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       **ALABAMA DEPARTMENT OF TRANSPORTATION**                  

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DATE: February 12, 1998 Special Provision No. [3038]{.underline}

SUBJECT: Concrete, Steel Reinforcement, Prestressed Concrete Bridge
Members, Concrete

Materials, and Bridges, **Project No. BR-267(3), Macon County**.

Alabama Standard Specifications, 1992 Edition, and Supplemental
Specification No. [3-92(2)]{.underline}, are hereby amended as follows
(this includes deleting existing SECTIONS 501 and 513 and adding NEW
SECTIONS 501 and 513):

SECTION 501

STRUCTURAL PORTLAND CEMENT CONCRETE

**501.01 Description.**

The work under this Section shall cover the furnishing of high
performance Portland cement (**HPC**) concrete to be used in cast-in
place concrete structures. Structures shall include but are not limited
to:

Superstructure concrete: bridge decks, barrier rails, and diaphragms.

Substructure concrete: columns, caps, footings, backwalls,

wingwalls, wing protection railings,

abutments and pile encasements.

**501.02 Materials.**

\(a\) GENERAL.

Handling, storage, and control of materials shall comply with
appropriate portions of Section 106. All materials shall conform to the
requirements set forth in Division 800, Materials. Cement, mineral
admixtures, aggregates, and all additives shall be selected from the
applicable list found in the Department\'s manual, \"Materials, Sources,
and Devices With Special Acceptance Requirements\" (available from the
Bureau of Materials and Tests). The Contractor may choose from any of
these products or materials, unless otherwise noted. Specific reference
is made to applicable portions of the following Sections:

Section 801 - Coarse Aggregate

Section 802 - Fine Aggregates

Section 806 - Mineral Admixtures

Section 807 - Water

Section 808 - Air Entraining Additives

Section 809 - Chemical Admixtures for Concrete

Section 815 - Cement

Section 826 - Local Sand and Sand Gravel for Miscellaneous

Construction Use

Section 830 - Concrete Curing Materials

Section 832 - Concrete Joint Fillers, Sealers and Waterstop

Material

Section 835 - Steel Reinforcement

\(b\) SPECIAL REQUIREMENTS.

In the event the coarse aggregate shows a tendency to segregate in the
stock pile, the Engineer may order the coarse aggregate be furnished and
batched in two fractions from two separate stock piles.

The Contractor may be required to adjust the size of coarse aggregate
for the concrete used around steel in heavily reinforced members. In
general, the nominal maximum size aggregate shall not exceed any of the
following: three-fourths of the minimum cover or of the minimum clear
spacing between reinforcing bars; one-fifth of the narrowest dimension
between sides of forms, or one-third of the thickness of slabs or
toppings.

\(c\) PROPORTIONING MATERIALS.

1\. GENERAL.

Mixture Design, trial design batches, and mixture proportioning studies,
as required for proportioning for High Performance Cast-in Place
Concrete, shall be the responsibility of the Contractor.

2\. CONCRETE MIX DESIGN.

a\. General.

The Contractor shall determine by trial batches and mixture
proportioning studies the exact proportions of the concrete mixture.
Strength requirements for the concrete mixture shall be based on 28 day
compressive strength as determined by test specimens fabricated in
accordance with AASHTO T 126 and tested in accordance with AASHTO T 22.
Samples of all materials used in mixture proportioning studies shall be
representative of those proposed for use in the project and shall be
accompanied by the manufacturer\'s or producer\'s test reports
indicating compliance with these specifications.

The required average 28 day strength f \'cr, used to select mix
proportions, with required minimum 28 day compressive strength f \'c,
shall be determined using the following equation (all quantities in
psi.).

f \'cr = f \'c + 1800

Mix proportions shall be selected on the basis of laboratory trial
batches using at least three different water-cementitious ratios that
will produce a range of strength encompassing the 28-day Target
Compressive Strength (f'cr). Trial mixtures having proportions,
consistencies and air content suitable for cast-in place work shall be
made based on methodology described in ACI 211.4R.

Laboratory trial mixtures shall be designed for the maximum permitted
slump and air content. Separate sets of trial mixture studies shall be
made for each combination of cementitious materials and each combination
of admixtures proposed for use. No combination of either shall be used
until proven by such studies. Separate trial mixture studies shall also
be made for concrete for any conveying or placing method proposed which
requires special properties and for concrete to be placed in unusually
difficult placing locations.

The temperature of concrete in each trial batch shall be reported. For
each water-cement ratio, at least three test cylinders for each test age
shall be made and cured in accordance with AASHTO T 126. They shall be
tested at 7 and 28 days in accordance with AASHTO T 22. From these test
results, a curve shall be plotted showing the relationship between
water-cement ratio and strength for each set of trial mixture studies.
In addition, a curve shall be plotted showing the relationship between 7
day and 28 day strengths. Each mixture shall be designed to promote easy
and suitable concrete placement, consolidation and finishing, and to
prevent segregation and excessive bleeding.

