........................................................................ 34-14
34.3.3.2 Rock Reinforcement .................................................................................... 34-15
34.3.3.3 Ribs and Lagging ......................................................................................... 34-15
34.3.3.4 Shotcrete ..................................................................................................... 34-15
34.3.3.5 Lattice Girder ............................................................................................... 34-15
34.3.3.6 Spiles and Forepoles ................................................................................... 34-16
34.3.3.7 Precast Segment Lining ............................................................................... 34-16
34.3.4 Groundwater Control during Excavation ............................................................. 34-16
Page i
CHAPTER 34: ROAD TUNNELS First Edition -January 2018
34.3.4.1 Dewatering at the Tunnel Face .................................................................... 34-16

34.3.4.2 Drainage Ahead of Face from Probe Holes.................................................. 34-16
34.3.4.3 Drainage from Pilot Bore or Tunnel .............................................................. 34-17
34.3.4.4 Grouting ....................................................................................................... 34-17
34.3.4.5 Freezing ...................................................................................................... 34-17
34.3.4.6 Closed-Face Machine .................................................................................. 34-17
34.3.4.7 Other Measures of Groundwater Control ..................................................... 34-18
34.3.5 Waterproofing of Tunnels in Rock ....................................................................... 34-18
34.4 Soft-Ground Tunnelling .............................................................................................. 34-19
34.4.1 Introduction ......................................................................................................... 34-19
34.4.2 Tunnelling-Induced Settlement ........................................................................... 34-19
34.4.2.1 General........................................................................................................ 34-19
34.4.2.2 Sources of Settlement ................................................................................. 34-19
34.4.2.3 Settlement Calculations ............................................................................... 34-20
34.4.3 Impact on and Protection of Surface Facilities .................................................... 34-21
34.4.3.1 Evaluation of Structure Tolerance to Settlement .......................................... 34-21
34.4.3.2 Mitigating Settlement ................................................................................... 34-22
34.4.3.3 Structure Protection ..................................................................................... 34-22
34.4.4 Soil Stabilization and Improvement ..................................................................... 34-23
34.4.4.1 Introduction .................................................................................................. 34-23
34.4.4.2 Typical Applications ..................................................................................... 34-23
34.4.4.3 Reinforcement Methods ............................................................................... 34-24
34.4.4.4 Micropiles .................................................................................................... 34-24
34.4.4.5 Grouting Methods ........................................................................................ 34-24
34.4.4.6 Ground Freezing .......................................................................................... 34-27
34.5 Steel and Concrete Tunnel Liners .............................................................................. 34-27
34.5.1 Scope ................................................................................................................. 34-27
34.5.2 Description.......................................................................................................... 34-28
34.5.3 Materials and Fabrication .................................................................................... 34-28
34.5.3.1 General........................................................................................................ 34-28
34.5.3.2 Forming and Punching of Steel Liner Plates ................................................ 34-28
34.5.4 Installation .......................................................................................................... 34-28
34.5.4.1 Steel Liner Plates......................................................................................... 34-28
34.5.4.2 Precast Concrete Liner Plates ..................................................................... 34-29
34.5.4.3 Grouting ....................................................................................................... 34-29
34.6 Immersed Tunnels ..................................................................................................... 34-29
34.6.1 Introduction ......................................................................................................... 34-29
34.6.1.1 Environmental Impact .................................................................................. 34-29
34.6.1.2 Types of Immersed Tunnel .......................................................................... 34-30
34.6.1.3 Single-Shell Steel Tunnel............................................................................. 34-30
34.6.1.4 Double Shell Tunnel .................................................................................... 34-30
34.6.1.5 Sandwich Construction ................................................................................ 34-30
34.6.1.6 Concrete Immersed Tunnels ........................................................................ 34-31
34.6.2 Construction Methodology .................................................................................. 34-31
34.6.2.1 General........................................................................................................ 34-31
34.6.2.2 Trench Excavation ....................................................................................... 34-32
34.6.2.3 Foundation Preparation ............................................................................... 34-33
34.6.2.4 Tunnel Element Fabrication ......................................................................... 34-33
34.6.2.5 Transportation and Handling of Tunnel Elements ........................................ 34-34
34.6.2.6 Lowering and Placing .................................................................................. 34-35
34.6.2.7 Element Placement...................................................................................... 34-35
34.6.2.8 Backfilling .................................................................................................... 34-36
34.6.2.9 Locking Fill................................................................................................... 34-37
34.6.2.10 General Backfill ........................................................................................... 34-37
34.6.2.11 Protection Blanket........................................................................................ 34-37
34.6.2.12 Anchor Release Protection .......................................................................... 34-37
34.6.3 Water Tightness and Joints between Elements................................................... 34-38
Page ii
34.6.3.1 External Waterproofing of Tunnels ............................................................... 34-38

34.6.3.2 Joints ........................................................................................................... 34-38
34.6.3.3 Design of Joints between Elements ............................................................. 34-40
34.7 Tunnel Construction Engineering ............................................................................... 34-40
34.7.1 Introduction ......................................................................................................... 34-40
34.7.2 Construction Staging and Sequencing ................................................................ 34-41
34.7.2.1 Construction Staging ................................................................................... 34-41
34.7.2.2 Construction Sequencing ............................................................................. 34-41
34.7.3 Mucking and Disposal ......................................................................................... 34-42
34.7.4 Health and Safety ............................................................................................... 34-43
34.7.5 Schedule............................................................................................................. 34-45
Index .. .................................................................................................................................... 34-46
LIST OF FIGURES
Figure 34-1: Gina-Type Seal .................................................................................................... 34-38
Figure 34-2: Omega-Type Seal ................................................................................................ 34-39
LIST OF TABLES
Table 34-1: Designations and titles for AASHTO and ASTM standards that apply to road tunnels
works ......................................................................................................................................... 34-2
Table 34-2: Relationship between volume loss, construction practice, and ground conditions . 34-20
Table 34-3: Limiting angular distortion ..................................................................................... 34-21
Table 34-4: Damage risk assessment chart ............................................................................. 34-21
Table 34-5: Ground treatment methods ................................................................................... 34-23
Table 34-6: Summary of jet grouting system variables and their impact on basic design elements
................................................................................................................................................ 34-26
Page iii
34 ROAD TUNNELS
34.1 General
This work shall consist of constructing, fabricating, furnishing, and installing road tunnels conforming
to these standard specifications, requirements of the Road Structures Design Manual (ADQCC TR-
516), the American Association of State Highway and Transportation Officials (AASHTO) LRFD
Bridge Design Specifications, and the details shown in the Contract documents.
Road tunnels as defined by the AASHTO Technical Committee for Tunnels (SCOBS-T-20 Tunnels)
are enclosed roadways with vehicle access that is restricted to portals, regardless of the type of
structure or method of construction. These standard specifications further define road tunnels that
do not include enclosed roadway created by highway bridges, railroad bridges, or other bridges. This
definition applies to all types of tunnel structures and tunnelling methods such as cut-and-cover
tunnels, mined and bored tunnels in rock and soft ground, and immersed tunnels.
Whenever the Contract documents permit the Contractor to select the method or equipment to be
used for construction or any operation, it shall be the Contractor's responsibility to employ methods
and equipment that will produce satisfactory work under the conditions encountered, such that no
damage is imparted on completed or partially-completed work.
Falsework and forms shall conform to the requirements of Section 1.20.8 of Chapter 1, General
Requirements, of these standard specifications. Generally, all concrete shall be fully-supported until
the required strength and age has been reached.
Other work involved in the construction of road tunnels shall be as specified in the applicable
chapters of these standard specifications, particularly:
• Chapter 1: General Requirements, of these Standard Specifications
• Chapter 4: Concrete Works, of these Standard Specifications
• Chapter 5: Reinforcing Steel, of these Standard Specifications
• Chapter 21: Concrete Structures, of these Standard Specifications
• Chapter 22: Prestressing Systems, of these Standard Specifications

and Testing;
AASHTO SCOBS- Subcommittee on Bridges and Structures;
T-20 Tunnels
FHWA Federal Highway Administration;
FHWA (2005e) Earth Retaining Structures. Publication no. FHWA NHI-05-046, National
Highway Institute, US Department of Transportation;
Page 34-1
FHWA (2005f) Micropile Design and Construction Reference Manual, Publication no. FHWA
NHI-05-039 ;
road tunnels. It also includes designations and titles.
Table 34-1: Designations and titles for AASHTO and ASTM standards that apply to road
tunnels works
AASHTO ASTM
Title
ASTM D4435 –
Standard Test Method for Rock Bolt Anchor Pull Test
08
ASTM D4436 – Standard Test Method for Rock Bolt Long-Term Load
08 Retention Test

The Contractor shall submit complete shop drawings complying with the Contract plans and Contract
documents. When complete details are not provided in the Contract plans or Contract documents,
the Contractor shall submit working drawings including shop drawings and substantiating
calculations of the proposed road tunnel structure, installation system, or construction method.
Construction, fabrication or installation of the structure shall not begin until the Engineer has
approved the drawings. Working drawings shall show complete details and substantiating
calculations of the structure, as well as the materials, equipment, and construction methods
proposed.
Shop drawings and working drawings shall be submitted in advance of the start of the work to allow
for review, revision, and approval without delay to the work. Approval by the Engineer shall not
relieve the Contractor of any contractual responsibility.
34.1.3 Materials
Concrete materials, manufacturing, protection, handling and placing, finishing, and curing shall
conform to the applicable requirements of Chapter 4, Concrete Works, and Chapter 21, Concrete
Structures, of these Standard Specifications.
Class of concrete to be used in each part of the structure shall be as specified or shown on the
Contract documents. If not shown or specified, the Engineer will designate the class of concrete to
be used in consistent with the requirements of Section 21.17 of Chapter 21, Concrete Structures, of
these standard specifications, as applicable.
Materials and installation of reinforcing and prestressing steel shall conform to the applicable
requirements of Chapters 5, Reinforcing Steel, and Chapter 22, Prestressing Systems, of these
34.1.4 Tunnel Shape and Internal Elements

Three main shapes of highway tunnels are considered in these specifications – circular, rectangular,
and horseshoe or curvilinear. Unless specified in the Contract plans, the shape of the tunnel shall
be dependent on the method used to construct the tunnel and on the ground conditions. Rectangular
tunnels shall be constructed by either the cut-and-cover method, by the immersed method, or by
jacked-box tunnelling. Circular tunnels shall be constructed by using either a tunnel boring machine
Page 34-2
(TBM) or by drill-and-blast in rock. Horseshoe configuration tunnels shall be constructed using drill-
and-blast in rock or by following the Sequential Excavation Method (SEM), also as known as the
New Austrian Tunnelling Method (NATM).
Road tunnels shall be lined with concrete and internal finish surfaces in compliance with the Contract
documents. Unless otherwise specified, some rock tunnels may be unlined, except at the portals
and in certain areas where the rock is less competent. In this case, rock reinforcement shall be
provided. Rock reinforcement for initial support shall include the use of rock bolts with internal metal
straps and mine ties, un-tensioned steel dowels, or tensioned steel bolts. To prevent small fragments
of rock from spalling, wire mesh, shotcrete, or a thin concrete lining shall be used. Shotcrete, or
sprayed concrete, shall be used as an initial lining prior to installation of a final lining, or as a local
solution to instabilities in the rock tunnel. It shall be placed in layers with welded wire fabric and/or
with steel fibres as reinforcement. Inside surfaces shall be finished smooth without the fibres. Precast
segmental lining shall be used in conjunction with the TBM in soft ground and if specified in rock.
Segments shall be erected within the tail shield of the TBM. Segmental linings could be made of cast
iron, steel, and concrete. Unless otherwise specified, all segmental linings shall be made of concrete.
They shall be gasketed and bolted to prevent water penetration. Precast segmental linings could be
used as a temporary lining, where a cast-in-place final lining can be placed, or as the final lining.
Road tunnels shall be finished with interior finishes for safety and maintenance requirements
conforming to the Contract documents. Walls and ceilings shall receive a finish surface, while the
roadway shall be paved with asphalt pavement. Interior finishes shall be either mounted or adhered
to the final lining, and shall consist of ceramic tiles, epoxy-coated metal panels, porcelain-enamelled
metal panels, or various coatings. They shall provide enhanced tunnel lighting and visibility, provide
fire protection for the lining, attenuate noise, and provide a surface easy to clean.
Tunnels shall be equipped with various systems such as ventilation, lighting, communication, fire-
life safety, and traffic operation and control, including messaging and operation and control of the
various systems in the tunnel. The Contractor shall furnish and install these elements in accordance
with the details and provisions of the Contract documents and the applicable requirements of other
chapters of these Standard Specifications.
34.1.5 Additional Investigations during Construction

The Contractor shall perform additional subsurface investigations and ground characterization
during the construction of the tunnel Project. Such construction phase investigations shall serve a
number of important functions, providing information for:
a. The Contractor design and installation of temporary work
b. Further defining anomalies and unanticipated conditions identified after the start of
construction
c. Documenting existing ground conditions for comparison with established baseline conditions,
thereby forming the basis of any cost adjustments due to differing site conditions
d. Assessing ground and groundwater conditions in advance of the tunnel heading to reduce
risks and improve the efficiency of tunnelling operations
e. Determining the initial support system to be installed, and the locations where the support
system can be changed
f. Assessing the response of the ground and existing structures and utilities to tunnelling
operations
g. Assessing the groundwater table response to dewatering and tunnelling operations
h. Determining the location and depth of existing utilities and other underground facilities
The construction phase investigation program shall include the following elements:
1. Subsurface investigation borings and probings from the ground surface
2. Test pits
Page 34-3
3. Additional groundwater observation wells and/or piezometers

4. Additional laboratory testing of soil and rock samples
5. Geologic mapping of the exposed tunnel face
6. Geotechnical instrumentation
7. Probing in advance of the tunnel heading from the face of the tunnel
8. Pilot tunnels
9. Environmental testing of soil and groundwater samples suspected to be contaminated or
otherwise harmful
Some of the above investigation elements, such as geotechnical instrumentation, may be identified
as requirements of the Contract documents, while others, such as additional exploratory borings,
may be left to the discretion of the Contractor for its benefit and convenience. Tunnel face mapping
and groundwater monitoring shall be required elements for the tunnel Project, since the information
obtained from these records will form the basis for evaluating the merits of potential differing site
condition claims.
34.1.5.1 Geologic Face Mapping

With open-face tunnelling methods, including the SEM, open-face tunnelling shield in soil, and the
drill-and-blast method in rock, all or a large portion of the tunnel face shall be exposed, allowing a
visual assessment of the existing ground and groundwater conditions. In such cases, the exposed
face conditions shall be documented in cross-section sketches (face mapping) drawn at frequent
intervals (every 15 metres minimum) as the tunnel advances and as required by the Engineer.
Information typically included in these face maps includes the station location for the cross-section;
the date and time the face mapping was prepared; the name of the individual who prepared the face
map; classification of each type of material observed; the location of interface boundaries between
these materials; rock jointing including orientation of principal joints and joint descriptions; shear
zones; observed seepage conditions and their approximate locations on the face; observed ground
behaviour noting particularly the location of any instability or squeezing material at the face; the
location of any boulders, piling, or other obstructions; the location of any grouted or cemented
material; and any other significant observations. In rock tunnels where the perimeter rock is left
exposed, sketches presenting similar information shall be prepared for the tunnel walls and roof. All
mapping shall be prepared by a geologist or geological engineer knowledgeable of tunnelling and
with soil and rock classification.
Face maps shall be used to accurately document conditions exposed during tunnelling, and to
develop a detailed profile of subsurface conditions along the tunnel horizon. However, there might
be limitations and considerable uncertainty in any extrapolation of the observed conditions beyond
the perimeter of the tunnel.
When used in conjunction with nearby subsurface investigation data and geotechnical
instrumentation records, the face maps shall be used to develop general correlations between
ground displacement, geological conditions, and other factors (depth of tunnel, groundwater
conditions, etc.).
34.1.5.2 Geotechnical Instrumentation

Geotechnical instrumentation shall be used during construction to monitor ground and structure
displacements, surface settlement above and near the tunnel, deformation of the initial tunnel
supports and final lining, groundwater levels, loads in structural elements of the excavation support
systems, and ground and structure vibrations, among others. Such instrumentation shall be a key
element of any program for maintenance and protection of existing structures and facilities.
Additionally, it shall provide quantitative information for assessing tunnelling procedures during the
course of construction, and shall be used to trigger modifications to tunnelling procedures in a timely
manner to reduce the impacts of construction. Instrumentation shall be also used to monitor the
Page 34-4
deformation and stability of the tunnel opening and to assess the adequacy of the initial tunnel
support systems and the methods and sequencing of tunnelling, particularly for tunnels constructed
using the SEM and tunnels in shear zones or squeezing ground.
34.1.5.3 Probing
If applicable, such as for SEM and hard rock tunnelling projects, probing ahead of the tunnel face
shall be used to determine general ground conditions in advance of excavation, and to identify and
relieve water pressures in any localised zones of water-bearing soils or rock joints. For tunnels
constructed by using the SEM, probing shall also provide an early indication of the type of ground
supports that may be needed as the excavation progresses.
Probing shall be carried out to:
a. reduce the risks and hazards associated with tunnelling
b. provide continuous site investigation data directly along the path of the tunnel
c. provide information directly ahead of the tunnel excavation, allowing focus on ground
conditions of most immediate concern to tunnelling operations
Probing from within the tunnel must be considered as a supplementary investigation method, to be
used in conjunction with subsurface investigation data obtained during other phases of the Project.
Probing shall consist of drilling horizontally from the tunnel heading by percussion drilling or rotary
drilling methods. Coring can be used for probing in rock, but is uncommon due to the greater time
needed for coring. Cuttings from the probe holes shall be visually examined, classified, and assessed
for potential impacts to tunnel excavation and support procedures. In rock, borehole cameras shall
be used to better assess rock quality, orientation of discontinuities, and the presence of shear zones
and other important features.
34.1.5.4 Pilot Tunnels

Pilot tunnels (and shorter exploratory adits) shall be to the size specified in the Contract documents
for large size rock tunnels in complex geological conditions (typically at least 2 m by 2 m in size).
Pilot tunnels, if specified, shall provide the following:
a. Complete and reliable information for design of both initial tunnel supports and final lining, if
any
b. Access for performing in situ testing of the rock along the proposed tunnel
c. Information for specifying and selecting appropriate methods of construction and tunnelling
equipment
d. Effective means of pre-draining groundwater, and more confidently determining short-term
and long-term groundwater control measures
e. Effective means for identifying and venting gassy ground conditions
f. Means for testing and evaluating potential tunnelling methods and equipment
g. Access for installation of some of the initial supports (typically in the crown area of the tunnel)
in advance of the main tunnel excavation
Consideration shall also be given to locating the pilot tunnel adjacent to the proposed tunnel, using
the pilot tunnel for emergency egress, tunnel drainage, tunnel ventilation, or other purposes for the
completed Project.
34.1.6 Waterproofing
Tunnel waterproofing systems are used to prevent groundwater inflow into the tunnel structure
completely. They shall consist of a combination of various materials and elements. Unless detailed
in the Contract plans or specified in the particular specifications, the Contractor shall design and
Page 34-5
submit for the Engineer’s approval a tanked waterproofing system based on the understanding of
the ground and geohydrological conditions, geometry and layout of the structure and construction
method to be used, and in accordance with requirements of this chapter. The waterproofing system
shall be an integrated system that takes into account intermediate construction stages, final
conditions of structures and their ultimate usage including maintenance and operations.
34.1.7 Expansion and Contraction Joints