The Contractor shall furnish to the Department (upon request by the
Department and without extra compensation) sufficient material
(aggregates, cementitious materials, and admixtures) to produce one
cubic yard of the proposed Mixture Design. These materials shall be
provided at least 45 days prior to placement of concrete, or at the time
of the preconstruction conference, whichever is sooner.

> b\. Guidelines for High Performance Concrete (HPC) Mix Proportions:

The minimum strength for the cast-in place HPC concrete shall be 6000
psi. However, mix proportions shall be selected using f'cr.

The cement shall be Type II and the cementitious content of the mix
shall be sufficient to meet the compressive strength requirements. The
concrete mix shall contain fly ash, or microsilica, or a combination of
fly ash and microsilica to provide improved durability. Acceptable
ranges of cement replacement for these mineral admixtures are:

Class "F" fly ash 15 to 25%

Class "C" fly ash 20 to 35%

Microsilica 7 to 15%

When combinations of fly ash and microsilica are used, the fly ash
content shall satisfy the above-specified ranges, and the microsilica
will be considered an addition. The microsilica addition shall be at
least 3% of the total cement plus fly ash content and no more than 15%.

The maximum water to total cementitious material ratio shall be 0.40.

Coarse aggregate shall be ALDOT \# 57 or \# 67 crushed limestone. Fine
aggregate shall be natural sand.

An air entrainment admixture shall be used. The air content of the fresh
concrete shall be 3.5% to 6.0%.

Concrete shall not be placed at a slump exceeding the following limits:

Superstructure concrete: Maximum slump of five inches (5").

Substructure concrete: Maximum slump of eight inches (8").

Any concrete delivered with a slump less than the maximum acceptable
slump value shall be acceptable as long as it is sufficiently workable
to consolidate and finish properly

The maximum allowable temperature of the fresh concrete shall be 95F.
When the temperature of the concrete is above 95F., the approved "Hot
Weather Concrete Plan" submitted by the Contractor shall be used.

c\. Submittal and Acceptance of Mix Proportions.

The mix design shall be submitted to the Department Concrete Engineer
for approval at least 45 days prior to its intended use. The submittal
of the mix design shall be accompanied by:

Test results of gradations performed on the aggregates used.

For each water-cementitious ratio, test results of at least three
cylinders for each test age made and cured in accordance to AASHTO
T 126. Cylinders shall be tested at 7 and 28 days in accordance to
AASHTO T 22.

Curves showing the relationship between water-cementitious ratio and
strength for each set of trial mixture studies.

Curves showing the relationship between 7 and 28 day strengths for each
water-cementitious ratio.

The effects of all additives on the slump, air content, and compressive
strength shall be reported within the mixture design study.

A statement giving the source of materials and certified test data from
a Department approved laboratory.

Test results for air entrainment, slump, temperature and unit weight.

A "HOT WEATHER CONCRETE PLAN" outlining the Contractor's contingency
plan to keep the temperature of the concrete at or below 95F. The plan
shall also outline the Contractor's procedures for handling, placing,
and finishing concrete during hot weather. "Hot Weather" is defined as
the weather when the ambient Temperature exceeds 90F.

The acceptance of the mix design will be based on the data submitted.
Any changes in the source or type of a material shall require a new mix
design study.

d\. Trial Pour.

The Contractor shall demonstrate through a trial pour that the submitted
mix design for the bridge deck will perform satisfactorily. The trial
pour shall be in the form of a flat slab to simulate a bridge deck
situation. The slab shall not be less than 400 square feet in surface
area nor less than 4" thick. Also it is the Contractor's responsibility
to demonstrate at the trial pour that its equipment and personnel are
capable to handle, place, finish, and cure the bridge deck concrete. The
trial pour will not be measured separately for payment.

Any pre-approved mix design that does not perform satisfactory in the
field will be rejected.

\(d\) FIELD SAMPLING AND TESTING.

Fresh concrete will be sampled and tested by the Department for air
content, slump, concrete temperature, unit weight, and compressive
strength. The following sampling and testing frequency applies to
superstructure and substructure concrete:

+-----------+---------------+-------------+---------+-----------------+
|           | **Minimum     |             |         |                 |
|           | Sampling and  |             |         |                 |
|           | Testing       |             |         |                 |
|           | R             |             |         |                 |
|           | equirements** |             |         |                 |
+-----------+---------------+-------------+---------+-----------------+
|           | **Control**   | **Sampling  | **Sam   | **Testing**     |
|           |               | and Testing | pling** |                 |
|           | **Parameter** | Methods**   |         | **Frequency**   |
|           |               |             | **Loc   |                 |
|           |               |             | ation** |                 |
+-----------+---------------+-------------+---------+-----------------+
|           | Slump, Air    | BMTP-328    | At      | One slump, one  |
|           | Content, and  |             | point   | air content,    |
|           | Concrete      | AASHTO      | of      | and one         |
|           | Temperature   | T-119       | pl      | concrete        |
|           |               |             | acement | temperature     |
|           |               | AASHTO      |         | test are        |
|           |               | T-152       |         | performed on    |
|           |               |             |         | concrete taken  |
|           |               | ASTM C-1064 |         | from the first  |
|           |               |             |         | load delivered  |
|           |               |             |         | to the job site |
|           |               |             |         | per day.        |
+-----------+---------------+-------------+---------+-----------------+
|           | Slump, Air    | AASHTO T-22 | At      | One slump test, |
|           | Content,      |             | point   | one air content |
|           | Concrete      | AASHTO T-23 | of      | test, one       |
|           | Temperature,  |             | pl      | temperature     |
|           | Unit Weight,  | AASHTO      | acement | test, one unit  |
|           | and           | T-119       |         | weight test,    |
|           | Compressive   |             |         | and one sample  |
|           | Strength      | AASHTO      |         | set for         |
|           |               | T-121       |         | compressive     |
|           |               |             |         | strength per    |
|           |               | AASHTO      |         | every 50 cubic  |
|           |               | T-141       |         | yards of        |
|           |               |             |         | concrete.       |
|           |               | AASHTO      |         |                 |
|           |               | T-152       |         |                 |
|           |               |             |         |                 |
|           |               | ASTM C-1064 |         |                 |
+-----------+---------------+-------------+---------+-----------------+
|           | NOTES:        |             |         |                 |
|           |               |             |         |                 |
|           | 1\. A sample  |             |         |                 |
|           | set for       |             |         |                 |
|           | compressive   |             |         |                 |
|           | strength      |             |         |                 |
|           | shall consist |             |         |                 |
|           | of two 7-day  |             |         |                 |
|           | cylinders and |             |         |                 |
|           | two 28-day    |             |         |                 |
|           | cylinders.    |             |         |                 |
|           |               |             |         |                 |
|           | 2\.           |             |         |                 |
|           | Additional    |             |         |                 |
|           | cylinders may |             |         |                 |
|           | be required   |             |         |                 |
|           | for early     |             |         |                 |
|           | monitoring of |             |         |                 |
|           | concrete      |             |         |                 |
|           | strength gain |             |         |                 |
|           | and form      |             |         |                 |
|           | removal. The  |             |         |                 |
|           | compressive   |             |         |                 |
|           | strength      |             |         |                 |
|           | shall be      |             |         |                 |
|           | determined as |             |         |                 |
|           | the average   |             |         |                 |
|           | of two equal  |             |         |                 |
|           | age cylinder  |             |         |                 |
|           | test results. |             |         |                 |
|           |               |             |         |                 |
|           | 3\. Any time  |             |         |                 |
|           | a set of      |             |         |                 |
|           | compressive   |             |         |                 |
|           | strength      |             |         |                 |
|           | cylinders are |             |         |                 |
|           | made, one     |             |         |                 |
|           | test for      |             |         |                 |
|           | slump, air    |             |         |                 |
|           | content,      |             |         |                 |
|           | temperature,  |             |         |                 |
|           | and unit      |             |         |                 |
|           | weight shall  |             |         |                 |
|           | be made also. |             |         |                 |
+-----------+---------------+-------------+---------+-----------------+

The Engineer reserves the right to take samples of aggregates from
stockpiles and cement from storage bins at the mixing or batching plant
and to make further tests as needed as a basis for continued acceptance
of the materials

\(e\) FIELD CURING AND TRANSPORT OF CONCRETE CYLINDERS.

The Contractor shall furnish, without extra compensation, a protected
environment for [all]{.underline} concrete test cylinders produced
incidental to any placement of concrete. This may be accomplished by
supplying a facility such as a cylinder curing box with a minimum
capacity of 24 6" x 12" test cylinders, equipped with heating/cooling
capabilities, and a high/low temperature readout. The protective
environment shall be capable of protecting all specimens within the
specification requirements given below and shall be available at the
site when concrete is placed and then maintained until such time that
all specimens have been transported from the project. The protective
environment shall be approved by the Engineer prior to the beginning of
any concrete placement.

Immediately after being struck off, the concrete test specimens shall be
moved to the protective environment where they will remain for the
ini­tial curing period. When moving the specimens to a protective
environment, precautions shall be taken to avoid any damage to the
freshly made specimens. During the initial curing period, the specimens
shall be stored in a temper­ature range between 60 to 80°F., and in a
moist environment pre­venting any loss of moisture for up to 48 hours. At
all times the tempera­ture in and between specimens shall be controlled
by shielding specimens from cooling/heating devices and the direct rays
of the sun. Storage temperatures shall be regulated by means of
thermostatically controlled heating devices, heat pumps, air
conditioners, or chilling equipment. A temperature record of the
specimens shall be established by means of maximum‑minimum thermometers
supplied by the Contractor. Only plastic molds shall be utilized for
specimens to be immersed in water.

Specimens shall remain undisturbed during the first 24 hours of initial
curing. Specimens shall be transported to the laboratory for standard
curing before 48 hours have elapsed and shall re­main in the molds in a
moist environment, until they are received in the labo­ratory, demolded
and placed in standard curing. Standard curing shall comply with AASHTO
T 23, Section 9.2.2. Standard Curing.

**501.03 Construction Requirements.**

\(a\) GENERAL.

Prior to the first concrete placement, a prepour conference shall be
held with the Project Engineer. The Contractor shall be responsible for
calling the meeting. The Contractor's Project Superintendent, Concrete
Foreman, ALDOT inspectors, Auburn University representatives and a
representative of the concrete producer shall be present.

All materials, labor, equipment, tools, and machinery necessary for
forming, mixing, placing, finishing and curing shall be available as
required and all necessary equipment for the proper construction and
completion of any section of the work shall be in satisfactory working
condition before the Contractor will be permitted to start placing
concrete.

All concrete batching plants shall be certified by the National Ready
Mix Concrete Association (NRMCA) to be in conformance with the NRMCA
Plant Certification Checklist. The concrete producer shall submit proof
of NRMCA certification to the Department Concrete Engineer (Materials &
Test Bureau) prior to any batching of concrete.

All batching plants shall meet the requirements of the Specifications
and BMTP-352. All batching plants shall be Class A plants as described
in BMTP-352. Producers who request that their batching plants be placed
on the LIST OF EVALUATED READY-MIX CONCRETE PLANTS will be charged a
submittal fee as specified by BMTP‑355, General Information Concerning
Materials, Sources, and Devices With Special Acceptance Requirements.

\(b\) EQUIPMENT.

1\. GENERAL.

The Contractor shall furnish equipment capable of producing concrete
meeting the requirements noted in this Section in sufficient quantities
to provide for orderly construction of the project. All equipment shall
be in good working order and so maintained throughout the requirement
for its use.

Specific requirements for certain types of equipment are designated in
subsequent items of this Subarticle.

2\. MIXING AND TRANSPORTING EQUIPMENT.

Concrete for all major structure work (bridges, culverts, retaining
walls, etc.) shall be \"ready-mixed\" concrete. Ready-mixed concrete is
defined as Portland cement concrete manufactured for delivery and
delivered to the work site in accordance with AASHTO M 157 Modified\*
and the requirements written herein in other parts of these
specifications. In case of discrepancy these specifications shall
govern.

(\*Modification of AASHTO M 157 are as follows: The requirements of
Paragraph 8.1 shall include the following: Should this method of
weighing fly ash cumulatively with cement produce unsatisfactory
results, it shall be discontinued and separate scales and hoppers
provided for these ingredients.)

Concrete for minor structure work (headwalls, inlets, junction boxes,
and other miscellaneous individual concrete units requiring three (3)
cubic yards or less of concrete, along with such applications as slope
paving, sidewalks, curbs, gutters, and combinations thereof) may be
mixed in mixers as noted above or an approved type of mobile mixing
plant designed with separate bins for fine aggregate, coarse aggregate,
cement, water, additives, etc. that will automatically proportion all
concrete aggregates either by weight or volume and be capable of
combining the ingredients into a uniform mass and discharging such
without segregation. It shall have approved equipment which will
determine the volume of concrete dispatched. Said alternate type mobile
mixing plant shall be capable of providing concrete complying with the
designated Mixture Design noted in Article 501.02. Prior written
approval of such alternate equipment shall be obtained before it is
allowed on the project. Basis for this approval will be upon the
satisfactory performance of the equipment when checked in accordance
with the provisions of AASHTO M 241. The costs of all materials and
labor furnished to perform the above mentioned test shall be absorbed by
the Contractor.

If the Contractor requests to use portable mixers, the Engineer may
approve their use and will furnish written requirements covering such
mixers.

All mixing and transporting equipment shall be supplied in sufficient
amounts to provide continuous delivery of the concrete as needed for an
acceptable, satisfactory operation. The volume of concrete mixed or
transported in a concrete truck mixer shall not be less than 15% of the
gross volume of the drum.

Each transit mixer shall be equipped with an approved automatic counter
that will record the number of drum revolutions turned at mixing speed;
or in lieu thereof, it may be equipped with an approved automatic
counter that will record the number of revolutions regardless of drum
speed, provided the drum is turned the required number of revolutions at
mixing speed before leaving the batching plant. The revolution counter
shall be reset to zero at the time of batching.

3\. VIBRATORS.