Joints are potential areas were leaks can occur. As such, they are potential sources of high
maintenance costs over the life of the tunnel. The number of joints shall be minimized and special
care shall be taken in the detailing of joints to ensure water tightness. The type and frequency of
joints required shall be in accordance with the details specified in the Contract plans and particular
specifications.
34.2 Cut-and-Cover Tunnels

34.2.1 Introduction
This work includes the construction and excavation support systems for cut-and-cover road tunnels.
It also includes maintenance of traffic and utilities, as well as control of groundwater during
construction.
34.2.2 Support of Excavation

34.2.2.1 General
The Contractor shall properly design and construct excavations for building cut-and-cover tunnels
as per Road Structures Design Manual (ADQCC TR-516), and applicable requirements of Chapter
20, Earth Retaining Systems, of these standard specifications, to provide a safe working space,
provide access for construction activities, and to protect structures, utilities, and other infrastructure
adjacent to the excavation. Design of excavation support systems shall be in consideration of a
variety of factors that affect the performance of the support system and that have impacts on the
tunnel structure itself. The Contractor shall consider these factors that are presented hereafter.
34.2.2.2 Monitoring of Ground Movement & Impact on Adjoining

Structures
The Contractor shall conduct the proper evaluation of soil movement as a result of the excavation
and mitigation of construction impacts on adjacent structures, facilities, and utilities. Soil movement
can be due to deflection of the support of excavation walls and ground consolidation.
a. Deflection of Support of Excavation Walls

Walls will deflect into the excavation as it proceeds prior to installation of each level of struts or
tiebacks supporting the wall. Deflections are greater for flexible support systems than for rigid
systems, are not recoverable, and are cumulative.
b. Consolidation Due to Dewatering

In excavations where the water table is high, it is necessary to dewater inside the excavation to avoid
instability. Dewatering inside the cut may lead to a drop in the hydrostatic pressure outside the cut.
Depending on the soil strata, this can lead to consolidation and settlement of the ground.
Existing buildings and facilities must be evaluated by the Contractor for the soil movement estimated
to occur due to the support wall movement during excavation. This evaluation depends on the type
of existing structure, its distance and orientation from the excavation, the soil conditions, the type of
foundations of the structure, and other parameters. The analysis shall be site specific. Empirical
methods and screening tools are available to more generally characterise the potential impacts.
Page 34-6
Existing buildings and facilities within the zone of influence must be surveyed and monitored by the
Contractor as directed by the Engineer. Measures to handle this issue shall include:
1. Design of stiffer and more watertight excavation support walls
2. Providing more closely spaced and stiffer excavation support braces and/or tiebacks
3. Use of pre-excavation soil improvement
4. Underpinning of existing structures
5. Providing monitoring and instrumentation program during excavation
6. Establishing requirements for mitigation plans if movements approach allowable limits
34.2.2.3 Base Stability

Poor soil beneath the excavation bottom may require that the excavation support structure be
extended down to a more competent stratum to ensure the base stability of the structure. This may
depend upon whether the earth pressures applied to the wall, together with its weight, can be
transferred to the surrounding soil through a combination of adhesion (side friction) and end bearing.
Soft clays below the excavation are particularly susceptible to yielding, causing the bottom of the
excavation to heave with a potential settlement at the ground surface, or worse, to blow up. High
groundwater table outside of the excavation can result in base instability as well. Measures to
evaluate the subsurface condition, and provide sufficient base stability must be addressed by the
Contractor. More details can be found in FHWA-NHI-05-046 "Earth Retaining Structure" (FHWA,
2005e).
34.2.3 Groundwater Control

34.2.3.1 Construction Dewatering
When groundwater levels are higher than the base level of the tunnel, excavations will require a
dewatering system. For cut-and-cover construction, the dewatering systems will depend on the
permeability of the various soil layers exposed. Lowering the water table outside the excavation
could cause settlement of adjacent structures, impacts on vegetation, drying of existing wells, and
potential movement of contaminated plumes, if present. Precautions shall be taken by the Contractor
when dewatering the area outside of the excavation limits. Within the excavation, dewatering shall
be accomplished with impermeable excavation support walls that extend down to a firm, reasonably
impermeable stratum to reduce or cut-off water flow.
Impervious retaining walls, such as steel interlocking sheeting, concrete secant pile or concrete
slurry walls, shall be placed into deeper, less pervious layers, to reduce groundwater inflow during
construction and limit draw-down of the existing groundwater table. If excavation is performed under
wet conditions, then the water shall be pumped out. Subsequent to the excavation, any water
intrusion shall be pumped from the trench by providing sumps and pumps within the excavation.
Pumped pressure relief system may be required to prevent the excavation bottom from heaving due
to unbalanced hydrostatic pressure.
If approved by the Engineer, the Contractor may use pumped wells to temporarily lower the
groundwater table outside of the excavation support during construction; however, this may have
environmental impacts or adverse effects on adjacent structures. To minimise any lowering of the
water table immediately outside of the excavation, water pumped from the excavation shall be used
to recharge the water-bearing strata of the groundwater system by using injection wells. Provision
shall have to be made for disposal of water in excess of that pumped to recharge wells, probably
through settlement basins draining to storm drains.
After construction is completed, if there is a concern that the permanent excavation support walls
above the tunnel might be blocking the cross flow of the groundwater or may dam up water between
walls above the tunnel, the Contractor may be required to breach the walls above the tunnel at
intervals or removed to an elevation to allow movement of groundwater.
Page 34-7
34.2.3.2 Methods of Dewatering and Their Typical Applications

Groundwater shall be controlled during construction either by using impervious retaining walls (such
as concrete slurry or tangent pile walls, steel interlocking sheeting, etc.), by well-points drawing down
the water table, by chemical or grout injection into the soils, or by pumping from within the excavation.
Groundwater may be lowered, as needed, by tiers of well-points. Improper control of groundwater is
often a cause for settlement and damage to adjacent structures and utilities; consequently it is
important that the method selected is suitable for the proposed excavation.
Where the area of excavations is not too large, an economical method of collecting water is through
the use of ditches leading to sump pumps. Provisions to keep fines from escaping into the dewatering
system shall be made.
In larger excavations in permeable soil, either well points or deep wells shall be used to lower the
water table. The Contractor shall install test wells to test proposed systems. In certain cases, multiple
stages of well points, deep wells with submersible pumps, or an eductor system shall be needed.
34.2.3.3 Piping and Base Stability

In fine-grained soils, such as silts or clayey silts, differential pressure across the support of
excavation may cause sufficient water flow (piping) for it to carry fines. This causes material loss and
settlement outside, as well as a loss of integrity of soils within, rendering the soils unsuitable as a
foundation. In extreme cases, the base of the excavation may become unstable, causing a blow-up
and failure of the excavation support. This situation may be mitigated by ensuring that cut-off walls
are sufficiently deep, by stabilizing the soil by grouting, or freezing, or by excavating below water
without dewatering and making a sufficiently thick tremie slab to overcome uplift before dewatering.
34.2.3.4 Potential Impact of Area Dewatering

Dewatering an excavation may lower the groundwater outside the excavation and may cause
settlements. Lowering of the external groundwater can be reduced by the use of slurry walls, tangent
or secant piles, or steel sheet piling. Adjacent structures with a risk of settlement due to groundwater
lowering may require underpinning.
34.2.3.5 Groundwater Discharge and Environmental Issues

In most cases, the water will require testing and possibly treatment before it can be discharged.
Settling basins, oil separators, and chemical treatments may be required prior to disposal. Excavated
material itself shall require testing before the method of disposal can be determined. Material
excavated below water may need to stand in settling ponds to allow excess water to run off before
disposal. Contaminated material may need to be placed in confined disposal facilities. Local
regulations and permitting requirements shall dictate the method of disposal.
34.2.4 Maintenance and Protection of Traffic

When decking is required by the Contract documents or the Engineer to maintain the existing road
traffic, the support of excavation walls must be designed to handle the imposed live loads. Depth of
the walls may need to be determined by the necessity of transferring decking loads to a more
competent stratum below. This may depend upon whether the load applied to the wall, together with
its weight, can be transferred to the surrounding soil through a combination of adhesion (side friction)
and end bearing. Thick types of excavation support walls, such as slurry walls, drilled-in-place soldier
piles, and tangent piles, are much more effective than thinner walls, such as sheet piles or driven
soldier piles, in carrying the live loads to the bearing stratum.
Decking shall consist of deck framing and roadway decking. Deck framing shall be designed for Abu
Dhabi Vehicular Load (ADVL) in accordance to Road Structures Design Manual (ADQCC TR-516),
or for loading due to construction equipment that will operate on the deck, whichever is greater.
Page 34-8
34.2.5 Utility Relocation and Support

34.2.5.1 Types of Utilities
When constructing cut-and-cover tunnels in urban areas, public and private utility lines such as
water, sewer, power, and communication are often encountered. Often, utilities are not located
where indicated on existing utility information. Therefore, it is important to identify and locate all
utilities in the field prior to excavation. Great care must be taken when excavating in the vicinity of
utilities, sometimes requiring that the final excavation to expose them is done by hand. Of particular
concern are those utilities that are movement-sensitive and those carrying hazardous substances.
These include large diameter water pipes, high-pressure gas lines, fibber optic lines, petroleum
pipes, and high voltage cables. Some utilities, such as buried high voltage lines, are not only
extremely expensive to move but have very long lead times. Utilities such as sewers can present a
different problem; if gravity flow is used, diversions around a proposed tunnel may pose a serious
challenge. Some older water and sewer lines are extremely fragile, particularly if they are of brick or
cast iron construction.
34.2.5.2 General Approach to Utilities during Construction

It is not uncommon to divert utilities away from the proposed construction corridor. However,
diversion is not always possible, it may be too expensive, or a utility crossing may be unavoidable.
In such cases, it will be necessary to support the utilities in place. It is essential to have a coordinated
effort so that no interferences among the various utilities occur and that the construction can be
performed while the utilities are in place. Sometimes, utility relocations are performed in stages to
accommodate the construction requiring relocating the utility more than once.
Before the start of underground construction, the Contractor shall conduct a condition survey of all
utilities within the zone of potential influence of construction, making detailed reports for those that
may incur movements in excess of those allowable for the utility. Nature of any work required for
each utility shall be identified as protection, support, or relocation, and the date by which action is
required. It is essential that all utilities that need action are identified in sufficient time to allow the
construction to progress as programmed.
Supports may either be temporary or permanent. Depending upon the sensitivity of the utility being
supported, it may be necessary to provide instrumentation to monitor any movement so that remedial
action can be taken before damage occurs. Systems providing vertical support shall be designed by
the Contractor as bridge structures. Lateral support may be considered as retaining walls.
Most utilities require access for repairs; it is therefore required to have provisions for access to
utilities passing beneath a tunnel. In some cases, it has been found appropriate to relocate utilities
to a trough or utility tunnel in which all utilities can be easily accessed. In some cases, utilities cannot
be raised sufficiently to clear the tunnel roof slab; it may be possible to create a narrow trough across
the roof in which the utility may be relocated. In certain situations, utilities were passed through the
tunnel by providing a special conduit below the tunnel roof. In all cases, the Contractor shall carefully
coordinate all utility work with the utility owner.
34.2.6 Waterproofing of Cut-and-Cover Tunnels

Waterproofing of cut-and-cover tunnels shall be Type B waterproofing, as specified in the Contract
plans, and in accordance with the requirements of Section 28.3 of Chapter 28, Waterproofing, of
34.3 Rock Tunnelling

34.3.1 Introduction
This work includes the construction of rock tunnelling including excavation methods, excavation
supports, groundwater control, and other ground control measures.
Page 34-9
Because of the range of behaviour of tunnels in rock, such as from a coherent continuum to a
discontinuum, stabilization measures range from no support, to bolts, to steel sets, to heavily
reinforced concrete lining and numerous variations and combinations in between. Certainly these
variations are to be expected when going from one tunnel to another, but often several are required
in a single tunnel because the geology and/or the geometry change. Thus, the Contractor must
recognise the need for change to allow for adjustments to be made in the field to adjust construction
means, methods, and equipment to the challenges presented by the vagaries of nature.
34.3.2 Rock Tunnelling Methods

34.3.2.1 Drill-and-Blast
The basic approach is to drill a pattern of small holes, load them with explosives, and then detonate
those explosives thereby creating an opening in the rock. Blasted and broken rock (muck) is then
removed and the rock surface is supported so that the whole process can be repeated as many
times as necessary to advance the desired opening in the rock.
By its very nature, this process leaves a rock surface fractured and disturbed. Disturbance typically
extends 1 m to 2 m into the rock and can be the initiator of a wedge failure. At a minimum, this usually
results in an opening larger than needed for its service requirement, and the need to install more
supports than shall be needed if the opening could be made with fewer disturbances. To reduce the
disturbance, the controlled blasting technique discussed in this section can be applied.
a. Controlled Blasting Principles

Explosives work by a rapid chemical reaction that results in a hot gas with much larger volume than
that occupied by the explosive. This is possible because the explosive contains both the fuel and the
oxidiser. When the explosive detonates, the rapidly expanding gas performs two functions —
applying a sharp impulse to the borehole wall (which fractures the rock) and permeating the new
fractures and existing discontinuities (which pries the fragments apart). To deliver this one-two punch
effectively, the explosive is distributed through the rock mass by drilling an array of boreholes that
are then loaded with explosives and fired in an orderly sequence.
b. Relief
To effectively fragment the rock, there must be space for the newly created fragments to move into.
If there is not, the rock is fractured but not fragmented, and this unstable mass will remain in place.
Therefore, the geometry of the array of boreholes must be designed to allow the fragments to move.
This is optimum if there is more than one free face available. Creating an artificial "free face" is
discussed in this section under “Burn Cut”.
c. Delay Sequencing
To optimise the relief, internal free faces must be created during the blast sequence. To do this,
millisecond delay detonators separate the firing times of the charges by very short lengths of time.
Because of scatter in the firing times of pyrotechnic detonators, "long" period delays between holes
(on the order of hundreds of milliseconds) shall be used in tunnel and underground mining, to result
in blasts that last several seconds. This could change as more accurate electronic detonators are
developed.
d. Tunnel Blast Specifics

Tunnel blasting (like underground mine blasting) differs from surface blasting in that there is usually
only one free face that provides relief. To blast a large tunnel, an upper heading shall be blasted
first, and the rest of the rock is taken with a bench blast. Often, the whole face shall be drilled and
blasted in one event. An array of blast holes shall be drilled out using drilling equipment that can drill
several holes at once. Taking into account the rock type, the existing discontinuities in the rock
(joints, fractures, bedding planes), and of course the desired final shape of the tunnel, the pattern of
drill holes shall be determined before the blast.
Page 34-10
e. Burn Cut
Because the start of each cut with a solid face has no relief, several extra holes shall be drilled and
not loaded with explosives in the immediate neighbourhood of the initiation point. These burn holes
are generally larger than the explosively loaded holes, requiring an additional operation beyond the
normal drilling. Many different geometries of burn holes shall be used to optimise the cut, depending
on the rock type and joint patterns in a specific tunnel geology. These holes shall be fired first, with
enough firing time to allow the creation of a free face for the following holes to expand into.
Production Holes: Following the initiation of the burn cut, the mass of the rock shall be fired in a
sequence so that the rock moves in a choreographed sequence, moving into the area opened up by
the burn cut, and out into the open space in front of the blast.
Wiring up the charges in the right sequence can be a challenging task in the confined environment
of a tunnel. The Contractor shall present the hook-up of the blast round, with the surface connectors,
and the period (corresponding to a specific delay time) next to each blast hole.
Desired sequence shall fire holes so that there is enough time for rock to move out of the way (create
relief), but not so much time that the rock surrounding unfired blast holes will fracture (creating a cut
off).
Perimeter Control: It is important to blast so that the final wall is stable and as close to the designed
location as possible. Final holes shall be loaded more lightly, and called "perimeter holes" or "smooth
wall holes", and fired with some extra delay so that there is sufficient time for rock to fracture cleanly
and create little damage to the rock outside of the "neat" line (such damage is called over break).
Though fired after the production holes have been detonated, the smooth wall holes shall be fired
on the same delay period, creating a "zipper" effect of the holes generating a smooth fracture on the
perimeter.
Environmental Effects – Vibration and Air blast: Not all of the energy from blasting goes into
fragmenting rocks, some of it is unavoidably wasted as vibration that propagates away from the blast
area. This vibration can be cause for concern both for the stability of the tunnel itself, as well as
neighbouring underground and surface structures.
Air blast is an air pressure wave that propagates away from the blast site, due to movement of the
rock face and also possible venting of explosive gases from the boreholes. This shall not be so much
a problem in tunnelling, where personnel are evacuated from the blast area before a blast, but still
must be taken into account.
f. Blasting – Art Versus Science

The Contractor shall study the scientific relationships between the properties of explosives, the
controllable variables such as the geometry of a blast and the timing, and uncontrollable variables
such as variations in rock type and existing jointing and fracturing. Many relationships can show the
most appropriate configuration of the blast holes, timing, and explosive type.
Experience, or the "art" of blasting, shall come into play in implementing the desired blast design.
34.3.2.2 Tunnel Boring Machines

TBMs shall excavate the rock mass in a form of rotating and crushing by applying enormous pressure
on the face with large thrust forces, while rotating and chipping with a number of disc cutters mounted
on the machine face (cutterhead).
a. Machine Types and Systems

TBMs shall be a full-face, rotational (with cutterheads) excavation machine that can be either gripper
or segment. There are three general types of TBMs suitable for rock tunnelling that the Contractor
may select from including open gripper/main beam, closed gripper/shield, and closed segment
shield.
Page 34-11
Open gripper/beam type of TBMs shall be selected for stable to friable rock with occasional fractured
zones and controllable groundwater inflows. Three common types of TBMs belonging to this
category could be used including main beam, Kelly drive, and open gripper (without a beam or Kelly).
Closed shield type of TBMs used for most rock tunnelling applications shall be selected for friable to
unstable rocks, which cannot provide consistent support to the gripper pressure. Closed shield type
of TBMs can either be advanced by pushing against segment or gripper. Although these machines
are classified as a closed type of machine, they are not pressurised at the face of the machine, and
cannot handle high external groundwater pressure or water inflows. The Contractor shall select the
most proper shielded TBMs for rock tunnelling. Shielded TBMs include single shield, double shield,
and gripper shield.
b. Machine Main and Support Elements

Main body and other supporting elements of the TBM shall be comprised of mechanisms for cutting,
shoving, steering, gripping, shielding, exploratory drilling, ground control and support, lining erection,
spoil (muck) removal, ventilation, and power supply. Main body of the rock TBM (either open or
closed) shall include some or all of the following components:
• Cutterhead and support
• Gripper (except single shield TBM)
• Shield (except open TBM)
• Thrust cylinder
• Conveyor
• Rock reinforcement equipment
Additionally, the main body of the TBM shall be supported with a trailing system for muck and
material transportation, ventilation, power supply, etc.
c. Compatible Ground Support Elements

Most ground support elements discussed in Section 34.3.3 can be specified with the use of hard
rock TBMs, especially if the TBMs are manufactured specifically for the Project.
• Rock reinforcement by roof bolting
• Spiling/forepoling
• Pre-injection
• Steel ring beams with or without lagging (wire mesh, timber, etc.)
• Invert segment
• Shotcrete
• Precast concrete segmental lining
• Others
34.3.2.3 Road Headers