Vibrators shall be of an approved internal vibrating type and design,
unless special authorization for other types is given by the Engineer.
Vibrators shall be capable of transmitting vibrations to the concrete at
frequencies of not less than 4500 impulses per minute. The Contractor
shall provide a sufficient number of vibrators to properly compact each
batch immediately after it is placed in the forms. At least one standby
vibrating unit in workable order shall be available before the start of
any placement of concrete.

\(c\) RETEMPERING.

No retempering of concrete will be allowed.

\(d\) TIME, LIGHT AND WEATHER LIMITATIONS.

1\. TIME OF HAULING AND PLACING CONCRETE.

Ready-mix concrete shall be transported and delivered as outlined in
BMTP-170. [B]{.smallcaps}atch tickets shall be submitted to the
Department for each load of ready-mix concrete at the time of delivery
of that load of concrete. If the use of a retarder is authorized in
writing by the Department's Concrete Engineer, the time limit for
delivery of the mixed concrete may be extended by an amount specified by
the Concrete Engineer.

2\. LIGHT.

All concrete shall be placed and finished during daylight hours, unless
written permission to the contrary is given. Such permission will not be
given unless an adequate approved lighting system is available for all
operations after sundown.

3\. WEATHER.

a\. General.

The temperature of the concrete, at the time of placing in the forms
shall not be less than 50ºF. nor more than 95ºF. unless otherwise
provided or directed.

b\. Cold Weather Operations.

No concrete shall be placed when the ambient air temperature is below
35ºF., or below 40ºF. and falling without written permission of the
Engineer. If the Contractor proposes to place concrete during seasons
when there is a probability of temperatures lower than 40ºF., the
Contractor shall have available on the project such suitable approved
equipment and materials as necessary to enclose the uncured concrete and
keep the air temperature inside the enclosure within the following
ranges and for the minimum times noted hereinafter.

If there are indications there will be temperatures below 40ºF. during
the first three days after placement of concrete, it shall be protected
from cold temperatures by keeping the surface at a temperature above
50ºF. for the first 72 hours after placement and above 32ºF. an
additional 72 hours. However, the protective covering shall be retained
in place until the temperature inside the protective covering reaches
that of the surrounding atmosphere.

When the Contractor is permitted to place concrete at temperatures below
35ºF., the aggregates and/or mixing water shall be heated as necessary
to keep the temperature of the plastic concrete above 50ºF. but no more
than 95ºF. from time of placement until initial set; however, in no case
shall the materials be heated in excess of 150ºF., nor shall aggregates
from frozen stockpiles be incorporated into the mixture. Materials
entering the mixer shall be free from ice, snow, or frozen lumps. Salt,
chemicals, or other materials shall not be incorporated in the concrete
to prevent freezing. Care shall be taken to heat all materials uniformly
and avoid hot spots which will burn or overheat the materials.

The Contractor shall assume all risk and added cost connected with
mixing, placing and protecting of concrete during cold weather.
Permission given by the Engineer to place concrete during such time will
in no way relieve the Contractor of responsibility for satisfactory
results. Should it be determined at any time that concrete placed under
such conditions is found to be unsatisfactory, it shall be removed and
replaced with satisfactory concrete by the Contractor without extra
compensation.

c\. Hot Weather Operations.

The Contractor shall submit in writing a proposed plan for controlling
the concrete mixture temperature during hot weather operations for
approval. The hot weather concrete plan shall outline the Contractor's
procedures to maintain the temperature of the concrete at or below 95ºF.
and the Contractor's procedures for transporting, handling, placing,
finishing, and curing concrete during hot weather. The hot weather
concrete plan shall be submitted to the Department's Concrete Engineer
for approval with the mix design submittal.

When the ambient temperature during concrete placing is expected to
exceed 90ºF., the concrete shall be properly placed and finished with
procedures previously submitted by the Contractor and approved by the
State Concrete Engineer. Cooling of the mixing water or aggregates or
placing in the cooler part of the day may be required to obtain an
adequate placing temperature. An approved retarder may be used to
facilitate placing and finishing. Steel forms and reinforcements shall
be cooled as approved prior to concrete placement when steel
temperatures are greater than 120ºF. Conveying and placing equipment
shall be cooled if necessary to maintain proper concrete placing
temperature.

\(e\) HANDLING AND PLACING CONCRETE.

1\. GENERAL.

In preparation for the placing of concrete all sawdust, chips and other
construction debris and extraneous matter shall be removed from the
interior of forms. Temporary struts, stays or braces serving to hold the
forms in place until the concrete is placed shall be removed prior to
being encased in the concrete. All permanent struts, stays or braces
shall be precast concrete struts or at the Contractor\'s option,
approved steel struts; no wooden struts will be permitted.

During the placing of concrete, the Contractor shall continuously check
the alignment of forms and immediately correct any yielding of the forms
or falsework.