Typical TBMs cut circular tunnels, which are the most practical cross section, but not always the
cross section that provides the most useable volume as a proportion of the total volume excavated.
The Contract shall use a specialised machine with the proper head that can cut the most favourable
shape, which can be more efficient in providing useable volume.
Another approach to cutting an opening closer to the actual required section is the road header.
Cutting tool for the road header shall be a very large milling head mounted on a boom, which boom,
in turn, is mounted on tracks or within a shield. Corners must be cut to the curvature of the milling
head, but the rest of the walls, crown, and invert can be cut to almost any desired shape. Single road
Page 34-12
header shall be capable of cutting variable or odd shapes that otherwise shall require TBM
excavation in combination with drill-and-blast or drill-and-blast itself.
Because of their adaptability, availability (a few months rather than a year or longer), and lower cost,
road headers shall be the method of choice for relatively short tunnels, approximately less than 1,600
m long, and for rock with an unconfined compressive strength less than 138 MPa.
The following is a general list when road headers shall be considered:
• Rock strength below 138 MPa – preferably below 103 MPa
• Short runs, one-of-a-kind-openings
• Odd, non-circular shapes
• Connections, cross passages, etc.
• Low to moderate abrasivity
• Preferably, self-supporting rock
• No or small inclusions – chert, etc.
• Nominal water pressure
34.3.2.4 Other Mechanised Excavation Methods

Other mechanised excavation methods that are being developed by specialised equipment
manufacturers shall be proposed by the Contractor to address specific issues in mining and civil
applications. One good example of a development such as the "mobile miner" developed by Robbins
as a "non-circular hard rock cutting system to be applied to underground mine development"
(Robbins, 1990). The mobile miner is described as follows:
A boom mounts a large cutter wheel with a transverse axis having rows of cutters arranged only on
the periphery of the wheel. As the boom is swung from side to side, an excavated shape is generated
with a flat roof and floor and curved walls. Although the prototype machines have operated only with
this side-swinging action, to cut openings which are better suited to vehicular tunnels, the cutterhead
boom must be elevated up and down and at the same time swung from side to side. In this way a
horseshoe-shaped excavation can be generated.
34.3.2.5 Sequential Excavation Method/New Austrian Tunnelling

Method
SEM/NATMs offer flexibility in geometry that can accommodate almost any size of opening. Regular
cross sections involve an ovoid shape to promote smooth stress redistribution in the ground around
the newly created opening. By adjusting the construction sequence expressed mainly in round
length, the timing of support installation, and the type of support the chosen method will allow for
tunnelling through rock, soft ground, and a variety of difficult ground conditions. Additionally,
depending on the size of the opening and quality of the ground, the tunnel cross section may be
subdivided into multiple drifts.
Application of the SEM shall involve practical experience, earth and engineering sciences, and
skilled execution. The SEM tunnelling process addresses the following:
a. Ground and excavation and support classification based on a thorough ground investigation.
b. Definition of excavation and support classes by the following:
• Round length, including maximum unsupported excavation length;
• Support measures, including shotcrete lining and its reinforcement, ground reinforcement
by bolts, or dowels in rock;
• Subdivision of the tunnel cross section into multiple drifts or headings, as needed,
including top heading, bench, invert, and side wall drifts;
Page 34-13
• Ring closure requirements;

• Timing of support installation, including typically every round;
• Pre-support by spiling, fore poling, and pipe arch canopy; and,
• Local, additional, initial support by dowels, bolts, spiles, face support wedge, and
shotcrete.
c. Instrumentation and monitoring.
d. Ground improvement measures prior to tunnelling.
34.3.3 Types of Rock Reinforcement and Excavation Support

34.3.3.1 Excavation Support Options
Initial support, sometimes called temporary lining, or temporary support of excavation, in rock
tunnelling keeps the opening open, stable, and safe until the final lining is installed and construction
is complete. As a consequence, the initial support system in a rock tunnel shall be one or a
combination of a number of the following options:
• Rock reinforcement, such as rock dowels, bolts, and anchors;
• Steel ribs;
• Wood or other lagging;
• Lattice girders;
• Shotcrete;
• Spiles or forepoling;
• Concrete;
• Re-steel mats;
• Steel mats;
• Cables;
• Precast concrete segments; and,
Rock reinforcement, steel ribs, wood or other lagging, lattice girders, and shotcrete are the most
common support options; and, of those, a combination of rock bolts or dowels and shotcrete is the
single most common. In good, or better, rock tunnels, modern rock bolting machines provide rapid
and adjustable support close to the heading by knitting and holding the rock, or ground, arch in place
— thus taking maximum advantage of the rock's ability to be self-supporting. Preferably, shotcrete
is added a diameter or so behind the face, where its dust, grit, and flying aggregate are not a problem
for workers and equipment at the heading. Where there is a concern with smaller pieces of rock
falling, the system can be easily modified by adding shotcrete closer to the face or by embedding
any of a number of types of steel mats in the shotcrete.
Where the rock quality is lower, the Contractor may replace steel ribs with lattice girders. Like steel
ribs, the lattice girders form a template for the shotcrete and spiling. Lattice girders differ from steel
ribs in that they are lighter and can be erected faster. To provide the same support capacity, the
lattice girder system may require nominally more shotcrete measuring an additional 12.5 mm to 25
mm, which is more than compensated for by the easier and faster erection. To avoid using additional
shotcrete, the Contractor may use steel fibre-reinforced shotcrete instead. Additional fibre does not
change the compressive strength significantly, but it does produce a significant increase in the
toughness or ductility of the shotcrete.
Page 34-14
34.3.3.2 Rock Reinforcement

Rock reinforcement, including rock dowels and bolts shall be used to hold loose, or key, blocks in
place; or to knit together the rock (ground) arch that provides the support for the opening in rock.
Dowels and bolts are similar but the differences in their behaviour can be quite significant. Unless
otherwise indicated in the Contract plans or specified in the particular specifications, rock dowels
and rock bolts shall be high yield threaded bars galvanized in accordance with Section 23.4.10,
Chapter 23, Steel Structures, of these standard specifications, with a standard mean coating
thickness of 140 µm.
Rock dowels/bolts shall be tested in accordance with ASTM D4435 – 08, Standard Test Method for
Rock Bolt Anchor Pull Test, and ASTM D4436 – 08, Standard Test Method for Rock Bolt Long-Term
Load Retention Test.
a. Rock Dowels
Rock dowels shall be passive reinforcement elements that require some ground displacement to be
activated. Similar to passive concrete reinforcement, the effect of dowels is activated by the
movement of the surrounding material. In particular, when displacements along discontinuities occur,
dowels are subject to both shear and tensile stresses. Levels of shear and tensile stresses, and the
ratio between them occurring during a displacement, depend on the properties of the surrounding
ground, the properties of the grout material filling the annular gap between the dowel and the ground,
and the strength and ductility parameters of the dowel itself. Additionally, the degree of dilation during
shear displacement influences the level of stress acting within the dowel.
b. Rock Bolts
Rock bolts shall have a friction or grout anchor in the rock and shall be tensioned as soon as that
anchorage is attained to actively introduce a compressive force into the surrounding ground. This
axial force acts upon the rock mass discontinuities, thus increasing their shear capacity and is
generated by pre-tensioning of the bolt. The system requires a bond length to enable the bolt to be
tensioned. Rock bolts shall be fully bonded to the surrounding ground after tensioning, for long-term
load transfer considerations. They shall be grouted full length. In any case, bolts begin to support or
knit the rock as soon as they are tensioned, that is, the rock does not have time to begin to move
before the bolt becomes effective.
34.3.3.3 Ribs and Lagging

There are still applications where the use of ribs and lagging is appropriate, such as unusual shapes,
intersections, short starter tunnels for TBM, and reaches of tunnel where squeezing or swelling
ground may occur.
Steel ribs may be installed with shotcrete being used instead of wood for the blocking, or lagging,
material. When shotcrete is used, it often does not completely fill the entire void between steel and
rock. Hence, with properly applied shotcrete, it is recommended that the maximum blocking point
spacing be measured at 0.5 m and the design shall proceed according to the Proctor and White
procedure.
34.3.3.4 Shotcrete
Shotcrete is simply concrete sprayed into place through a nozzle. It contains additives to gain
strength quicker and to keep it workable until it is sprayed. Shotcrete can be made with or without
the addition of reinforcing fibres and can be sprayed around and through reinforcing bars or lattice
girders. Both the quality and properties of shotcrete can be equal to those of cast-in-place concrete,
but only if proper care and control of the total placement procedure is maintained throughout.
34.3.3.5 Lattice Girder

Lattice girders shall consist of support members made up of steel reinforcement bars laced together
in a triangular pattern and rolled to match the shape of the opening. Because their area is typically
Page 34-15
small compared to the surrounding shotcrete, lattice girders do not, by themselves, add greatly to
the total support of the opening. However, they do provide the following two significant benefits:
• They are typically spaced similarly to rock bolts, thus they quickly provide temporary support
to blocks having an immediate tendency to loosen and fall.
• They provide a ready template for assuring that a sufficient thickness of shotcrete is being
applied.
Generally, lattice girders are used much more frequently in tunnels driven by the SEM.
34.3.3.6 Spiles and Forepoles

Spiles and forepoles shall be used interchangeably to describe support elements consisting of pipes,
pointed boards, or rods driven ahead of the steel sets or lattice girders. These elements (herein
called spiles) provide temporary overhead protection while excavation for, and installation of, the
next set or girder is accomplished. Spiles shall be driven in an overlapping arrangement so that there
is never a gap in coverage. Design of spiles is best described as intuitive, as it must be kept flexible
and constantly adjusted in the field as the ground behaviour is observed during construction. A
working first approximation of design load might be a height of rock equal to 0.1B to 0.25B, where B
is the width of the opening.
34.3.3.7 Precast Segment Lining

Tunnel lining consisting of precast segments shall be used in single- or double-pass lining systems
to support rock loadings and water pressures. Precast segment lining shall comply with the concrete
durability parameters in Section 21.3.3, Chapter 21, Concrete Structures, of these standard
specifications. Concrete segments shall be reinforced either with reinforcement bars or fibre.
Segment rings shall consist of five to seven segments with a key segment. Ring divisions and the
segment dimensions have to be optimised according to the Project-specific requirements that include
tunnel diameter, maximum size for transport and installation or erector, and the number of thrust
jacks and their distribution over the range of the ring.
Precast segment concrete lining shall be used in TBM tunnel construction and in soft-ground tunnels.
Segmental rings shall be erected in the TBM tail shield and during the advance, the rams shall act
on the ring. Rings shall never be independent from the TBM, hence the design of the TBM and the
segmental ring must be harmonised. Rams must act on prepared sections of the ring, rolling of the
tunnel shield and the ring must be taken into account. Ram axis shall be identical with the ring axis
and ring tapers shall be designed according to the TBM curve drive capabilities and not only
according to the designed tunnel axis.
34.3.4 Groundwater Control during Excavation

This work shall consist of controlling groundwater in rock that can take many forms, depending on
the nature and extent of the problem. A combination of control methods for the tunnel may be
employed by the Contractor, which may also apply different solutions at different locations along the
alignment.
34.3.4.1 Dewatering at the Tunnel Face

Dewatering at the tunnel face is the most common method of groundwater control. This consists
simply of allowing the water to drain into the tunnel through the face, collecting the water, and taking
it to the rear by channels or by pumping. It then joins the site water disposal system. Consideration
shall be taken by the Contractor that if there are hydraulic or other leaks or spills at the TBM or other
equipment in the tunnel that such contaminants are in this water.
34.3.4.2 Drainage Ahead of Face from Probe Holes

Probe holes may be placed by the Contractor ahead of the tunnel to verify the characteristics of the
rock and to provide information for machine operation and control. These holes shall also pre-drain
Page 34-16
the rock and provide warning of, and drain, any methane; hydrogen sulphide; or any other gas,
petroleum, or contaminant that may be present. In areas where there are such known deposits of
gas or other contaminants, it is recommended to keep one or more probe holes out in front of the
machine. When such materials are encountered, the probes shall alert the workers of the need to
increase the frequency of gas readings, to increase the volume of ventilation, or to take other steps
to avoid the problem of unexpected or excessive gas in the tunnel.
34.3.4.3 Drainage from Pilot Bore or Tunnel

Pilot tunnels shall be constructed by the Contractor as per the Contract documents. These pilot
tunnels shall provide the following benefits to the main tunnel drive:
• Groundwater drainage;
• Gas or other contaminant drainage;
• Exploratory information on the geology;
• Grouting or bolting galleries for pre-support of a larger opening; and,
• Rock behaviour and loading information for design of the larger opening.
Pilot tunnels are typically 2 m to 2.5 m in general size, and may be located at one or more of several
locations.
34.3.4.4 Grouting
Groundwater inflow into rock tunnels almost exclusively comes in at joints, bedding planes, shears,
fault zones, and other fractures. Because these can be identified, grouting shall be the most
commonly used method for groundwater control. A number of different grout materials shall be used
depending on the size of the opening and the amount of the inflow. Zones of potentially high
groundwater inflow shall first be detected by the Contractor by drilling probe holes out in front of the
tunnel face. Second, the zones shall be characterised and, hopefully, the major water carrying joints
tentatively defined. Third, a series of grout holes shall be drilled out to intercept those joints 3 m to a
tunnel diameter beyond the tunnel face or wall. Fourth, using tube-a-machetes, cement, or water-
reactive grouts shall be injected to seal off the water to a level such that succeeding holes are drilled
as the fifth step and injected with finer, more penetrating grouts — such as micro- or ultra-fine
cements or sodium silicate — can be injected to complete the sealing process. Based on evaluation
of the grouting success, additional holes and grouting may be required to finally reduce the inflow to
an acceptable level. Steps four and five shall be repeated until the required reduction in flow is
achieved.
34.3.4.5 Freezing
On rare occasions, it may become necessary for the Contractor to try freezing in a tunnel in rock for
groundwater control. This might occur, for example, at a shaft where it is necessary to control the
groundwater locally for a breakout of a TBM into the surrounding rock. If upon beginning excavation
of the TBM launch chamber it is found that the water inflow is too great, the alternative control
methods shall be to grout, as discussed above, or to freeze.
The maximum groundwater velocity for which it is feasible to perform effective freezing shall not
exceed 1.8 m per day. Therefore, freezing shall not be used in rock tunnelling, except locally, and
even then it might be necessary to use liquid nitrogen to perform the freezing.
34.3.4.6 Closed-Face Machine

A closed-face machine may be used by the Contractor for rock tunnelling in high groundwater flow
conditions over short lengths. In reality such a machine shall be similar to an earth pressure balance
(EPB) machine with sufficient rock cutters installed to excavate the rock. For any extended length
measuring greater than a 100 m, this process shall be uneconomical because the machine shall
have to grind up the rock cuttings and mix and the resulting fines with large quantities of conditioners
Page 34-17
and the existing water shall result in a plastic material. This is necessary for the EPB to control the
face in front of the bulkhead and to bring the material from its pressurised state at the face down to
ambient by means of the EPB screw conveyor.
For these reasons, the Contractor shall not build a closed-face rock machine but to equip an EPB
with rock cutters for driving short stretches in rock within a longer soft-ground tunnel. An exception
to this general statement shall be a rock tunnel in weak or soft rock, such as chalk, marl, shale, or
sandstone of quite low strength that essentially behaves as high-strength soft ground.
34.3.4.7 Other Measures of Groundwater Control

Groundwater control methods presented above shall account for more than 95 percent of the cases
where such control will be required in the rock tunnel. In case, for the tunnels or shafts where
something else is required, the Contractor may rely on experience or ingenuity to come up with the
solution. A few suggestions are presented here, but the Contractor may have to develop inventive
solutions on a case-by-case basis.
Compressed Air: Where the tunnel, or shaft, can be stabilised by relatively low pressures measuring
0.07 MPa, or less, the Contractor may use compressed air; however, it requires compressor plants,
locks, special medical emergency preparation, and decompression times.
Panning may be attractive in some cases where the water inflow is not too excessive and is
concentrated at specific points or seams. In this case, pans are placed over the leaks and shotcreted
into place. Water is carried in chases or tubes to the invert and dumped into the tunnel drainage
system.
Drainage fabric could be used in rock tunnels. These geotechnical fabrics shall be installed over the
whole tunnel circumference, in strips on a set pattern, or where the leaks are occurring. Fastened to
the surface of the rock with the waterproof membrane portion facing into the tunnel, this fabric shall
then be sandwiched into place by the cast-in-place concrete lining. Fibrous portions of the fabric
shall provide a drainage pathway around and down the tunnel walls and into a collection system at
the tunnel invert.
34.3.5 Waterproofing of Tunnels in Rock

Unless otherwise specified, tunnels in rock shall be waterproofed by a sandwich consisting of:
a. A geotechnical drainage fabric that is put in place directly against the rock either continuously
or in strips. This may be held in place by pins or nails driven or shot into the rock.
b. A continuous waterproof membrane of high density polyethylene (HDPE) or polyvinylchloride
(PVC) or other similar material, as indicated in the Contract plans, specified in the particular
specifications, and approved by the Engineer. To be continuous the membrane has to be cut
and fit to all strange shapes and corners encountered and welded together (by heat) to make
a continuous waterproofing membrane within the tunnel. The Contractor shall successfully
install the waterproofing system and provide the proper workmanship in:
• Avoiding puncturing, tearing and the like of the membrane.
• Correctly making and testing all joints.
• Connecting the waterproof membrane to the wall without introducing leaks.
c. A cast in place lining of concrete placed to hold the sandwich together and to provide the
desired inner surface of the tunnel. The Contractor shall ensure that the concrete is placed
without damaging the membrane(s).
Page 34-18
34.4 Soft-Ground Tunnelling

34.4.1 Introduction
This work shall construct tunnelling, mostly shield tunnelling, in soft ground — including cohesive
soils, cohesionless soils, and silty sands.
34.4.2 Tunnelling-Induced Settlement

34.4.2.1 General
Ground settlement is of greater concern for soft-ground tunnels than for rock for the following two
reasons:
• Settlements are nearly always greater for soft-ground tunnels.
• Typically more facilities that might be negatively impacted by settlements exist near soft-
ground tunnels than near rock tunnels.
To minimise settlements and their impact on other facilities, the Contractor shall be fully equipped.
34.4.2.2 Sources of Settlement

Although there are a large number of sources or causes of settlement, they can be conveniently
lumped into the following two broad categories:
• those caused by groundwater depression; and,
• those caused by lost ground.
a. Groundwater Depression
Groundwater depression may be caused by intentional lowering of the water during construction or
by the tunnel or other construction acting as a drain. When any of these occurs, the effective stress
in the ground increases. For tunnels in granular soil, the settlement due to this increase in effective
stress is usually reflected as an elastic phenomenon requiring knowledge of the low-stress modulus
of the ground and calculation of the change in effective stress. Unless the soil contains silt or very-
fine sand, this elastic settlement will typically represent the majority of the total but its absolute value
will also be relatively small.
With fine-grained soils, the conditions are reversed. In most instances, the settlement is mostly due
to consolidation brought on by the changes in effective stress. In some instances, primarily if lenses
of sands are contained in the soil, there may also be a relatively small contribution by elastic
compression. In comparison to the settlement of granular soils, consolidation can lead to
considerable settlement when the consolidating soils are thick and the change in effective stress is
significant.
b. Lost Ground
Lost ground has a number of root causes and is usually responsible for the settlements. By definition,
lost ground refers to the act of taking, or losing, more ground into the tunnelling operation than is
represented by the volume of the tunnel. Thus it is highly reflective of construction means and
methods. Modern machines shall be used by the Contractor in controlling lost ground and employ
high-quality workmanship.
For the purposes of this section, the causes of lost ground shall be lumped into the following three
groups:
• Face losses results from movement in front of and into the shield. This includes running,
flowing, caving, and squeezing behaviour of the ground itself or simply mining more ground
than displaced by the tunnelling machine.
Page 34-19
• Shield losses occur between the cutting edge and the tail of the shield. All shields employ
some degree of overcut so that they can be manoeuvred. Additionally, any time a shield is
off alignment, the shield yaws, pitches, or plows, when brought back to alignment. Mother
Nature abhors a vacuum and the surrounding soils begin to fill these planned or produced
voids the instant they are produced. The Contractor shall note that a 25-mm overcut plus a
3-mm hard facing on a 6-m shield produces lost ground of nearly 2 percent, if not properly
filled.
• Tail losses are similar to shield losses in that they are caused by the space being vacated
by the tail itself — as well as the extra space that must be provided between the tail and the
support elements so these elements can be erected and so that they do not become iron
bound and seize the tail shield. However, like the shield losses, these tail voids will rapidly fill
with soil if they are not first eliminated by grouting or expansion of the tunnel support
elements.
34.4.2.3 Settlement Calculations

In tunnelling, the Contractor shall rely heavily on its experience with some assistance from analysis.
Thus, there are two related methods to attack the problem: experience and empirical data.
Experience can be used where a history of tunnelling and of taking of measurements exists. It shall
be anticipated that an experienced Contractor shall achieve between 0.5 percent and 1 percent
ground loss (refer to Table 34-2) while an inexperienced Contractor shall attain 1 percent to 2 percent
loss.
Table 34-2: Relationship between volume loss, construction practice,

and ground conditions
Case VL (%)
Good practice in firm ground; tight control of face pressure within closed-face
0.5
machine in slowly ravelling or squeezing ground
Usual practice with closed-face machine in slowly ravelling or squeezing ground 1
Poor practice with closed-face machine in ravelling ground 2
Poor practice with closed-face machine in poor, or fast ravelling, ground 3
Poor practice with little face control in running ground 4, or more
When there is no record to rely upon, the design shall be based strictly on empirical data and an
engineering assessment of what the Contractor could be expected to achieve with no track record
to rely upon. In that case, the above evaluations might be bumped up one-half of a percentage point
each as an insurance measure.
Pressurised-face TBMs, such as EPB and SFM, shall be employed by the Contractor to minimise
the magnitude of ground losses. These machines control face stability by applying active pressure
to the tunnel face, minimizing the amount of overcut, and using automatic tail void grouting to reduce
shield losses. Typically, ground loss during soft-ground tunnel excavation using this technology limits
ground loss to 1 percent, or less — assuming excellent tunnelling practice that includes adequate
pressure applied to the face and effective and timely tail void grouting.
Ground settlement can be predicted by numerical methods, which are extremely useful when the
tunnel geometry is not a circular or horse-shoe shape because the analytical, or empirical, method
was not directly applicable.
Page 34-20
34.4.3 Impact on and Protection of Surface Facilities

34.4.3.1 Evaluation of Structure Tolerance to Settlement
Evaluation of structural tolerance to settlement requires definition of the possible damage that a
structure might experience. Surface structures damaged due to tunnelling-induced settlement shall
be defined by the following:
1. Architectural Damage: Damage affecting the appearance but not the function of
structures, usually related to cracks or separations in panel walls, floors, and finishes.
Cracks in plaster walls greater than 0.4 mm wide and cracks in masonry or rough
concrete walls greater than 0.8 mm wide are representative of a threshold where damage
is noticed and reported by building occupants.
2. Functional Damage: Damage affecting the use of the structure, or safety to its occupants,
usually related to jammed doors and windows, cracking and falling plaster, tilting of walls
and floors, and other damage that requires nonstructural repair to return the building to
its full-service capacity.
3. Structural Damage: Damage affecting the stability of the structure, usually related to
cracks or distortions in primary support elements — such as beams, columns, and load-
bearing walls.
Table 32-2 presents the correlation of angular distortion (the relative settlement between columns or
measurement points) and building damage.
As an alternative initial screening method, Table 34-3 presents a damage risk assessment chart,
based on maximum building slope and settlement.
Table 34-3: Limiting angular distortion
Category of Potential Damage Angular Distortion

Danger to machinery sensitive to settlement 1/750
Danger to frames with diagonals 1/600
Safe limit for no cracking of building 1/500
First cracking of panel walls 1/300
Difficulties with overhead cranes 1/300
Tilting of high-rigid building becomes visible 1/250
Considerable cracking of panel and brick walls 1/150
Danger of structural damage to general building 1/150
Safe limit for flexible brick walls* 1/150
*A safe limit includes a factor of safety
Table 34-4: Damage risk assessment chart
Risk Maximum Maximum Description of risk

Category slope of settlement of
building building (mm)
1 Less than 1/500 Less than 10 Negligible; superficial damage unlikely.
Page 34-21
Table 34-4: Damage risk assessment chart
Risk Maximum Maximum Description of risk

Category slope of settlement of
building building (mm)
2 1/500 – 1/200 10 – 50 Slight; possible superficial damage that is
unlikely to have structural significance
3 1/200 – 1/50 5 – 75 Moderate; expected superficial damage and
possible structural damage to buildings, possible
damage to relatively rigid pipelines.
4 Greater than Greater than 75 High; expected structural damage to buildings.
1/50 Expected damage to rigid pipelines, possible
damage to other pipelines
34.4.3.2 Mitigating Settlement

Where the settlement is, or shall be, caused by groundwater lowering, the Contractor shall reduce
or eliminate the conditions causing or allowing dewatering. This could include the following, for
example:
a. Reduce drawdown at critical structures by re-injecting water or using impervious cut off walls.
b. Using closed- and pressurised-face tunnelling machines so that drawdown cannot occur.
Pressure at the face shall be equal to the groundwater head.
c. Grouting the ground around the tunnel to eliminate water inflow into the tunnel.
Where the settlement is or could be caused by lost ground in the tunnelling operation, the Contractor
shall mitigate that settlement with proper construction means and methods. For example, the
Contractor shall consider the following:
• Requiring a closed-face, pressurised TBM, such as an EPB or SFM, and keep the pressure
at least equal to — if not greater than — the combined soil and groundwater pressure in the
ground at tunnel level.
• Immediately and completely grout the annular space between the tunnel lining and the
ground at the tail of the machine. Use automated grouting systems that will not permit the
machine to advance without this void being simultaneously grouted.
• Control the operation, or steering, of the machine so that it is not forced to pitch or yaw to
make excessive alignment corrections. Each 1 percent of correction translates to a potential
1.5 percent of ground loss.
• Use compaction or compensation grouting to make up for ground loss before it migrates to
the building.
• Treat areas of loose soils by consolidation or jet grouting before tunnelling into them.
34.4.3.3 Structure Protection

When protecting structures, first and foremost are the tunnelling procedures of maintaining face
pressure, or control, and immediately grouting to fill the annular — or any other — void.
The next step is ground improvement either by consolidation or jet grouting, and closely related
compensation or compaction grouting.
As a last resort, the Contractor shall apply underpinning, when all else appears to be unsuccessful
and or unworkable. Typical steps of underpinning method are summarised as follows:
• Break out and hand excavate down to, or nearly to, the potentially impacted foundation.
Page 34-22
• Install piles or other founding elements to a bearing below or outside the impacted foundation
and the tunnel.
• Install a needle beam or similar method to transfer the impacted foundation load to the new
elements.
• Preload the new elements, such as unloading the impacted foundation onto those new
elements.
• Cut or release any load to the impacted foundation. At this point, all loads are transferred
through the new elements to a bearing location/condition that is completely independent of
the tunnelling operation and the tunnel.
• As required or necessary remove or leave in place the original foundation.
34.4.4 Soil Stabilization and Improvement

34.4.4.1 Introduction
This work shall include soil stabilization and improvement works.
34.4.4.2 Typical Applications

The Contractor shall take the decision to use soil stabilization or improvement based on each
individual case. This decision may be easy with there being no other way to construct the tunnel. Or
the decision may come down to a trade-off among treating the ground, using high-tech machines, or
a combination of the two. Table 34-5 summarises the challenging ground sites and corresponding
treatment methods.
Table 34-5: Ground treatment methods
Challenging Ground Conditions Treatment Methods
Weak Soils Vibro Compaction

Dynamic Compaction
Compaction Grouting
Permeation Grouting
Jet Grouting
Groundwater Dewatering
Freezing
Grouting
Unstable Face Soil Nails
Spiling
Soil Dowelling
Micro-Piles
Soil Movement Compensation Grouting
Compaction Grouting
The Contractor shall note that the boundaries between both ground conditions and treatment
methods are not fixed. Additionally, the use of vibro compaction techniques or dynamic compaction
is typically applicable at or near the tunnel portals, as these techniques are applied to the ground
surface and are not effective beyond an approximate 30-m-depth for vibro compaction and 10-m-
depth for dynamic compaction. Both are generally effective only in granular soils.
Page 34-23
34.4.4.3 Reinforcement Methods

a. Soil Nails
Soil nails may be used to stabilise a tunnel face in soil during construction. Steel or fibreglass rods
or nails shall be installed in the face and the resulting reinforced blocks shall be analyzed for stability
— much as for usual slope stability analyses. Several methods, such as Davis, Modified Davis,
German, French, Kinematrical, Golder, and Caltrans, are used for these analyses. However, it must
be recognised that application of any method must be tempered with appropriate judgment,
measurements, and case history experience.
b. Soil Dowelling
Soil dowelling entails the installation of reinforcement members that are larger than nailing. These
dowels act in tension, like soil nails, but are large enough in the cross section that they also develop
some shearing resistance where they pass through the sliding surfaces.
34.4.4.4 Micropiles
As they are applied to tunnelling, micropiles are essentially the same as soil dowels. These shall be
drilled piles measuring 50 mm to 150 mm in diameter that contain a large, reinforcing bar centred in
the hole and the hole backfilled with concrete. As opposed to pin piles that are typically installed at
the surface, and that act in compression, the pin piles placed in tunnels typically act in tension and
shear across the sliding surfaces.
Soil nails, soil dowels, and pin piles shall be installed at the face of the tunnel to stabilise that face
for construction. Thus, they are continually being installed and mined out of the face. For ease in this
mining operation, fibreglass bars — or rods — shall be used in these applications because they are
much easier to mine out and cut. In contrast, spiling tends to look out around the perimeter of the
tunnel, thus steel is more likely to be used for spiling bars or plates.
For more details, the Contractor shall comply with requirements of the “Micropile Design and
Construction Reference Manual,” FHWA, 2005f.
34.4.4.5 Grouting Methods

All grouting involves the drilling of holes into the ground, the insertion of grout pipes in the holes, and
the injection of pressurised grout into the ground from those pipes. Details of the operations,
however, are distinctly different.
a. Permeation Grouting
Permeation grouting involves the filling of pore spaces between soil grains, and displacing water.
Grout may be one of a number of chemicals, but is usually sodium silicate or polyurethane; or neat
cement using regular, micro-, or ultra- fine cement, along with chemicals and other additives. Once
injected into the pore spaces, the grout sets and converts the soil into a stable, weak sandstone
material. Permeation grouting usually involves grout holes with 0.9-m to 1.2-m centres and enough
secondary holes at split spacing to verify that all the ground is grouted. If necessary to get full
coverage, all of the split-spacing holes may have to be grouted and verification performed by the
tertiary holes.
b. Compaction Grouting
Compaction grouting uses a stiffer grout than permeation grouting. In compaction grouting, the goal
is to form a series of grout bulbs or zones 1.2 m to 1.8 m above and around the tunnel crown. By
pumping the stiff grout under pressure, these bulbs compress, or densify, the ground above and
between the tunnel and overlying facilities.
Pipes for compaction grouting are prepositioned and drilled into place and all the grouting pumps,
hoses, header pipes, and instrumentation are in place before the tunnel drive begins. Instrumentation
is read as the tunnel approaches and passes a facility and the grouting operation is adjusted in real
Page 34-24
time in response to the movement readings. Additionally, it is possible to either preheave the ground
or to jack it back up, at least partially, by pumping more grout at higher pressures.
c. Compensation Grouting
Compensation grouting is, in some ways, similar to compaction grouting. The goal is to monitor
ground movements, primarily between the tunnel and any overlying facility. When it is apparent that
ground is being lost in the tunnelling operation, a grout, typically slightly more liquid than the
compaction grout mix, is injected to replace — or compensate for — the lost ground. As indicated,
the differences between these two schemes are relatively minor, as compaction grouting seeks to
recompact the ground by forming grout bulbs and compensation grouting seeks to refill voids created
by the tunnelling operations.
d. Jet Grouting
Jet grouting uses high-pressure jets to break up the soils and replace them with a mixture of
excavated soils and cement. This is typically referred to as soilcrete. There are a number of variations
of jet grouting, depending on the details of the application and on the experience and expertise of
the Contractor.
Design of a jet-grouted column is influenced by a number of interdependent variables related to in
situ soil conditions, materials used, and operating parameters. Table 34-6 presents a summary of
the principal variables of the jet grouting system and their potential impact on the three basic design
aspects of the jet-grouted wall: column diameter, strength, and permeability. Table 34-6 also gives
typical ranges of operating parameters and results achieved by the three basic injection systems of
jet grouting. It shall be noted that the grout pressures indicated in this table are based on certain
equipment and can vary. This table can be used in feasibility studies and preliminary design of jet-
grouted wall systems. Actual operating parameters used in production are usually determined from
initial field trials performed at the beginning of construction.
Jet grouting shall be used as a ground control measure in conjunction with tunnelling in soft ground
using SEM.
Page 34-25
Table 34-6: Summary of jet grouting system variables

and their impact on basic design elements
Principal General Effect of the Variable on Basic Design Elements (Strength,

Variables Permeability, and Column Diameter)
(a) Jet-Grouted Soil Strength
Degree of Strength is higher and less variable for a higher degree of mixing.
mixing of soil
and grout
Soil type and Sands and gravels tend to produce stronger material while clays and silts tend
gradation to produce weaker material.
Cement factor Strength increases with an increase in cement factor, such as weight of cement
per volume of jet-grouted mass.
Water to cement Strength of the jet-grouted soil mass decreases with increase to in situ water to
ratio of grouted cement ratio.
mass
Jet grouting The strength of the double fluid system may be reduced due to air entrapment in
system the soil-grout mix.
Age of grouted As the jet-grouted soil mass cures, the strength increases but usually at a
mass slower rate than that of concrete.
(b) Wall Permeability
Wall continuity Overall permeability of a jet-grouted wall is almost entirely contingent on the
continuity of the wall between adjacent columns or panels. Plumb, overlapping
multiple rows of columns shall produce lower overall permeability. In cases of
obstructions, such as boulders and utilities, if complete encapsulation is not
achieved then overall permeability may be increased, due to possible leakage
along the obstruction-grout interfaces.
Grout Assuming complete wall continuity and complete replacement of in situ soil, the
composition lowest permeability that can be obtained is that of the grout, typically measuring
10-6 cm/sec to 10-7 cm/sec. Lower permeabilities may be possible if bentonite,
or a similar waterproofing, additive is used.
Soil composition If complete replacement is obtained, as may be possible with a triple fluid
system, then soil composition does not matter. Otherwise, if uniform mixing is
achieved than finer-grained soils shall produce lower permeabilities, as
compared to granular soils.
(c) Column Diameter
Jet grouting The diameter of the completed column increases in size as the number of fluids
system is increased from the single to the triple fluid systems.
Page 34-26
Soil density and As density increases, column diameter reduces. For granular soils, the diameter
gradation increases with reducing uniformity coefficient (D60/D10).
Degree of Larger and more uniform diameters are possible with a higher degree of mixing.
mixing of soil
and grout
34.4.4.6 Ground Freezing

Ground freezing provides means of obtaining access in unfavourable ground conditions, of providing
emergency support in unstable ground below the water table, and of maintaining stability of working
faces below the water table.
Ground freezing involves the extraction of heat from the ground until the groundwater is frozen, thus
converting the groundwater into a cementing agent and the ground into frozen sandstone. Heat is
extracted by circulating a cooling liquid, usually brine, in an array of pipes. Each pipe is actually two
nested pipes, with the liquid flowing down the centre pipe and back out through the annulus between
the pipes. When the pipes are close enough and the time long enough, the cylinders of frozen soil
formed at each pipe eventually coalesce into one solid frozen mass. This mass may be a ring or
donut as needed to support a shaft or a solid block of whatever shape necessary to stabilise the
working face or heading.
In early design of ground freezing, the Contractor is recommended to take the following two steps:
• A professional engineer shall advise on the design and construction of the Project.
• Laboratory tests shall be carried out using soil samples from the actual site. Only in this
manner can meaningful properties of frozen soil be obtained for the site involved.
However, a few general guidelines can be stated as follows:
• Pipes are normally spaced 0.9 m to 1.2 m apart.
• Select a spacing-to-diameter ratio <13 for pipes measuring 120 mm or less in diameter.
• Use a brine temperature <25 degrees Celsius.
• Provide 0.013 tons to 0.025 tons of refrigeration per 300 mm of freeze pipe.
• Determine typical frozen ground properties by laboratory testing.
Groundwater flow across the site requires special considerations, such as closer pipe spacing and
multiple rows of pipes. Groundwater flow velocities of approximately >2 m/day may impede or
prevent freezing. A number of special challenges associated with ground freezing shall be
considered in both the design and construction stage. Those are creep of frozen ground, sensitivity
of frozen ground properties to loading condition, and ground heave or settlement.
34.5 Steel and Concrete Tunnel Liners

34.5.1 Scope
These Specifications are intended to cover the installation of tunnel liner plates in tunnels
constructed by conventional tunnel methods.
Tunnels excavated by full face, heading and bench, or multiple drift procedures are considered
conventional methods.
Liner plates used with any construction procedure using a full or partial shield; a tunnelling machine;
or other piece of equipment that will exert a force on the liner plates for the purpose of propelling,
steering, or stabilizing the equipment are considered special cases and are not covered by these
Specifications.
Page 34-27
34.5.2 Description
This work shall furnish cold-formed steel tunnel liner plates or precast concrete plates, conforming
to these Specifications and of the sizes and dimensions required in the Contract documents, and
installing such plates at the locations specified in the Contract documents or by the Engineer and in
conformity with the lines and grades established or by the Engineer. Completed liner shall consist of
a series of liner plates assembled with staggered longitudinal joints.
Steel tunnel liner plates shall be of a type that is commercially available. Precast concrete tunnel
liner plates shall be such that their size and shape suits the method and equipment being used to
install them.
34.5.3 Materials and Fabrication

34.5.3.1 General
Steel liner plates herein described must meet the sectional properties of thickness, area, and
moment of inertia shown in the Contract documents. Liner plates shall be fabricated to fit the cross-
section of the tunnel. If not shown in the Contract documents, steel liner plate requirements and
properties shall be as specified in the AASHTO LRFD Bridge Design Specifications, Section 12.13.3,
and Road Structures Design Manual (ADQCC TR-516), as applicable.
All steel plates shall be connected by bolts on both longitudinal and circumferential seams or joints
and shall be so fabricated as to permit complete erection from the inside of the tunnel. Bolt sizes and
properties shall be in accordance with the Manufacturer's standard, but not less than those specified
in the AASHTO LRFD Bridge Design Specifications, Section 12.13.3.1.
Grout holes measuring 50 mm or larger in diameter shall be provided, as shown in the Contract
documents to permit grouting as the erection of tunnel liner plates progresses.
Precast concrete tunnel liner plates shall conform to the details shown in the Contract documents
and the requirements of Section 21.13 of Chapter 21, Concrete Structures, of these standard
specifications. If such details are not provided, and the Contract documents allow the Contractor to
propose the use of concrete liner plates, the Contractor shall submit working drawings to the
Engineer for approval. Such drawings shall describe materials to be used, plate dimensions,
reinforcement details, connecting details, and erection procedures. Fabrication of the Contractor-
proposed types of concrete tunnel liner plates shall not begin until the working drawings have been
approved. Such approval shall not relieve the Contractor of any responsibility under the Contract
documents for the successful completion of the work.
34.5.3.2 Forming and Punching of Steel Liner Plates