Concrete shall be deposited continuously for each monolithic section of
the work by placing the fresh concrete in horizontal layers of
approximately twelve (12) inches in thickness. Each additional layer
shall be placed and compacted before the preceding layer has taken its
initial set, 45 minutes for mixtures without retarder and 60 minutes for
mixtures with retarder.

For vertical members the maximum height of a concrete placement shall
not exceed 20 feet, except for underwater concrete or when steel forms
are used. When structurally sound steel forms are used, concrete
placements may be made up to 30 feet in height provided that an approved
mortar tight downspout of sufficient length to reach within five (5)
feet of the bottom of the concrete placement and a vibrator of
sufficient length to provide good consolidation throughout the concrete
placement are used. Any vertical member exceeding 20 feet in height
shall be broken into two or more approximately equal concrete placements
unless the preceding requirements are met.

When succeeding pours are necessary, the next pour will not be permitted
until the concrete in the underlying pour has aged at least 12 hours or
attained a minimum compressive strength of 2400 psi from cylinders
prepared in conformity with AASHTO T 23. When set retarding admixtures
were used in the preceding pour, the next pour will not be permitted
until a 2400 psi cylinder strength is attained.

The forms shall not be jarred nor shall any strain be placed on
reinforcing bars partially encased in concrete that will cause damage to
bond. All accumulations of mortar splashed on the reinforcing steel and
surfaces of forms shall be removed before the next concrete placement.

When it is necessary to pump water from the excavation during placing of
concrete to deposit the concrete in the dry, the sump for the intake
hose shall be located outside the forms.

The use of aluminum pipes, chutes or other devices made of aluminum that
come into direct contact with the concrete shall not be utilized in the
handling and placing operations.

a\. Use of Chutes, Pipes or Belts.

Concrete shall not be dropped a distance of more than five (5) feet
unless confined in an approved mortar tight downspout of not less than
four (4) inches in diameter. Downspouts shall be equipped with suitable
hoppers at their inlet end and shall be provided in sectional lengths
that will permit adjustment of the level of the outlet during placement.

The number of downspouts furnished shall be sufficient to insure the
concrete placement in horizontal layers. Depositing large quantities of
concrete at one point in the form and running, flowing or working the
concrete along the forms will not be permitted.

In wall sections where a 4 inch downspout cannot be utilized without
displacing the reinforcing steel, the concrete may be dropped in excess
of the five (5) feet previously noted, provided such does not displace
the reinforcing steel nor produce segregation of the concrete.

\(1\) Chutes, pipes or power belts may be used to convey concrete from
the concrete mixer or transporting vehicle to the forms, and they shall
convey it to its final position without segregation and without
displacing the reinforcing steel. If the use of this equipment results
in honeycombed or otherwise inferior concrete, the Engineer will require
it to be changed or its use discontinued.

\(2\) Chutes, pipes and power belts shall be flushed with water after
each run and this water shall be discharged free of the freshly placed
concrete. All hardened concrete shall be promptly removed.

b\. Pumping.

Direct placement of concrete by an approved pumping device will be
permitted. The equipment shall be so arranged that no vibrations result
which might damage freshly placed concrete. The operation of the pump
shall be such that a continuous stream of concrete without air pockets
is produced. 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. After each placement the equipment shall be cleaned to
prevent improper results on subsequent operations.

c\. Compacting and Vibrating.

Concrete, except underwater concrete, shall be thoroughly compacted by
mechanical vibration applied internally, during and immediately after
depositing.

The application of a vibrator or vibrators shall be at points uniformly
spaced and not farther apart than twice the radius over which the
vibration is visibly effective. Vibrators shall be manipulated so as to
thoroughly work the concrete around the reinforcement and embedded
fixtures and into the corners and angles of the forms. Vibration shall
be supplemented by as much spading as is necessary to insure smooth
surfaces and dense concrete.

The vibrators shall be methodically inserted and withdrawn from the
concrete. The vibration shall be of sufficient duration and intensity to
thoroughly compact the concrete, but vibrators shall be withdrawn before
segregation and localized areas of grout result.

Vibration shall not be applied directly or through reinforcement to
sections or layers of concrete which have hardened to the degree that
the concrete ceases to be plastic under vibration. Vibrators shall not
be used to make concrete flow in the forms over distances so great as to
cause segregation.

d\. Prevention of Plastic Shrinkage Cracking.

To prevent plastic shrinkage cracking the expected evaporation rate
shall not exceed 0.1 pounds per square foot per hour as determined by
Figure 1, "Evaporation Rate of Surface Moisture." When it becomes
necessary to reduce the evaporation rate, the Contractor shall take one
or more of the following actions:

\(1\) Construct windbreaks or enclosures to effectively reduce the wind
velocity throughout the area of placement.

\(2\) Use fog sprayers or sprinklers upwind of the placement operation
to effectively increase the relative humidity.