All plates shall be formed to provide circumferential flanged joints. Longitudinal joints may be flanged
or of the offset lap seam type. All plates shall be punched for bolting on longitudinal and
circumferential seams or joints. Bolt spacing in circumferential flanges shall be in accordance with
the Manufacturer's standard spacing and shall be a multiple of the plate length so that plates having
the same curvature shall be interchangeable and will permit staggering of the longitudinal seams.
Bolt spacing at flanged longitudinal seams shall be in accordance with the Manufacturer's standard
spacing. For lapped longitudinal seams, bolt size and spacing shall be in accordance with the
Manufacturer's standard but not less than that necessary to meet the longitudinal seam strength
requirements specified in the AASHTO LRFD Bridge Design Specifications, Section 12.13.3.1.
34.5.4 Installation
34.5.4.1 Steel Liner Plates
All steel liner plates for the full length of a specified tunnel shall be of one type only, either the flanged
or the lapped seam type of construction.
Liner plates shall be assembled in accordance with the Manufacturer's instructions.
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Coated-steel plates shall be handled in such a manner as to prevent bruising, scaling, or breaking
of the coating. Any plates that are damaged during handling or placing shall be replaced at the
Contractor's expense, except that small areas with minor damage may be repaired by the Contractor
as directed by the Engineer.
34.5.4.2 Precast Concrete Liner Plates

Installation of precast concrete tunnel liner plates shall not start prior to receipt of approval of working
drawings submitted, as required by Article 34.5.3.1, General. Installation shall conform to the
specified or approved erection procedures.
34.5.4.3 Grouting
When directed by the Engineer, voids occurring between the liner plate and the tunnel wall shall be
force-grouted. Grout shall be forced through the grouting holes in the plates with such pressure that
all voids will be completely filled. Full compensation for backpacking or grouting shall be considered
as included in the Contract price paid for tunnel and no separate payment will be made therefore.
34.6 Immersed Tunnels

34.6.1 Introduction
This work consists of constructing various types of immersed tunnels and their construction
techniques, including fabrication, transportation, placement, joining, backfilling, water tightness, and
the trench stability and foundation preparation requirements.
Immersed tunnels consist of large precast concrete or concrete-filled steel tunnel elements
fabricated in the dry and installed under water. Immersion tunnels shall be fabricated by the
Contractor in convenient lengths on shipways, in dry docks, or in improvised floodable basins, sealed
with bulkheads at each end, and then floated out. Tunnel elements can be towed successfully over
great distances. They may require outfitting at a pier close to their final destination. They shall be
then towed to their final location, immersed, lowered into a prepared trench, and joined to previously
placed tunnel elements. After additional foundation works have been completed, the trench around
the immersed tunnel shall be backfilled and the water bed reinstated. Unless specified in the Contract
documents, the top of the tunnel shall be at least 1.5 m below the original bottom to allow for sufficient
protective backfill. If the Contract documents and hydraulic regime allows, the tunnel may be placed
higher than the original water bed within an underwater protective embankment.
Immersed tunnel elements shall be floated to the site using their buoyant state; however, additional
external buoyancy tanks attached to the elements may be used, if necessary. The ends of the tunnel
elements shall be equipped with bulkheads, like dam plates, across the ends to keep the inside dry,
located to allow only approximately 2 m to 2.5 m between the bulkheads of adjacent elements at an
immersion joint; this space shall be emptied once an initial seal is obtained during the joining process.
Joints shall be equipped with gaskets to create the seal with the adjacent element. They shall also
be equipped with adjustment devices to allow placement of the elements on line and grade. Tunnel
elements shall be lowered into their location after adding either temporary water ballast or tremie
concrete.
34.6.1.1 Environmental Impact

Immersed tunnels have potential disadvantages in term of environmental disturbance to the water
body bed. They may have impact on fish habitats, ecology, current, and turbidity of the water. All
precaution measures shall be taken by the Contractor to minimise the impact of constructing
immerse tunnels on the surrounding environment. Furthermore, impacts on navigation in all
navigable waterways shall be considered and often extensive permitting shall be required.
Additionally, many of the water bodies, such as harbours, or causeways have contaminated
sediments requiring special handling. Use of immersed tunnel techniques might encounter such
contaminated ground and shall require its regulated disposal.
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34.6.1.2 Types of Immersed Tunnel

There are two types of immersed tunnels that are known as steel and concrete tunnels. Steel tunnels
shall be structural steel in the form of stiffened plate, working compositely with the interior concrete
as the structural system. Concrete tunnels shall rely on steel reinforcing bars or prestressing cables.
Steel-immersed tunnel elements shall be fabricated in ship yards or dry docks similar to ships,
launched into water, and then outfitted with concrete while afloat. Concrete-immersed elements shall
be cast in dry docks, or specially built basins, then the basin shall be flooded and the elements are
floated out. Steel tunnels may have an initial draft of as little as about 2.5 m, whereas concrete
tunnels have a draft of almost the full depth. Tunnel cross sections may have flat or curved sides
that shall comply with the Contract plans.
Concrete tunnels shall be rectangular while steel tunnels shall be circular, curved with a flat bottom,
rectangular, or double-shell tunnel that is a circular shell within an octagonal shape. Most or all of
the concrete in steel tunnels shall be placed while the steel shell is afloat, in direct contrast to
concrete tunnels that are virtually complete before being floated out. The order in which concrete is
placed for a steel tunnel shall be tightly controlled to minimise deformations and the resulting
stresses. Steel immersed tunnels may be single shell, double shell, and sandwich.
34.6.1.3 Single-Shell Steel Tunnel

In this type, the external structural shell plate shall work compositely with the interior reinforced
concrete and no external concrete shall be provided. The shell plate shall require corrosion
protection in the form of cathodic protection.
The initial draft of a single shell tunnel shall be less than that for other immersed tunnel types
because of the elimination of the outer shell. However, leaks in the steel shell may be difficult to
identify and seal; subdividing the surface into smaller panels by using ribs will improve the chances
of sealing a leak. Great care and considerable testing shall be required to ensure that the welds are
defect free. Permanent leakage risks can be higher in single-shell immersed tunnels than in other
types. To avoid this, the external structural steel shell shall require a positive form of corrosion
protection.
34.6.1.4 Double Shell Tunnel

A double-shell tunnel element shall be comprised of an internal structural shell that acts compositely
with concrete placed within the steel shell. The top and invert concrete outside the structural shell
plate shall also be structural. A second steel shell shall be constructed outside the structural steel
shell to act as formwork for ballast concrete at the sides placed by tremie. In this configuration, the
interior structural shell plate shall work compositely with internal reinforced concrete while it is
protected by external concrete placed within non-structural steel form plates. The steel portion of the
double shell tunnel element shall be fabricated at a shipyard. Prior to launching, the invert concrete
may be placed to make the element more stable during towing and outfitting and to internally brace
the steel elements. Due to the double shell configuration, this element is stiffer than the single shell
section. However, due to the potential for rough conditions during towing and in particular during
launching if not constructed in a dry dock, internal bracing may be required until the tunnel element
is in its final position.
Multiple bores shall be created by linking sections with diaphragms. The diaphragms shall also serve
to stiffen the steel shell. Diaphragms shall be spaced along the length of the tunnel element.
Longitudinal stiffeners in the form of plates or T-sections shall be used in the longitudinal direction
of the element between diaphragms to stiffen the shell.
34.6.1.5 Sandwich Construction

This construction type shall consist of a structural concrete layer sandwiched between two steel
shells. Both the inner and outer shells shall be load carrying and both shall act compositely with the
inner concrete layer. The concrete shall be non-reinforced and formulated to be non-shrink and self-
consolidating. Inner surfaces of the steel shells shall be stiffened with plates and L-shaped ribs shall
Page 34-30
also provide the connection required for composite action with the internal concrete. Internal
concrete, once cured, shall carry compression loads and shall also serve to stiffen the steel shells.
Steel shells shall carry the tension loads.
As with the other types, the steel shells shall be fabricated at a shipyard and launched and towed to
the tunnel site. Internal diaphragms between the two shells shall stiffen the section sufficiently to
resist the loads imposed during transport and outfitting. Once at the outfitting pier, the internal
concrete shall be placed and the element draft increases. Elements shall be towed to their locations
along the tunnel alignment and the final ballast and structural concrete shall be placed so that it can
be lowered into place.
Steel sandwich construction shall provide a double layer of protection against leaks; however, this
complex arrangement shall require the Contractor to carefully define the executed procedures for
fabrication and concreting. Distortion of the section during welding and poor quality welds can be
costly mistakes for this type of construction.
34.6.1.6 Concrete Immersed Tunnels

Concrete immersed tunnel elements will float with large drafts. Freeboard for concrete elements is
often less than 0.3 m, resulting in almost the entire element being underwater when towed into
position. This requires careful planning from the Contractor during the floating process. Paths from
the fabrication site to the tunnel alignment must contain water deep enough for the element to pass.
Therefore, concrete elements shall be cast in a basin constructed close to the Project site. A dredged
channel may be required from the basin to the tunnel alignment. Once the concrete elements have
been fabricated, the basin shall be flooded. These elements shall be towed out of the basin and to
the tunnel alignment.
Recent development in the use of materials and construction methods that reduce the number of the
construction joints shall be employed by the Contractor, who shall submit the mix design with
reduced water to cement ratio and reduced heat of hydration, both of which result in fewer through-
cracks during the curing of the concrete, to the Engineer for approval. Reducing the through cracks
is key to making the sections waterproof.
Concrete cast lengths in a single operation for a full-width segment, or bay, of a tunnel element shall
be approximately 20 m, despite the large volumes of concrete to be place and the expansion and
contraction that occurs during the first few days due to the heat of hydration.
To prevent cracking due to heat of hydration, mitigation measures shall be used including concrete
cooling using refrigerated pipes cast into the concrete; mix design; low-heat cement, such as ground
granulated blast furnace cement; shielding from the elements; and proper curing.
Typically, the floor slab shall be cast first, followed by walls and then roof. However, if techniques
have evolved permitting the outer walls and even the base slab to be cast with the roof slab, the
Contractor might be allowed to do that for reducing the number of construction joints in the exterior.
Since construction joints are particularly susceptible to leakage, most often due to thermal restraint,
it is most desirable to minimise their numbers. However, the Contractor shall ensure that all
construction joints are watertight.
Unless specified otherwise, prestressing may be used in certain cases to resist bending moments
and to reduce cracking. Tunnels may be prestressed transversely, or may have a nominal
longitudinal prestressing applied. Careful detailing and good workmanship shall be employed by the
Contractor to eliminate virtually all deleterious cracking in concrete.
34.6.2 Construction Methodology

34.6.2.1 General
The Contractor shall submit the construction methodology of the immersed tunnel in compliance with
Contract documents and requirements of the specifications of this section for the Engineer’s review
and approval. This construction methodology shall include excavating the open trench in the bed of
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the body of water being crossed. Tunnel elements shall be fabricated off-site, at a shipyard or in dry
docks. Elements constructed on launching ways shall be launched similar to ships by sliding them
into the water. Elements constructed in dry docks, shall be floated by flooding the dry dock and the
ends of each element shall be closed by bulkheads to make the element watertight. Bulkheads shall
be set back a nominal distance from the end of the element, resulting in a small space at the ends
of the adjoining sections that shall be filled with water and will require dewatering after the
connections with the previous element is made. After fabrication and launching, the elements shall
be towed into position over the excavated trench; once positioned and attached to a lowering device,
such as the lay barge, pontoons, or crane; ballast shall be placed in or on the element so that it can
be lowered to its final position. Ballasting of the element may be achieved by water ballast in
temporary internal tanks or by adding concrete. After placing the element in its position, the
connection shall be made between the newly placed element and the end face of the previously
placed element or structure to which it is to be joined. Once the element is in its final position, butted
up against the adjacent element, the water within the joint between two elements shall be pumped
out. After any remaining foundation work has been completed and locking fill is in place, the joint
can be completed and the area made watertight. Once locking fill is in position, another element
shall be placed. Bulkheads shall be removed, making the tunnel opening continuous. For safety
reasons, the bulkheads at the joint to the most recently placed tunnel element shall be left in position.
Tunnels shall then be backfilled and a protective layer of stone shall be placed over the top of the
tunnel.
34.6.2.2 Trench Excavation

The Contractor shall use the most common method of excavation for immersed tunnels, such as the
use of a clamshell dredger. Sealed buckets shall be used for contaminated materials or to reduce
turbidity in environmentally sensitive areas. Cutter suction dredgers may be used to remove most
materials other than hard rock. Blasting may be required in certain areas, though it is highly
environmentally undesirable.
The tunnel trench shall be dredged to longitudinal profiles and bottom widths taking potential
sloughing of the sides and accuracy of dredging into account so that the necessary bottom width
and profile can be maintained during lowering of the elements and placing of the foundation
materials. Over-dredging shall be avoided; however, over-dredged areas shall be refilled with
materials conforming to the design requirements for foundation materials. Dredging shall be carried
out in at least two stages: the removal of bulk material and trimming, which shall involve removal of
at least the last 1 m above final dredge level. All silt, or other material that may accumulate on the
bottom of the trench, shall be cleared immediately before placing the element. Dredging methods
and equipment shall be designed by the Contractor to limit the dispersal of fine materials in the water.
Turbidity, silt curtains, or other measures shall be used where appropriate. Methods, materials, and
mitigation measures shall be used to avoid or reduce to acceptable levels the impacts of excavation,
filling and other operations on the marine environment.
Trench excavation in any waterway is an environmentally sensitive issue. Once the environmental
conditions have been set by the planning and permitting process, extreme care shall be taken to
meet these conditions. Trench excavation underwater is a difficult and complex process that can be
complicated by contaminated materials, tides, storms, and construction restrictions in waterways
due to environmental concerns associated with fish migration and mating patterns and with ecology
and marine life. When scheduling construction activities, environmentally friendly construction
techniques, equipment, and innovative methods for dealing with contaminants must be considered
by the Contractor for the excavation and backfill.
The Contractor shall determine locations, elevations and dimensions of all underwater utility lines
and marine structures in the area of the dredging and provide protection, if required. Excavations
shall be evaluated for stability using appropriate limit state methods of analysis. Temporary offshore
slopes shall be constructed with a minimum factor of safety of 1.3. Side slopes of the trench shall
not be steeper than 2 horizontal to 1 vertical in soil, nor steeper than 1 horizontal to 4 vertical in rock
provided the minimum specified factor of safety is achieved. The Contractor shall ensure that the
bottom of any excavation is stable. Excavation base stability shall be taken into account by the
Page 34-32
Contractor against heave in any cohesive soils. Remedial measures, such as ground improvement,
may be required to provide stability of the excavation base against heave.
Disposal of dredge materials shall be handled by the Contractor in compliance with the requirements
of the Contract documents. Contaminated materials must be disposed of in special spoil containment
facilities, while uncontaminated materials, if suitable, can be reused for backfill. Materials for reuse
must be stored in areas where excess water can drain away.
34.6.2.3 Foundation Preparation

Once the trench excavation is complete, installation of the foundation shall begin. Two types of
foundations can be used in immersed tunnel construction; continuous bedding, screeded foundation,
or pumped sand; or individual supports.
a. Continuous Bedding
Continuous bedding shall consist of clean, sound, hard durable material with a grading compatible
with the Contract plans and design criteria. These include applied bearing pressure, the method with
which the bedding is placed, and the material onto which the bedding is placed. Foundation
thicknesses shall not be less than 500 mm and preferably less than 1.4 m. Gaps between the
underside of the tunnel and the trench bottom shall be filled with suitable foundation material.
Foundations can be prepared prior to lowering the elements (screeded), or they can be completed
after placing the elements on temporary supports in the trench (pumped sand); foundations formed
after placement shall include sand jetting, sand flow, and grout. For a screeded foundation, the
bedding shall be fine-graded with a screed to the line and grade required for section placement, or
a stone bed may be placed with a computer-controlled tremie pipe (scrading). Settlement analyses
for the immersed tunnel shall be performed by the Contractor and should consider compression of
the foundation course placed beneath the tunnel elements. Analyses shall also be performed to
estimate the longitudinal and transverse differential settlement within each tunnel element, between
adjoining tunnel elements, and at the transitions at the ends of the immersed tunnel. Measures shall
be taken to prevent sharp transitions from soil to rock foundations. Varying the thickness of the
continuous bedding can accomplish this. Alternately the tunnel structure shall be designed to resist
the load affects from the potential differential settlement of the subfoundation material.
b. Individual Supports
Individual supports shall consist of driven piles. Pile foundations shall be designed in accordance
with generally recognised procedures and methods of analysis. The piles shall be designed to fully
support all applied compression, uplift and lateral loads; and any possible down-drag, or negative
friction, loads from compressible soil strata. The load-bearing capacity, foundation settlement, and
lateral displacement shall be evaluated for individual piles and for pile groups, as appropriate. The
load capacity for bearing piles shall be confirmed by static or dynamic pile load testing, in accordance
with recognised standards. Piles and tunnel sections are usually detailed to be adjustable to fine
tune the horizontal and vertical placement of the tunnel. Once the tunnel sections are in their final
potions, the adjustment shall be locked off and a permanent connection between the tunnel and pile
may be made. Spaces between the bottom of the tunnel section and the bottom of the trench below
the tunnel section shall be then filled with granular material. This process must be carefully controlled
so that the bottom of the trench is not disturbed and that the void is completely filled. Since in most
cases, the weight of the tunnel section being placed is less than the weight of the soil it is replacing,
pile foundations are rarely used.
34.6.2.4 Tunnel Element Fabrication

For steel tunnels, fabrication shall be done by modules, each module being in the range of 5 m long,
spanning between diaphragms. Modules shall be then connected and welded together to form the
completed shell of the tunnel element. Electro-slag and electro-gas welding shall not be permitted,
and all groove and butt welds shall be full-penetration welds. Measures need to be taken to eliminate
warping and buckling of steel plates resulting from their local overheating during welding. Welds
must be tested by non-destructive methods; it is recommended that ultrasonic testing be
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supplemented by X-ray, spot-check testing. In some cases, stress relieving may be necessary. Keel
concrete placement shall be done in such a way that it avoids any overstressing or excessive
deflections in the bottom shell and its stiffeners. All length and angular measurements for tolerances
need to be made while the structure is shielded from direct sunlight to eliminate errors due to warping
from differential temperatures.
Concrete tunnel elements shall be constructed in a number of full-width segments to reduce the
effects of shrinkage. Segment joints may consist of construction joints with reinforcement running
through them, or they may be movement joints. All joints must be watertight. Tight controls on casting
and curing must be maintained to minimise cracking. Differential heat of hydration shall be controlled
by the use of high percentages of blast furnace slag to replace Portland cement or by using internal
cooling system. Where concrete segments are cast with movement joints, they shall be joined
together using temporary or permanent post-tensioning to form complete elements at least during
transportation and installation. Care must be taken to ensure that long-term movements of short
segments free to move are acceptable.
Tunnel elements shall be fabricated to be approximately 90 m to 120 m in length, each. Actual length
is a function of the capacity of the fabrication facility; restrictions along the waterway used to float
the elements to the construction site; restrictions at the tunnel, including accommodation of marine
traffic during construction, currents, element shape and the availability of space for an outfitting pier;
and the capacity of the equipment used to lower the elements into place.
All construction hatches and openings shall be sealed by welding or other secure means, upon
completion of concreting or other works for which they were required. Before the launching or floating
of elements, bulkheads, manholes, and doors shall be inspected to ensure that they are secure and
watertight. When no longer needed, any temporary access manholes through the permanent
structure shall be closed and a permanent seal made.
As tunnel elements are installed, the actual installed length of tunnel and position shall be monitored
so that any changes to the overall length of future tunnel elements and the orientation of the end
faces can be adjusted, as required to ensure fit with the actual surveyed positions of installed tunnel
elements. This is especially important prior to fabrication and placement of the closure, or last,
element.
34.6.2.5 Transportation and Handling of Tunnel Elements