\(3\) Ponding of water, application of wet burlap, or placement of
plastic sheeting on the surface after finishing.

\(4\) Reduce the temperature of the concrete by the methods suggested
before.

Plastic shrinkage cracks that occur will be evaluated by the Department.
Remedial measures shall be performed as directed by the Engineer.
Plastic shrinkage cracks shall never be troweled over or filled with
slurry.

  ------------ ----------------------------------------------------------
               **FIGURE 1. Evaporation Rate of Surface Moisture**

               ![](media/image1.emf)

               *Note: Example shown by dashed lines is for an air
               temperature of 80°F, relative humidity of 50 percent,
               concrete temperature of 87°F, and a wind velocity of 12
               miles per hour. This result is a rate of evaporation of
               0.24 pounds per square foot per hour.*
  ------------ ----------------------------------------------------------

2\. CULVERTS.

See Section 524 for specific details not covered in this Section.

3\. RETAINING WALLS.

See Section 525 for specific details not covered in this Section.

4\. BRIDGES.

See Section 510 for specific details not covered in this Section.

5\. DEPOSITING CONCRETE UNDER WATER.

a\. General.

Concrete shall not be deposited in water unless provided for on the
plans, or authorized, as provided in Subarticle 503.03(g). Concrete
placed under water shall be placed as hereinafter provided.

b\. Control.

Seal concrete shall be placed continuously from start to finish to
insure the concrete placement being monolithic. The surface of the
concrete shall be kept as nearly horizontal as practicable at all times.
To insure bonding, each succeeding layer of seal or foundation concrete
shall be placed before the preceding layer has initially hardened. All
laitance or other foreign matter shall be removed from the top surface
to the concrete, and bonding of construction joints effected as provided
by Item 501.03(f)4.

c\. Placing Methods.

Concrete specified to be deposited in water shall be concrete as
provided in Article 501.02 with a maximum slump of eight inches (8"). To
prevent segregation, it shall be carefully placed in a compact mass in
its final position by means of a tremie, a bottom dump bucket, pumping,
or other approved method. Concrete shall not be disturbed after being
deposited. Still water shall be maintained at the point of deposit as
nearly as practical.

\(1\) Use of Tremie.

A tremie shall consist of a rigid, water tight tube of sufficient
strength to withstand the stress to which it is subjected and be at
least 8 inches in diameter. The tremie shall be supported so as to
permit rapid lowering when necessary to retard or stop the flow of
concrete, the tremie shall be plugged at the start of work with an
approved device capable of separating the concrete from the water until
the tube is filled with concrete. The tremie tube shall be kept
partially filled with concrete at all times during the concrete
placement. When a batch is dumped into the hopper, the flow of concrete
shall be induced by slightly raising the tremie, always keeping the
discharge end in the deposited concrete. The flow shall be as nearly
continuous as possible and in no case shall it be intentionally
interrupted until the entire seal concrete foundation work is completed.

\(2\) Use of Bottom Dump Bucket.

The bottom dump bucket shall have a capacity of not less than 1/2 cubic
yard and be mechanically equipped to prevent dumping until it rests on
the foundation or previously placed concrete. The bucket shall be
completely filled and lowered very carefully until it rests upon the
foundation or concrete already placed so as not to get a wash over the
bucket top, it shall then be raised very slowly during the discharge
travel, the intent being to maintain as nearly as possible, still water
at the point of discharge and to avoid agitating the mixture; also to
allow the concrete to be deposited by the time the bucket emerges from
the concrete already on the foundation.

\(3\) Pumping.

In addition to the requirements of Subitem 501.03(e)1.b., the following
shall also apply for placing concrete under water by pumping. Concrete
may be pumped into a tremie, or directly to the point of placement. If
the concrete is pumped directly to the point of placement, a rigid pipe
shall be provided that shall extend a minimum of five (5) feet above the
water level when resting on the bottom of the excavation. A flexible
hose suitable for pumping concrete may be used from the top of the rigid
pipe to the concrete pump. The method of placing and handling the
concrete shall be as specified in Subitem 501.03(e)5.c.

\(f\) CONSTRUCTION JOINTS.

1\. GENERAL.

Construction joints shall be placed only at the locations shown on the
plans, or as directed. In case of emergency, if a construction joint is
permitted, it shall be placed as directed by the Engineer.

2\. HORIZONTAL JOINTS.

Generally, horizontal joints shall be made by placing 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
outlined in Item 4. below. Insert form work shall be used to obtain
neat, horizontal lines.

3\. VERTICAL JOINTS.

Vertical joints shall be formed with substantial bulkheads or headers as
required. Feather edged joints will not be permitted.

4\. BONDING.

Before placing concrete against any construction joint, the surface of
the hardened concrete shall be scarified in such a manner that all
foreign matter, laitance, and loose material is removed to expose sound
concrete. The prepared concrete at the construction joint shall be kept
wet for a minimum of one hour period prior to placing concrete against
it. Keyways and dowels shall be placed as shown on the plans or
directed.