Tunnel element stability must be ensured at every stage of construction, especially when afloat. In
checking tunnel elements for stability while floating, the Contractor shall pay due attention to effects
of variations in structural dimensions, including results of thermal and hydrostatic effects. Items to
consider include the following:
• Sufficient freeboard for marine operations, so that tunnel elements are relatively unaffected,
even when waves run over the top. A positive buoyancy margin exceeding 1 percent is
recommended to guard against sinking due to variations in dimensions and the densities of
both tunnel materials and the surrounding water.
• Lateral stability of the element using cross-curves of stability analysis should have a factor of
safety in excess of 1.4 of the area under the righting moment curve against the heeling
moment curve. A positive metacentric height, or static stability, exceeding 200 mm is also
recommended.
When a storm warning is issued, or forecast wave heights are expected to exceed operational limits,
all marine operations shall be ceased temporarily; and marine plant and floating tunnel elements
shall be sent to their designated storm moorings or shelters. It is recommended that an emergency
berth be identified for tunnel elements, preferably within or close to the placement site. Special
measures may be required to control tunnel elements in areas with currents or navigation channels.
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34.6.2.6 Lowering and Placing

After outfitting at their final destination, immersed tunnel elements shall be prepared for immersion
and lowering onto prepared foundations in a trench in the bed. Equipment used may typically be
provided on a purpose-built catamaran straddling the element. Other methods include the placement
of pontoons on top of elements, or cranes have sometimes been used.
To lower an element to its final position, it is usual for either a temporary ballasting system to be
used or for the element weight to be such that the element will itself have sufficient negative
buoyancy. The method of immersion must include the following:
• Maintain stability, including control over the tunnel element, while it is lowered to its final
position.
• Enable the negative buoyancy to be increased as necessary so that a minimum factor of
safety against flotation and overturning of 1.025 is obtained immediately after lowering.
• Enable the negative buoyancy to be increased to give a minimum factor of safety against
flotation and overturning of 1.04 within a few hours of lowering and placing, ignoring
assistance from adjacent elements.
• Maintain a vertical downward load of not less than 500 kN on every temporary seabed
support, if used, until the element is placed on its final foundation.
Calculations for the factor of safety may include items such as external ballast, for example concrete
blocks or internal ballast water tanks.
Lowering equipment shall be designed to enable the lowering operation to be effectively controlled
from a central control point and to make available at the central control accurate information on the
position of the element and the loads on the lowering and the holding lines.
Elements shall be lowered and butted up to preceding elements. Thereafter, the joint between them
shall be dewatered. A typical joint between elements includes watertight bulkheads, like dam plates;
watertight access bulkhead doors; joint seal and gaskets; dewatering equipment, including any
pumps and piping; location devices to guide the element horizontally and vertically into place relative
to the preceding element; provisions for shear keys, both horizontal and vertical; and vertical and
horizontal adjustment devices, such as wedges, jacks, and shims.
Tunnel elements shall be installed at an elevation that considers an allowance for settlement such
that after completion of the foundation works and all backfilling, they will be expected to be located
within a tolerance of 50 mm laterally and vertically from their theoretical location, or any such lower
figure on which the design methods are based. Allowances for settlement included in the
determination of the installation level shall be determined before installation. Notwithstanding the
above, the relative location laterally and vertically shall not be more than 25 mm across any joint.
Relative locations vertically across the terminal joints to other structures shall not exceed 50 mm.
Where foundation pads are used for temporarily supporting tunnel elements, any requirements for
preloading and all subsequent behaviour of the pads shall be determined. Effects of potential hard
spots beneath the tunnel element created by the foundation pads shall be evaluated. Settlement of
the foundation pads shall be measured from the time of installation through any period of preloading
until the tunnel element no longer requires support by the pads.
Permanent survey markers shall be needed within and on top of each element so that at any time
its position relative to its position at time of casting is known. Survey towers or other markers or
systems shall be needed so that the position of the element during lowering and placing is accurately
known.
34.6.2.7 Element Placement

Element placement is the most delicate of all operations involving immersed tunnel elements.
Weather window durations must be defined as well as go and no-go hold points. Where prevailing
currents could affect placing operations, the Contractor shall use a weather-forecasting modelling
Page 34-35
system to forecast the required window; this may require monitoring of the hydrological and
meteorological conditions concurrently to develop a forecasting model. Such a model shall provide
an understanding of the relationship between observed flow and meteorological and hydrological
conditions. The last go and no-go decision shall be based upon the current waves, and other physical
conditions staying below the designed upper limits with a statistical probability of more than 90
percent. In all cases, the actual current at the element position shall be checked immediately before
lowering and continuously observed during the lowering and placing operation.
Elements shall have sufficient negative buoyancy to maintain stability and control of the tunnel
element during immersion, so that the element can be lowered safely to its final position. Design
shall enable the negative buoyancy to be increased, if required, to give the minimum factors of safety
given in Article 34.6.2.1.
Valves for dewatering of immersed joints shall be operated from inside the previously placed tunnel
element. No watertight doors or hatches shall be opened until it can be confirmed that there is no
water on the other side. Access must be maintained to the inside of the first element that is placed
from the time when the element is placed until completion of permanent access through one of the
terminal joints. Where hydrostatic pressure exists on a temporary bulkhead, the next two bulkheads
shall remain in place — with one at the remote end of the same element, and the immediately
adjacent one in the next tunnel element. Watertight doors in these bulkheads shall remain closed at
all times when the last tunnel element is unoccupied by personnel. Watertight doors shall not be
opened until the absence of water on the far side has been confirmed. Stability of the installed
immersed tunnel elements during removal of temporary ballast and joint dewatering must be
controlled to ensure that necessary factors of safety are maintained for the element as a whole, not
only for the ends and for the sides, and so that the bearing pressure on the foundation remains
approximately uniform.
After lowering and initial joining of each immersed tunnel element, its position shall be precisely
surveyed before the next element is placed. Settlement monitoring of tunnel elements shall be
carried out using the survey markers installed inside the elements. Levels shall be recorded weekly
until completion of backfilling of the subsequent element to ensure no remedial action is required
and monthly thereafter until settlement becomes negligible.
34.6.2.8 Backfilling
The Contractor shall take into account the suitability of excavated material for use as backfill and
shall ensure that backfill placed next to the immersed tunnel is placed uniformly on both sides of the
structure to avoid imbalanced lateral loads. Maximum differences in backfill levels outside such
structures above the locking fill shall be 1 m until the lower side has been filled to its final level.
Elements with more than 1 m difference in backfill level shall be designed to accommodate the
resulting transverse loads.
All fill materials subject to waves and currents shall be of appropriate size and type to prevent scour
and erosion. All underwater filling and rock protection material shall be placed in a way that avoids
damage to the waterproofing membranes, if present, or to the structure from impact or abrasion.
Materials shall be placed in even layers on either side of the tunnel to avoid unequal horizontal
pressures on the structures, and shall be placed by means of buckets or tremie.
Prior to, and during the placing of fill, the trench shall be checked for sediment, which shall be
removed if determined to be detrimental to the performance of the material being placed.
Backfill shall be provided around the tunnel. In seismic areas, where there is a risk of liquefaction,
the foundation and backfill shall be constructed as free-draining to prevent the development of
excess pore-water pressure during and following a seismic event. Armour protection, if needed, shall
be provided to prevent long-term loss of backfill at the sides and on top of the tunnel.
Backfill shall consist of the following:
• Selected locking fill to secure the elements laterally.
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• General backfill to the sides and top of the tunnel structure, also providing an impact-
absorbing/load-spreading layer above the tunnel.
• A rock protection blanket generally above and adjacent to the tunnel to provide scour
protection.
• Rock-fill, anchor-release bands at both sides of the tunnel if required.
34.6.2.9 Locking Fill

Selected locking fill shall be placed in the trench to a minimum level of half the height of each element
after the joint to the adjacent tunnel has been dewatered. Locking fill shall extend at least 2 m
horizontally from the tunnel element before being allowed to slope down not steeper than 1:2.
Locking backfill shall be placed in layers of uniform thickness not exceeding 600 mm, such that
lateral and vertical forces on the tunnel element are minimised and no displacement of the element
occurs. Placement of locking backfill shall proceed from the inboard, or jointed, end of tunnel
elements and shall progress towards the outboard end of tunnel elements in a manner that produces
a uniformly dense backfill bearing tightly against the tunnel periphery.
Locking fill must be a granular, clean, sound, hard, durable material that will compact naturally and
that will remain stable under both nonseismic and seismic conditions, where required. It may include
crushed, sound rock or gravel. Well-graded, sub-angular sand may be included. Sand fill, if used,
must be free-draining.
34.6.2.10 General Backfill

General backfill shall be used to fill the remainder of the trench above the selected locking fill to the
underside of any protection layer, or to the pre-existing seabed level — if no protection layer is used.
General backfill shall be placed by a method that avoids segregation or misplacement of the fill.
Properties of general fill must suit the proposed design and method of placing. General fill may
comprise soft cohesionless material that will remain stable. General fill must be free from clay balls
and be chemically inert. Often the dredged materials for the trench are suitable as general backfill.
34.6.2.11 Protection Blanket

Elevations of the top of the protection layer shall approximate pre-existing seabed levels unless
instructed otherwise; however, in certain situations, the top of the tunnel can extend above the
original seabed in an underwater embankment — if permitted. In this situation, the protective blanket
shall be provided above the embankment backfill.
Rock protection blanket material shall consist of hard inert material, usually sound, dense, newly
quarried rock in clean angular pieces, well graded between 25 mm to 250 mm. These materials shall
be durable for at least the design life of the tunnel. Methods of placing this material must ensure that
the large-size stones do not penetrate the general backfill and must cause no damage to
waterproofing of the tunnel, if used. Protection layers shall not be placed by bottom dumping.
34.6.2.12 Anchor Release Protection

In navigable waters, anchor release protection shall be provided, if required, and if the tunnel cover
extends above the bed. Rock armour for anchor release bands shall be of sound, dense, newly
quarried rock in clean angular pieces and well graded. The intent of the anchor release protection is
to bring the anchor to the surface and choke the gape, or the space between the hook and the shank.
Anchor sizes shall be for vessels plying those waters. These material needs to be durable for at least
the design life of the tunnel.
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34.6.3 Water Tightness and Joints between Elements

34.6.3.1 External Waterproofing of Tunnels
External waterproofing for tunnel elements shall be considered for both steel tunnels and concrete
tunnels. This waterproofing shall envelop every part of the element exposed to soil or water with
materials impervious to the surrounding waters. For steel tunnels, the outer steel membrane shall
act as waterproofing membrane, while for concrete elements either steel or synthetic membrane
shall be used. For steel waterproofing membranes used on either concrete or steel elements, an
appropriate corrosion protection and monitoring system shall be used to ensure that the minimum
design thickness is maintained during the life of the facility or an added sacrificial thickness shall be
provided. Non-structural steel membranes shall measure no less than 6 mm thick.
Membranes shall be watertight and the materials used for concrete elements shall include two coats
of a spray-applied elasticised epoxy material; steel plates; and flexible PVC waterproofing sheet.
Minimum thickness shall be no less than 2.0 mm, and anchored to the concrete using T-shaped ribs.
Waterproofing system materials shall have a proven resistance to the specific corrosive qualities of
the surrounding waters and soils. The materials of the system shall be flexible and strong enough to
span any cracks that may develop during the life of the structure. Bituminous membranes shall not
be used. Waterproofing systems shall adhere at every point to the surfaces to which they are applied
so that, if perforated at any one location, water may not travel under it to another. Areas of free water
flow between the membrane and the underlying concrete shall be limited to no more than 10 m 2, in
case of leakage. For a steel tunnel, the membrane could be the external steel shell, provided that
an adequate corrosion protection is provided either by cathodic protection or additional sacrificial
thickness. Steel plates shall be joined using continuous butt welds. All welds shall be inspected and
tested for soundness and tested for water tightness. Notwithstanding the provision of a membrane,
the underlying structural concrete shall be designed to be watertight.
Depending upon the type of waterproofing used, it may require protection on the sides and top of
the tunnel elements to ensure that it remains undamaged during all operations up to final placement
and during subsequent backfilling operations.
34.6.3.2 Joints
Joints between immersed tunnel elements shall be classified as follows:
a. Immersion Joint (or Typical Joint)
Immersion joints are the joints formed when a tunnel section is joined to a section that is already in
place on the seabed. After placing the new element, and joining it with the previously placed element,
the space between the bulkheads, or dam plates, of the two adjoining elements shall be then
dewatered. To dewater this space, a watertight seal must be made. A temporary gasket with a soft
nose, such as the Gina gasket, shall be used. Additionally, an omega seal or equivalent shall be
provided after dewatering the joint from inside the joint.
Figure 34-1: Gina-Type Seal
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Figure 34-2: Omega-Type Seal

For immersion joints, the primary compression or immersion seal shall consist of natural or neoprene
rubber compounds. Cross sections used shall be the Gina type or equivalent. This consists of a main
body with designed load/compression characteristics and an integral nose and seating ridge. These
materials shall have a proven resistance to the specific corrosive qualities of the water and soils and
an expected life no shorter than the design life of the tunnel unless the gasket is considered
temporary. For flexible joints, a secondary seal shall be required in case of failure of the primary
seal. It shall be manufactured from chloroprene rubber to an overall cross section corresponding to
that known as an Omega-type, the materials shall have proven resistance against the specific
corrosive qualities of the water and soils, oil, fungi and micro-organisms, oxygen, ozone, and heat.
It is essential that immediately after dewatering the chamber between the two bulkheads that an
inspection of the primary seal is made so that any lack of water tightness can be remedied. Similarly,
the secondary seal of a flexible joint shall be pressure tested up to the expected maximum service
pressure via a test pipe and valve to ensure that it too can function as required; after a successful
testing, the chamber between the seals shall be de-watered.
b. Closure or Final Joint
Where the last element has to be inserted between previously placed elements, rather than
appended to the end of the previous element, a marginal gap will exist at the secondary end. This
short length of tunnel shall be completed as cast-in-place, and is known as the closure or final joint.
Forms of the closure or end joint shall be dependent on the sequence and method of construction.
Closure joints may also be immersion joints, although details may need to be different. Potential
options for the closure joints include the following:
• Place the last element between two previously placed elements and dewater one joint
between the newly placed element and the one of the previously placed elements. Then
insert under water closure form plates and place tremie concrete around the closure joint to
seal it. This joint can then be dewatered and interior concrete can be completed from within
the joint. Other methods, such as telescopic extension and wedge joints, have been
developed to make the closure joint similar to the immersion joint.
• Construct end, or terminal, joints first; lay the tunnel elements outwards from these and
complete the immersed tunnel with a special closure, or final, joints.
• Construct one terminal joint first and lay all the immersed tunnel elements outwards from that
side and backfill over the top of the final element, using a soil-cement mixture — or other
reasonably watertight material — in the vicinity of the second terminal joint. Construct the
structures abutting the second terminal joint after the immersed tunnel is complete.
• Lay and complete the immersed tunnel with or without a special closure joint and backfill at
the terminal elements using a soil-cement mixture, or other reasonably watertight material,
in the vicinity of both terminal joints. Construct the structures abutting the both terminal joints
after the immersed tunnel is complete.
c. Earthquake Joint
This shall be an immersion joint of special design to accommodate large differential movements in
any direction due to a seismic event. It shall also apply to a semi-rigid or flexible joint strengthened
to carry seismic loads and across which stressed or unstressed prestressing components may be
installed.
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d. Segment or Dilatation Joint

Moveable segment joints must be able to transmit shear across the joint, allowing dilatation and
rotation. Joints shall contain an injectable, rubber-metal waterstop — as well as neoprene and
hydrophilic seals.
34.6.3.3 Design of Joints between Elements

All immersed tunnel joints must be watertight throughout the design life, and must accommodate
expected movements caused by differences in temperature, creep, settlement, earthquake motions,
and method of construction. Displacements in any direction shall be limited so that the waterproof
limits of a joint are not exceeded. Joint shear capability shall take into account the influence of normal
forces and bending moments on the shear capacity of the section; the design shall take account of
shear forces generated where the faces of the joints are not normal to the tunnel axis. Joints must
be ductile in addition to accommodating longitudinal movements. Tension ties may be used to limit
movement so that joints do not leak or break open, especially during a seismic event.
Axial compressions of tunnel elements and bulkheads due to depth of immersion shall be taken into
account in determining joint dimensions at installation.
Primary flexible seals at tunnel joints must be designed to take into account the maximum deviations
of the supporting frames relative to their theoretical location, the maximum deviation of the planes of
the frames, and any relaxation of the seal. Seals are required to have a minimum compression of 10
mm greater than the compression required to maintain a seal. Just in case an initial seal is not
obtained after immersion and joining, it may be advisable in some cases for the immersion joint to
be designed so that a backup method of obtaining an initial seal is available.
For flexible joints, a secondary seal, or Omega–type seal, capable of carrying the full water pressure
shall be fitted across the inside of the joint and shall be capable of being inspected, maintained, and
replaced. Seals shall be capable of absorbing the long-term movements of the joint and secondary
seals shall be provided with a protective barrier against damage from within the tunnel. All joints in
the tunnel shall be finished to present a smooth surface.
Metal hardware in joints shall have a design life adequate to fulfil its purpose throughout the design
life of the joint. Nuts and bolts for primary and secondary seals shall be stainless steel. Plate
connections between elements shall be corrosion-protected to ensure that the design life is obtained.
Mounting procedures or mounting surfaces for the primary seal of immersion joints must allow for
fine adjusting and trimming of the seal alignment to compensate for construction tolerances. Gaskets
shall be protected from accidental damage until the time of immersion. All embedded parts; fixings,
including the bolts and their corrosion protection system; mating faces; clamping bars; and other
fixings must have a design life at least equal to that of the tunnel structure. Where clamping bars
and other fixings are used for the secondary seal, these need to have a design life at least equal to
that of the secondary seal. Gasket assemblies shall have provision for injection in case of leakage.
34.7 Tunnel Construction Engineering

34.7.1 Introduction
This work shall consist of mined/bored tunnel construction engineering; the engineering that must
go into the road tunnel Project to make it constructible.
Construction operations shall be guided by people experienced in the actual construction of these
underground works so that the Project is constructible. Schedules must be realistic and reflect all
the restrictions that are imposed on the Project, whether they are physical, political, or from a third
party.
Tunnels are long linear undertakings with few opportunities to perform the work at more than one
location. Tunnels are also a series of repetitive operations, each of which usually must be finished
before the next can be started.
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This uniqueness and the linear, repetitive nature of the work must be understood by the Contractor
to control and manage the Project to a successful conclusion.
Perhaps the most significant factor impacting schedule is the type of geologic material that the tunnel
will be mined through and the amount of ground and surface water that will be encountered or
crossed. Tunnels are mined through rock, soil, or a combination of both. The geology encountered
determines the tunnelling methods that will be used, the speed that the tunnel can be constructed,
and the types of specialised equipment that are required.
Geologic material can also present some unique health and safety concerns that must be accounted
for in the construction of road tunnels. Gas, petroleum, contamination, voids in the ground, hot water,
or large quantities of groundwater all pose safety concerns that must be addresses so that the
workers building the tunnels are provided an environment free of hazards.
Of similar importance to the tunnelling methods and hours of operation are the communities that the
tunnel will pass under, the locations of the major work shafts or portals from which the work will be
serviced and the streets through which the equipment, personnel and material will get to and from
the worksite as well as how the muck removed from the tunnel is disposed of.
All of these factors will have impacts on the schedule of road tunnels, and in fact, represent risks to
the Project. The Contractor shall acknowledge, allocate, and mitigate these risks. Dealing with these
risks shall be accomplished by the Contractor complying with the requirements of the Contract
documents.
34.7.2 Construction Staging and Sequencing

34.7.2.1 Construction Staging
The mined/bored tunnel construction Project requires land area to set up the Contractor's offices,
shops storage yards, muck storage piles, electrical substations, and many other space needs. It
therefore is logical that the more space that can be made available to the Contractor to locate needed
structures, store needed materials, and allow for the movement of materials and equipment into and
out of the worksite, the more efficient the operation will be. Property shall be acquired by the Owner
to provide the Contractor with adequate space for efficient operation.
The mined/bored tunnel construction Project serviced by shafts require room to excavate the shaft.
There shall be room all around the shaft to allow equipment access and easy flow of the work around
the shaft location. Adequate property shall be acquired by the Owner to locate the shaft for efficient
operation.
34.7.2.2 Construction Sequencing

Underground construction shall be a series of individual activities that must be completed before the
subsequent activities can start. This series of unique activities is then repeated and repeated until
the operation is complete. For tunnels that employ drilling and blasting to create the tunnel opening
the series shall be drill, load, shoot, muck, and support. Each round shall be drilled a certain length
or depth using a pre-engineered drill pattern. Once the drilling is done, the explosives shall be loaded
into the drill holes and wired up. Equipment and crews shall be then pulled back a safe distance from
the loaded face and the blast shall be shot. Exhaust gasses produced by the explosives shall be
removed from the face and fresh air shall be sent to the heading area. After around 30 minutes, the
crew shall be brought back into the area to scale or knock down any loose rock and remove the
excavated material or muck. Once the muck is removed, the initial tunnel support shall be installed
to make the excavated opening stable and safe for the crew to work under. The cycle will be complete
and the tunnel has been advanced some distance. When all of these activities have been completed,
the Contractor shall then start the next round.
In TBM excavated tunnels, there shall be a defined sequence of activities needed to advance the
heading. The TBM shall complete this series much faster than in drill-and-blast tunnels, but the
elements remain similar. TBMs shall cut into the rock or earth a certain distance at the same time
the muck is removed by conveyor to either waiting muck cars or to a continuous horizontal conveyor,
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so the TBM can combine these two operations thereby saving time and speeding up the tunnel
progress. After the end of the TBM's stroke, when the hydraulic pistons used to push the TBM cutting
head into the rock have a defined length, the excavation shall be stopped and the TBM readied to
start the next excavation cycle. While this is happening, the length of tunnel that has just been
exposed must be supported to provide a stable and safe opening. TBMs shall be configured to
perform this support function concurrently with the excavation sequence, depending on the size of
the tunnel opening, the type of ground being excavated, and the design of the machine. This
operation must be done before the next excavation cycle can begin.
Tunnels shall be stabilised for long-term use by placing an internal final concrete liner. This operation
shall contain a series of individual steps that must be completed in sequence before the next length
of tunnel can be lined.
34.7.3 Mucking and Disposal

Muck is the industry term for excavated material produced during the advancement of the tunnel. All
tunnel mining produces muck. This excavated material must be removed from the working face of
the tunnel so that the next advance can be made. Once the muck is produced, it must be removed
from the tunnel and finally disposed of in a legal manner or used as fill for some portion of the tunnel
Project or other project where it could have a beneficial use.
Muck is actually a broken-down state of the in situ material through which the tunnel is driven.
Because the natural material is disturbed by either blasting, cut with a TBM or road-header, or cut
out with a bucket excavator, the volume of muck removed actually is larger than the natural bank
material. This swell is usually approximated as 70 percent to 100 percent more in rock and 25 percent
to 40 percent for soil.
Excavated material must be removed from the tunnel. Methods chosen to remove this material
depends on many factors, such as the diameter or size of the excavation, the length of the tunnel
excavated from any given heading, the material being moved, the grade of the tunnel being driven,
and whether the material is going to a shaft for removal or a portal. Horizontal conveyor belts shall
be used for large excavated tunnels that are longer than a few thousand meters and are excavated
by a TBM. Conveyors shall move a large quantity of material quickly. Conveyors require that the
excavated material be of relatively uniform small size so that it will sit in the belt during the transfer
to the shaft or portal. Conveyors can be used with a drill-and-blast excavation method if the
Contractor employs a crusher to make the drill-and-blast rock a more even and smaller consistency.
This crushing is necessary to ensure that the material sits nicely on the belt, is small enough that
when it is loaded onto the belt it does not damage or rip the belt material. Conveyors shall be limited
to a grade, or slope, less than 18 degrees to successfully transport muck. Conveyors shall transport
rock or soil, which must not be too wet — or it will not transport well. Conveyors can also be used in
tunnels where there are curves in the alignment but this requires some special care and equipment.
Material that is too wet to carry on a conveyor belt shall be pumped out of the tunnel through a
pipeline from the TBM to the shaft or portal. This method shall be used on soft-ground tunnels where
the material is clay-like or where sufficient water — and often, conditioners — is mixed with the
excavated material to make it slurry like.
For smaller tunnels excavated by a TBM, the Contractor shall choose to load the excavated muck
into rail cars and haul it out of the tunnel using locomotives. Rail haulage also has some limitations,
such as the grades are usually limited to less than 4 percent, a great amount of rolling stock is
required, and great care must be paid to maintaining the track.
Once the muck arrives at the shaft or portal, it must be off-loaded and then disposed. The shaft shall
be a vertical hole through which all excavated material must be lifted and removed and through
which all material required for the tunnelling operations must be lowered to the tunnel level.
Additionally, all personnel working on — or inspecting — the tunnel must come in and out of this
shaft. There are many ways to transport the muck up the shaft. Muck cars shall be lifted one by one
up the shaft, dumped in a pile on the surface, and lowered back down to the tunnel. Muck cars can
be dumped into a hopper at the bottom of the shaft and then loaded into a bucket that is hoisted to
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the top and dumped or the muck from the hopper could be loaded onto a vertical conveyor and
conveyed to the top of the shaft and dumped onto a pile or hopper. Similarly, the muck can be
pumped to the surface and deposited on a horizontal conveyor, a stockpile, or run through a
processing plant to remove the water and the residual dumped on a pile or into hoppers.
Portals shall provide easier access to a tunnel since they eliminate the bottleneck that the shaft
imposes. Muck is easier to remove at a portal because the track can be placed on the ground or on
an elevated trestle so that muck cars can be pulled outside to dump their loads onto a muck pile.
Any disruption in the muck removal operation will delay the start of the next round or the next
advance. If the Contractor cannot get rid of the muck, it cannot produce more. This is also true once
the muck reaches the surface. There shall be a place to store the muck that is brought out of the
tunnel until it can be loaded into trucks or rail cars and hauled away. Without this storage capability
on the surface, all muck brought out of the tunnel must immediately be loaded into surface trucks or
rail cars for disposal. If there is a holdup in the surface trucking or rail cars then no more muck can
be brought out and the tunnel advance must stop. This situation is called being muck-bound and
must be avoided at all costs. The more muck storage that is available, the more unlikely it will be for
the Project to become muck-bound. Worksites must be large enough to provide this storage cushion,
the larger a worksite the bigger the cushion. Special care must be taken to ensure a steady stream
of vehicles to remove the muck as it is produced, and to deliver workers and materials — as needed.
Thought must also be given to the hours of operation allowed in the tunnel Project. If the hours of
operation for surface work are restricted, such as if surface work is not allowed after 10 p.m., then
to operate the tunnel 24 hours per day, there must be some place to store muck underground, and
construction noises must be kept below a threshold based on local ordinances and/or certain realistic
decibel levels.
34.7.4 Health and Safety

Construction engineering and safety shall go hand-in-hand. Underground construction is inherently
a dangerous undertaking. Work goes on in a noisy environment, in close quarters often with moving
heavy machinery. Careful attention must be paid to the layout of the worksites; workers must be
protected at all times. The overriding philosophy must be that, “everyone goes home safely at the
end of their shift.”
Every step of the operation shall be planned with safety in mind. Normal surface safety concerns are
also appropriate for underground construction. Workers must be safeguarded from falling off the
work platforms used in the mining process. Workers must be protected from being struck by the
moving equipment used throughout the mining process. Workers must be protected from being
electrocuted; however, there are also many additional hazards that workers must be protected from
and guarded against.
Work underground involves mining through rock or soil or a combination of both. To excavate the
opening required for the tunnel the natural properties of the ground are disturbed. The ground is
usually not a homogeneous mass but has been subjected to massive forces of nature and has been
altered. Once the opening has been excavated it must be supported in order for the workers to be
protected from falling material, collapse or other deterioration of the tunnel roof or crown. So, it is the
job of the Contractor to plan on making the tunnel opening stable to allow workers to move freely
and without concern of falling material.
Because tunnels are by definition below the surface, lighting of the workspace is an important part
of underground safety. OSHA has regulations governing all elements of working underground and
the Contractor must be familiar with them all. There are required levels of lighting for the actual work
locations as well as the previously excavated openings. It is important to remember that the tunnels
are long linear work places. As the tunnels are advanced more and more safety plant must be added
along with the productive support elements.
One of the more challenging aspects of tunnel safety is the fact that workers must be constantly
supplied with high quality breathable air. Again OSHA is specific in its requirements. Each person
underground must be supplied with 5.66 m3 per minute of air. Additionally, much of the equipment
Page 34-43
underground shall be powered by internal combustion engines. Diesel fuel is the only fuel allowed
underground. OSHA also has specific requirements for the equipment and for the amount of air that
must be delivered to the underground for each and every piece of diesel equipment working
underground. This diesel air requirement is in addition to the requirement for each and every person
underground. Tunnel atmosphere quality must be tested on a regular schedule to ensure that
sufficient quantities of oxygen are present and that concentrations of undesirable gasses and by-
products of the internal combustion engines are controlled to acceptable levels.
Also tests must be performed on a regular basin to ensure that the air movement across the
excavated cross section is no less that 10 m per minute.
If this is not enough, Mother Nature can often provide challenges to the safety of workers
underground. There can be gasses underground that can seep into the tunnel opening after the
excavation operation. These gasses can be poisonous, like hydrogen sulphide, or explosive like
methane. Whenever these gasses are present, or suspected to be present, the Contractor has
additional OSHA requirements to be aware of and to follow. Extra ventilation will be required, in
addition to the air needed for both people and diesel equipment and the required quantity can be
substantial. Whenever these gasses are suspected, there are extra requirements for continuous
monitoring of the atmosphere with automatic shutdown of equipment should the gasses be detected
in concentrations higher than allowed.
Water entering the tunnel opening is also a safety issue. Most tunnels are excavated below the water
table, therefore, the opening acts like a big drain and any water running through the rock or contained
in the soil tends to collect in the tunnel. Water running through the tunnel bottom or invert can cause
several potential safety issues. Tunnels can be accessed by one or more shafts, by a combination
of shafts and portal or from a portal alone. It is desirable to drive tunnels uphill so that any water that
seeps into the excavated opening flows away from the working face by gravity. This water shall be
allowed to run in a ditch located at the side of the tunnel invert. Care must be taken that workers do
not step into or fall into this ditch. The higher the inflow of water into the tunnel the greater the
problem of safely conveying it back along the tunnel and finally out the shaft or portal.
Tunnels that are driven down hill have the problem that water flows to and accumulates at the
working face. This collected water must be removed from the work area by pumping. The water is
pumped through a pipe at the side of the excavation. This pipe must extend all the way to the shaft
or portal where it can be removed from the tunnel. Water can also enter the tunnel in sudden large
flows. These can be dangerous occurrences and any tunnel where this is a possibility extra care
must be taken in the planning for worker safety. Tunnels under bodies of water are of particular
concern for this risk of sudden large inflows of water.
Fires in tunnels are especially dangerous and can lead to extensive damage and risk to a worker's
safety and life. Awareness of this potential danger shall be the responsibility of the Contractor, which
shall plan to mitigate the risk at every stage of the Project. Most tunnels are driven from one point to
another from a single point of entry, which is what makes tunnel fires so dangerous and concerning.
The tunnel environment contains numerous potential sources of fire. Equipment can malfunction and
catch fire. Workers using welding or burning torches can set off a fire. Leaking hydraulic fluid or fuel
from equipment can be ignited by a stray spark or discarded cigarette. Conveyor belts used to
transport muck can build up heat from rubbing on or over something and ignite. All of these possible
fire risks, and more, must be addressed by the Contractor to minimise the possibility of a fire or to
minimise the potential damage and injuries resulting from a fire. Only retardant material and hydraulic
fluid shall be allowed on any underground equipment or material. Fire suppression systems shall be
required for all underground equipment, conveyor belt motors, and storage magazines. Vertical muck
removal belts shall be equipped with deluge water systems to dump large quantities of water on any
belt fire event.
Of equal importance in dealing with tunnel fires is how to provide for the safety of the workers
underground. This can be accomplished in several ways. Rescue chambers, where workers can
take refuge in a fire, shall be fully equipped, and supplied with independent air supplies; and
insulation shall be deployed along the tunnel as the tunnel is advanced. Of equal importance, the
Page 34-44
tunnel can be planned with intermediate access points that can be fully equipped to be able to
remove workers from the tunnel, when the tunnel has been excavated past these locations.
34.7.5 Schedule
The importance of the development and use of a realistic schedule for all phases of the Project
cannot be overemphasised. It is critical for the Contractor to understand the relationships among all
the activities that go into the Project, as well as the needs and interests of all those who are affected
by the construction, testing, and commissioning of the work. With this understanding, the Project can
go forth in an orderly, predictable manner, which in the end benefits everyone.
The schedule is the road map of how the Project progresses through all the necessary steps. It is
required that a comprehensive schedule be developed by the Contractor during the early stage of
the Project. During this early stage, the Project must be assigned to each and every component such
as construction, testing, commissioning, start up, and any activity or phase that is important to the
Owner. As the Project develops, and more of the actual work and restrictions are known, the
schedule must be re-evaluated and updated to reflect this new knowledge. The schedule
development shall be a living process that is used and revised constantly to be of maximum benefit
to the Project.
Realistic time needed to accomplish all aspects of the Project must finally be reflected in the
schedule. It makes no sense to handicap the tool, or schedule, or the process by introducing artificial
or incorrect restrictions or by putting unrealistic expectations into the schedule. In fact, these
restrictions and incorrect assumptions always create problems later in the Project, usually in the form
of delays, claims, and higher costs. There can be a positive case made for the Owner to actually
build some float time into the schedule, if possible, so that there is some way to cushion the effects
of unknown occurrences that could impact the Project schedule.
Unrealistic schedules sometime might result from external forces, such as the desire to have the
Project completed in time for an upcoming event. These external forces always need to be
acknowledged and addressed on a case-by-case basis. They can wreak havoc on the schedule, but
they must be taken seriously. It shall be noted that throughout the Project's life, its schedule will be
at the mercy of these external forces. Having said this, the best, and only, way to begin the Project
is with a realistic, well-thought-out schedule. This will reduce the risk that the Owner will be called
on to defend an inaccurate timeline necessary to complete the Project. It is important for the
Contractor to remember that the schedule numbers that are initially released to the public and the
Owner are the same numbers the Contractor will have to live with and defend throughout the
Project's life. It is much easier if these schedules are reasonable and defendable, backed by
professional experience and industry standards.
Having realistic schedules produces a win-win situation for both the Owner, as well as the Contractor,
by eliminating or at least minimising the conflicts that can occur on the Project.
The schedule shall divide the work into discrete activities each with an amount of time needed for
completion. Each activity shall be quantified with the important items of work such as linear meters
of tunnel or cubic meters of concrete. Production rates shall be then applied to these activities and
quantities. These discrete activities can then be combined in sequences that depict the way the
Contractor anticipates the work to be constructed. These sequences can be linear or overlapping;
but at the end, a roadmap of all the elements of the Project shall be developed, how they fit together
and how long the Project is expected to take.
Page 34-45
INDEX
gas lines, 11
adverse effects, 10 Geologic mapping, 7
angular distortion, 22 Geotechnical instrumentation, 7, 8
Architectural Damage, 21 gripper, 14
baseline conditions, 7 ground characterization, 7
boom, 15 ground conditions, 6, 7, 8, 9, 15, 21, 24, 26
bored, 5, 37, 38 ground improvement, 23, 31
bulkheads, 28, 30, 32, 33, 35, 36, 37 groundwater conditions, 7, 8
calculations, 6 groundwater control measures, 9
cathodic protection, 29, 35 Groundwater depression, 20
chemical treatments, 11 groundwater table, 7, 10
circular, 6, 15, 21, 29 grouting, 11, 18, 21, 23, 24, 25, 26, 27, 28
communication, 7, 11 handling, 6, 28
condition survey, 12 hazards, 8, 37, 39
construction method, 6 heave, 10, 27, 31
Contaminated materials, 31 high voltage cables, 11
curing, 6, 30, 32 horseshoe, 6, 15
curvilinear, 6 hydrophilic seals, 37
cut-and-cover, 5, 6, 9, 10, 11 immersed, 5, 6, 28, 29, 30, 31, 32, 33, 34, 35,
cutterhead, 14, 15 36, 37
deformation, 8 Immersion joints, 35
Design, 5, 6, 9, 10, 11, 17, 24, 25, 27, 33, 37 Impervious retaining walls, 10
dewatering system, 10, 11 improvised floodable basins, 28
differential pressure, 11 initial draft, 29
dilatation, 37 initial support, 6, 7, 16
displacements, 8, 17 injectable, 37
double-shell tunnel element, 29 installation, 6, 7, 9, 15, 16, 17, 18, 24, 27, 31,
dredge materials, 31 32, 33, 37
drill-and-blast, 6, 7, 15, 38, 39 installation system, 6
dynamic compaction, 24 Internal diaphragms, 29
environmental disturbance, 28 internal finish, 6
environmental impacts, 10 jacked-box tunnelling, 6
Environmental testing, 7 laboratory testing, 7, 26
equipment, 5, 6, 8, 9, 11, 12, 13, 14, 15, 16, Lateral stability, 32
18, 25, 27, 31, 32, 33, 37, 38, 39, 40 Lattice girders, 16, 17
excavation support systems, 8, 9 lighting, 7, 40
existing structures, 7, 8, 10 lining, 6, 7, 8, 12, 14, 15, 16, 18, 19, 23
explosives, 12, 13, 14, 38 locking fill, 30, 34
External waterproofing, 35 Longitudinal joints, 27
fabrication, 6, 28, 29, 30, 32 Lost ground, 20
factor of safety, 22, 31, 32, 33 marine operations, 32
Falsework, 5 micropiles, 24
fault zones, 18 mined, 5, 24, 37, 38
fibber optic lines, 11 monitoring, 7, 10, 16, 33, 34, 35, 40
fill materials, 34 Muck, 38, 39
finishing, 6 New Austrian Tunnelling Method, 6, 15
fire-life safety, 7 non-shrink, 29
Fires, 40 observation wells, 7
flexible support systems, 9 oil separators, 11
forms, 5, 18 Perimeter Control, 13
freezing, 11, 19, 26 permeability, 10, 25, 26
Functional Damage, 21 Permeation grouting, 24
Page 34-46
piezometers, 7 steel tunnel liner plates, 27

Pilot tunnels, 7, 8, 18 Structural Damage, 22
placing, 6, 28, 30, 31, 33, 34, 35, 38 subsurface investigations, 7
portals, 5, 6, 24, 38 surface blasting, 13
power, 11, 14 Test pits, 7
precast concrete plates, 27 traffic operation and control, 7
precast segments, 18 treatment, 11, 23, 24
Precautions, 10 trench stability, 28
Pre-injection, 14 Tunnel blasting, 13
probing, 8 tunnel boring machine, 6
protection, 6, 7, 8, 12, 17, 29, 31, 34, 35, 37 unanticipated conditions, 7
pumped wells, 10 uncontrollable variables, 14
rectangular, 6, 29 utilities, 7, 9, 11, 12, 26
re-injecting, 22 ventilation, 7, 9, 14, 18, 40
ribs and lagging, 17 vertical downward load, 33
rigid systems, 9 vibrations, 8
risk assessment, 22 vibro compaction techniques, 24
risks, 7, 8, 29, 38, 40 Walls, 7, 9
road traffic, 11 water, 7, 8, 9, 10, 11, 14, 15, 18, 19, 20, 22,
rock, 5, 6, 7, 8, 12, 13, 14, 15, 16, 17, 18, 19, 24, 25, 26, 28, 29, 30, 31, 32, 33, 34, 35, 36,
20, 30, 31, 34, 35, 37, 38, 39, 40 37, 39, 40
Rock bolts, 17 water pressures, 8, 18
Rock dowels, 17 water tightness, 35
rock mass, 13, 17 waterstop, 37
rock protection blanket, 34 wheel, 15
Rock reinforcement, 6, 14, 16
rotation, 37
Round length, 15
safe limit, 22
samples, 7, 26
Sampling, 5
sandwich construction, 29
schedule, 37, 38, 40, 41
Sealed buckets, 30
secant pile, 10
segment, 14, 18, 30, 37
seismic loads, 36
self-consolidating, 29
Sequential Excavation Method, 6, 15
settlement, 8, 9, 10, 11, 20, 21, 22, 27, 31, 33,
34, 37
Settling basins, 11
sewer, 11
Shield, 14, 20
shield tunnelling, 20
shotcrete, 6, 15, 16, 17
single-shell immersed tunnels, 29
slurry walls, 10, 11
soft ground, 5, 6, 15, 19, 20, 25
Soil dowelling, 24
Soil movement, 9
Soil nails, 24
soldier piles, 11
spalling, 6
stabilization, 12, 23
steel interlocking sheeting, 10
Page 34-47
PART 2
ROAD STRUCTURES
CHAPTER 35 - BRIDGE AND UNDERPASS LOAD

TESTING
DOCUMENT NO: TR-

FIRST EDITION
JANUARY 2018
Chapter 35: Bridge and Underpass Load Testing

TABLE OF CONTENTS
List of Tables .................................................................................................................................. ii
35 Bridge and Underpass Load Testing ............................................................................... 35-1
35.1 Objectives .................................................................................................................... 35-1
35.3 Definitions .................................................................................................................... 35-1
35.4 Static Load Testing of Bridges ..................................................................................... 35-1
35.4.1 General Guidelines ............................................................................................... 35-1
35.4.2 Calculations Required before Load Testing .......................................................... 35-2
35.4.3 Load Testing Procedures ...................................................................................... 35-2
35.4.4 Static Load Testing Method Statement ................................................................. 35-3
35.4.5 Required Loading and Monitoring for Static Load Testing ..................................... 35-3
35.4.5.1 Monitoring Type A.......................................................................................... 35-4
35.4.5.2 Monitoring Type B.......................................................................................... 35-4
35.4.6 Static Load Testing Analysis Report ..................................................................... 35-4
35.5 Static Load Testing of Underpasses ............................................................................ 35-5
Index .......................................................................................................................................... 35-6
Page i
CHAPTER 35: BRIDGE AND UNDERPASS LOAD TESTING First Edition -January 2018
LIST OF TABLES
Table 35-1: Static Load Test - Load arrangement and required monitoring ................................ 35-4
Page ii
35 BRIDGE AND UNDERPASS LOAD TESTING

This chapter outlines standards and requirements that apply to bridge and underpass static load
testing activities for the Project. If required in the Contract documents, the dynamic load testing shall
be carried out in accordance with the Contract Particular Specifications.
The Contractor shall carry out static load tests on the bridge and underpass superstructures, as part
of the acceptance process of new bridges and underpasses, after completion of the bridge or
underpass. Static load tests shall verify that the bridge and underpass’s actual structural behaviour
matches that of the theoretical design.
The Contractor shall complete the static load test, as well as the dynamic load test if required,
according to the provisions of this chapter and shall comply with any further requirements that the
Engineer will supply to the Contractor in due course. On receipt of the Engineer’s further
requirements, the Contractor shall prepare a Method Statement and provide it to the Engineer for
approval.
35.1 Objectives
The purpose of the load testing is to evaluate the structural performance and functional adequacy of
the bridge and underpass tested as an exact full-sized model with an appropriate margin of safety.

Standards and codes for bridge and underpass load testing shall be as specified in these
specifications, in the Contract documents, if any, and the following, in their latest edition:
35.3 Definitions
"Design Live Load" means the Abu Dhabi Vehicular Load (ADVL) as defined in Road Structures
Design Manual (ADQCC TR-516), including the corresponding impact factor and multi-lane reduction
factor.
"Test Load" means the actual loads used at each stage of testing.
35.4 Static Load Testing of Bridges

35.4.1 General Guidelines
The Contractor shall carry out a static load test on the bridge in compliance with the following general
guidelines:
a. Load testing shall be performed after construction of the bridge is complete and all the
superimposed dead loads (such as pavement layers, parapets, and footways) have been
applied, but not sooner than 28 days after the pouring of concrete for the bridge deck.
b. The Contractor shall ensure that all the stress relieving operations for the bridge bearings are
completed before load testing.
c. The Contractor is responsible for ensuring the bridge’s general and structural safety during
testing. This responsibility includes ensuring that the bridge does not exceed its elastic limit
and that tests do not damage the bridge or its components, including bearings and expansion
joints.
d. The Contractor shall predetermine the test Load patterns and positions on the bridge deck to
simulate load effects for which the bridge has been designed. The amount and configuration
of the test load applied during the test must produce internal forces (bending moments, shear,
and axial forces) and reactions at critical sections that equal the corresponding live load
Page 35-1
values in the bridge design. The Contractor shall place the test load in standard width design
traffic lanes, spaced across the entire bridge roadway width between curbs, at pre-marked
locations.
e. The Contractor shall provide sufficient supporting calculations for selected test load values,
patterns, and positions to enable simulation of the most critical cases.
f. During the static load test, the Contractor shall increase the test load (in at least four
increments) to achieve the predetermined design maximum live longitudinal sagging and
hogging (if any) moments in mid-spans, design maximum live longitudinal hogging at internal
supports, and maximum live reactions at supports.
g. Precast concrete blocks may serve as truck loads to achieve the required axle loads. Lorries
that are loaded with aggregates may also serve as truck loads if the required axle loads can
be achieved. The Contractor may apply concentrated loads to the deck by jacking against
dead weight. Load testing shall be carried out for every span, pier, and abutment.
h. Deflections and strains shall be measured accurately and at a sufficient number of
Measurement Reference Points (MRPs) where maximum deformations are expected to
produce sufficient data to plot the theoretical and measured deflected shapes of the structure.
The Contractor shall take measurements at least at one fourth of the middle spans, at one
fifth of exterior spans, and at the tops of piers and abutments. The Contractor shall take
measurements at each section at no fewer than two measurement points, one at the centre
line and one at the edge of the bridge deck slab.
i. After completing load testing, the Contractor shall carry out a bearing performance inspection
to ensure that no additional restraint is present. Vertical deflections and compression of
bearings and differential translations (that is, the temperature induced movements at
expansion joints) shall be well below the design (or manufacturer) limits.
35.4.2 Calculations Required before Load Testing

To ensure the structure’s safety, the Contractor shall take the following actions before conducting
load testing:
a. Calculate the theoretical bending moment, shear, and deflection diagrams, and reactions for
each test load stage. Maximum values for these factors shall not exceed the corresponding
values under design live loads.
b. Longitudinal flexural stresses and shear stresses along the bridge shall be calculated at
critical sections and checked, so that they do not exceed the allowable stresses of the bridge
at any time during the test.
c. Calculate the theoretical deflections at all MRPs for each test load increment. These values
shall not exceed the corresponding values under design live loads.
35.4.3 Load Testing Procedures

The Contractor shall comply with the following procedures when testing the bridge’s static load:
a. Three days before load testing, take temperature measurements every hour at the top and
underside of the bridge’s deck slab (or the underside of its steel or concrete girder). Measure
temperature at a location that will produce average values for the whole bridge.
b. Gradually apply the test load, in no fewer than four increments, before reaching the full, final
load. At each test load increment, sustain the load for at least one hour before reading the
deflections. Apply the maximum test load for at least twelve hours.
c. After each load increment, measure deflection at all MRPs, including above piers and
abutments. These measurements shall not exceed the corresponding theoretical values
calculated for the same loading.
d. After each load increment, visually inspect the bridge at critical locations for the appearance
or widening of cracks and for any other unwanted consequences. After detecting any crack,
measure its length and width and determine its form and orientation.
Page 35-2
e. After reading deflections and performing a visual inspection at each MRP, verify and
determine that the bridge is performing as expected and, consequently, decide whether to
continue or postpone testing.
f. After removing test loads, measure deflections again to verify that any permanent deflection
is minimal and within acceptable limits. The ratio of permanent irreversible deflection to the
total deflection shall not exceed (0.2).
g. At each stage of load testing, when reading deflections, measure temperature at the top and
bottom of the bridge’s deck. In case of significant temperature effects, the theoretical
deflections due to temperature shall be calculated and considered in comparing of theoretical
and measured deflections.
35.4.4 Static Load Testing Method Statement

The Contractor shall submit a load testing Method Statement for the bridge to the Engineer at least
two months before the testing date. This statement shall include at least the following items:
a. The current status of the bridge to be tested
b. A Traffic Management Plan for managing traffic during the test
c. A load testing procedures
d. A discrietization for the bridge deck’s MRP positions.
e. Descriptions of the types of dial gauge and strain gauge to be used, their locations, their
sensitivities, and other relevant information.
f. Description of the type of truck to be used in the testing, its load intensity, its type of load, its
maximum and incremental loads, and the corresponding axle loads with justification for
assumed axle loads (based on model specification). Required loading for static load testing
shall be as per Section 35.4.5 of this chapter.
g. Descriptions of test truck configurations (in longitudinal and transverse directions for each
test load); such descriptions shall include supporting calculations for selected truck
configurations.
h. Bending moment, shear force, and theoretical deflection diagrams with the reaction of
supports due to the test load.
i. A comparison between design live load moments, shears, reactions, and deflections and
their corresponding theoretical test load values at all MRPs. A load testing statements shall
include a comparison of deflections at each test load increment.
j. Any additional information that the Contractor considers useful for load testing.
k. Bearings performance inspection.
35.4.5 Required Loading and Monitoring for Static Load Testing

During static load testing, the Contractor shall move the load across the bridge in stages, as specified
in the method statement.
The test’s load intensity shall replicate the Abu Dhabi Vehicular Load (ADVL) in accordance to Road
Structures Design Manual (ADQCC TR-516), applied to all the existing traffic lanes and the outer
hard shoulders. The load intensities that correspond to design live loads shall be based on the actual
geometry of the bridge to be tested by the Contractor.
The Engineer shall approve the detailed disposition of each vehicle at each stage.
The Contractor shall provide vehicles for these tests as indicated in their method statement or in
accordance with alternative directions from the Engineer (given that such alternatives achieve the
required load intensity).
The Contractor shall set up on site a calibrated weighing bridge and confirm the weight of all vehicles
used in the test.
Page 35-3
The Contractor shall load the bridge on each span based on the actual geometry and as indicated
in the method statement. After obtaining approval from the Engineer for the precise location for the
front of each train of vehicles at each stage, the Contractor shall incorporate these locations into the
method statement. As a typical example, Table 35-1 provides the load arrangement and required
monitoring for a 5 span bridge.
Table 35-1: Static Load Test - Load arrangement and required monitoring
Test stage Spans loaded Duration Elapsed Monitoring Spans (piers)

time required to be
monitored1
1 1 6 hours 6 hours Type A 1
2 1,2 1 hour 7 hours Type B (1)
3 1,3 6 hours 13 hours Type A 1,3
1. A value in parentheses indicates the Pier’s number
At the start of each stage, the Contractor shall move the test load to ensure the gradual application
and removal of load. Halfway through each stage, such movement shall achieve the maximum load,
which shall be sustained for the remainder of the period.
The Contractor shall obtain approval from the Engineer in advance for any deviations from or breaks
in the schedule outlined in Table 35-1.
At all stages, the Contractor shall report to the Engineer any unanticipated events or delays, to which
the Engineer will, if appropriate, provide further instructions on how to proceed with load testing.
The Contractor shall supply all necessary facilities, access, measuring, and photographic equipment
to enable the Engineer to inspect critical locations during the test.
35.4.5.1 Monitoring Type A

The Contractor shall provide approved deflection measuring devices consisting of dial gauges with
an accuracy of ±1 mm and strain gauges. Such deflection measuring devices shall be placed at mid
span and over supports of the span being monitored, as directed by the Engineer. The Contractor
shall take readings at the start of each stage, when reaching the maximum load for each stage, and
at the end of each stage. Temperature readings shall be taken by the Contractor throughout the test
on the deck surface and on concrete in the shade at locations that have been approved by the
Engineer.
35.4.5.2 Monitoring Type B

The Contractor shall carry out visual inspection of key elements only, including bearings.
35.4.6 Static Load Testing Analysis Report

The Contractor shall prepare a comprehensive static load testing analysis report and submit three
(3) copies of the report to the Owner and the Engineer two weeks after completing load testing for
the entire bridge. This report shall include at least the following items:
a. Details of adopted procedures, load configurations, and a summary of all items mentioned
above in the method statement.
Page 35-4
b. An interpretation of the test results.

c. A table with theoretical deflections (that is, design live load and test load) and measured
deflections for all MRPs and for each test load increment. This table shall also include
measured deflections after removal of each test load increment. The Contractor shall apply
linear interpolation between loaded and unloaded bridge measurements to remove the
effects of temperature from the measured deflections in this table.
d. Longitudinal theoretical deflections (design live load and test load) and measured deflection
curves along the bridge centreline for each test load increment.
e. Graphs that compare measured deflections to theoretical deflections at major MRPs (that is,
along the bridge’s centre line at mid-span and support locations). A static load testing
analysis report shall include the slope of the compatibility line, which the Contractor can
derive from the deflection graphs.
f. Any local effects observed during testing.
g. Final analyses, conclusions, and recommendations.
h. Results of a performance inspection for bearings.
i. A statement of approval for the bridge load testing.
j. Statement that load testing verifies that the completed bridge complies with its design
requirements.
35.5 Static Load Testing of Underpasses

The Static Load Testing of underpasses shall be carried out in accordance to the same principles
and procedures stated for bridges. Any traffic lanes above the underpass deck shall be loaded as
stated for bridge traffic lanes. The loading shall be repeated along the underpass length sequentially
for the whole length of underpass or as agreed by the Owner.
In case of double underpasses, the unsymmetrical loading shall also be considered. The contractor
shall consider all safety issues and submit the load testing method statement including loading
procedure and instrumentation for approval of the Owner.
Page 35-5
INDEX
acceptance process, 35-1 longitudinal sagging and hogging, 35-2

actual geometry, 35-3, 35-4 Measurement Reference Points, 35-2
actual structural behaviour, 35-1 Method Statement, 35-1, 35-3
analysis report, 35-4, 35-5 new bridges, 35-1
bearings, 35-1, 35-2, 35-4, 35-5 parapets, 35-1
calculations, 35-2, 35-3 pavement layers, 35-1
calibrated weighing bridge, 35-3 Precast concrete blocks, 35-2
conclusions, 35-5 reactions, 35-1, 35-2, 35-3
critical sections, 35-1, 35-2 recommendations, 35-5
Deflections, 35-2 stages, 35-3, 35-4
Design Live Load, 35-1 standard width design traffic lanes, 35-2
dial gauge, 35-3 static load testing, 35-1, 35-3, 35-4, 35-5
discrietization, 35-3 strain gauge, 35-3
double tunnels, 35-5 strains, 35-2
dynamic load testing, 35-1 superimposed dead loads, 35-1
elastic limit, 35-1 superstructures, 35-1
equipment, 35-4 temperature measurements, 35-2
exact full-sized model, 35-1 Test Load, 35-1
expansion joints, 35-1, 35-2 test Load patterns, 35-1
flexural stresses, 35-2 test truck configurations, 35-3
footways, 35-1 theoretical design, 35-1
Graphs, 35-5 traffic lanes, 35-3, 35-5
inspection, 35-2, 35-3, 35-4, 35-5 Traffic Management Plan, 35-3
internal forces, 35-1 truck loads, 35-2
interpretation, 35-5 tunnel deck, 35-5
load increment, 35-2, 35-3, 35-5 underpass, 35-1, 35-5
Page 35-6

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PART 2

DOCUMENT NO: TR-

DOCUMENT NO: TR-

Chapter 16: Introduction

CHAPTER 17 - DRILLED PILES

DOCUMENT NO: TR-

Chapter 17: Drilled Piles

17.17.3 Equipment .......................................................................................................... 17-26

17.1 Reference Standards and Codes

Standard Test Method for Density of Bentonitic

ASTM Standard Test Method for Marsh Funnel Viscosity

ASTM Standard Test Method for Sand Content by Volume

Standard Test Methods for Deep Foundations

Standard Test Methods for Piles Under Lateral

Standard Test Method for Low Strain Impact

Standard Test Method for Integrity Testing of

Standard Test Method for High-Strain Dynamic

17.2 Working Drawings

17.3 Ground Investigation

17.4 Piling Method and Programme

17.5 Ensuring Safety when Drilling Piles

17.5.1 General Safety Requirements for Drilled Piles

17.5.2 Life-saving Appliances

17.6 Avoiding Disturbances and Damage when Drilling

17.6.1 Reducing Noises and Disturbances from Pile Drilling

17.6.2 Avoiding Damage to Adjacent Structures

17.6.3 Avoiding Damage to Piles

17.8 Pile Construction Record

17.9 Construction Tolerances

17.10 Pile Construction

17.10.1 Protection of Existing Structures

17.10.2 Submittals for Drilled Pile Construction

17.10.3 Drilled Pile Construction Sequence

17.10.4 Drilled Pile Construction Methods

17.10.4.1 Dry Method

17.10.4.2 Wet Method

17.10.4.3 Temporary Casing Construction Method

17.10.4.4 Permanent Casing Construction Method

17.10.4.5 Alternate Construction Methods

17.11 Support for Pile Bores

17.11.1 Support Fluid

Table 17-4 show acceptable values for those physical properties.

17.11.2 Use of Bentonite

Slurry Unit Range of results at 20o C Test method

Density g/cm3 <1.10 <1.15 Mud density balance

Viscosity Sec 32 to 50 32 to 50 Marsh funnel and cup

pH 8.0 ~ 11 - pH indicator paper strips or electrical pH

Sand content % - 4.0 %

17.11.3 Polymer Slurry

Table 17-4: Polymer slurry properties

Slurry property Unit Requirements Test method

Density g/cm3 1.03 Max Mud density balance

Viscosity Sec 32 to 135 Marsh funnel and cup

pH 8.0 ~ 11.5 pH indicator paper strips or

Sand content % 1.0% Max

17.11.4.1 General Casing Requirements for Drilled Piles

17.11.4.2 Permanent structural Casing

17.11.4.3 Permanent Non-structural Casing

17.11.4.4 Temporary Casing