5\. WATER STOPS.

Water stops shall be furnished and placed as required by the plans. They
shall form continuous watertight joints.

\(g\) EXPANSION JOINTS.

All joints shall be constructed according to details shown on the plans,
providing the design width designated for the expansion joint. The
insertion and removal of joint forming material shall be accomplished
without chipping or breaking the corners of the concrete. Expansion
material, when required, shall be placed as shown on the plans.

\(h\) FORMS.

1\. GENERAL.

Reference is made to Article 105.02 concerning working drawings and
other details which require submission.

Forms shall be substantial and unyielding and so designed and
constructed that the finished concrete will conform to the plan
dimensions and contours within tolerances listed in other portions of
these Specifications.

Basic bridge plan design is for removable forms and plan concrete
quantities computed accordingly. Hence, removable forms are to be used
unless stay-in-place forms are allowed by contract plan notes and
details. When shown by contract plan details, the Contractor will be
allowed the option of using permanent steel forms under deck slabs
between girders, beams or stringers, provided the cost of extra concrete
and materials required by this type of form is at the Contractor\'s
expense.

2\. DESIGN.

a\. Removable Forms.

All removable forms shall be designed so that they may be removed
without damage to the concrete. Forms shall be so constructed that
portions where finishing is required can be removed for that purpose
without loosening supports or disturbing portions of forms that must
still remain in place.

b\. Permanent Steel Bridge Deck Forms.

The forms and supports shall be zinc coated (Galvanized) steel
conforming to ASTM A 446 (Grade A through E) with coating Class of G165
according to ASTM A 525 and shall otherwise meet all requirements
relevant to permanent steel forms and the placing of concrete as
specified herein and as noted on the plans. Miscellaneous fastener
hardware (bolts, nuts, metal screws and washers) shall be common stock
hardware galvanized to provide a zinc coating equal to or better than
that required by ASTM B 633.

The following criteria shall govern the design of permanent steel bridge
deck forms:

\(1\) The steel forms shall be designed on the basis of dead load of
form, reinforcement and plastic concrete plus 50 pounds per square foot
for construction loads. The unit working stress in the steel shall not
be more than 0.725 of the specified minimum yield strength of the
material furnished, but not to exceed 36,000 pounds per square inch. The
uncoated thickness of the forms shall not be thinner than 0.0359 inch.

\(2\) Deflection under the weight of the forms, the plastic concrete and
reinforcement shall not exceed 1/180 of the form span or 1/2 inch,
whichever is less, but in no case shall this loading be less than 120
PSF total. The permissible form camber shall be based on the actual dead
load condition. Camber shall not be used to compensate for deflection in
excess of the foregoing limits.

\(3\) The design span of the form sheets shall be the clear span of the
form plus 2 inches measured parallel to the form flutes.

\(4\) Physical design properties shall be computed in accordance with
requirements of the American Iron and Steel Institute Specification for
the Design of Cold Formed Steel Structural Members, latest published
edition.

\(5\) The plan dimensions of both layers of primary deck reinforcement
from the top surface of the concrete deck shall be maintained. A minimum
concrete cover of one inch shall be maintained for the bottom slab
steel.

\(6\) Welding of the forms to bridge elements fabricated from
non-weldable grades of steel or to flanges in tension will not be
permitted. Plan details will indicate stringer and girder top flange
tension limits. Attaching Stay-In-Place bridge deck forms in tension
areas of stringers and girders may be done by the welding together of
attachment straps if backing plates of galvanized steel are installed
under the attachment straps. The attachment straps may be furnished
without galvanization. The backing plates shall be thick enough to
prevent burn-through. The width of the backing plates shall be at least
one inch wider than the width of the welded attachment straps so that
the backing plates extend out at least one half inch beyond each edge of
the welded straps. The installation of attachment straps, shelf angles
and forms shall be carefully monitored to make sure that no welding is
done to the structural steel.

3\. CONSTRUCTION.

a\. Removable Forms.

\(1\) Forms shall be mortar tight and placed and maintained true to
designated lines and grades until the concrete has been placed and
hardened. Forms found unsatisfactory in any respect shall not be used
and, if rejected, shall be removed from the immediate work site.

\(2\) All moldings, panel work, and bevel strips shall be straight and
true with neatly mitered joints and all corners in the finished work
shall be true, sharp and clean cut and of good workmanship. Forms shall
be filleted and chamfered at all sharp corners except where angles
exceed 90º, such as at the face of bridge curbs and deck overhangs.
Unless otherwise shown on the plans, the equal sides on triangular
molding or chamfer shall be 3/4 inch, except that for small members the
width shall be 1/2 inch.

\(3\) For narrow walls, columns, et cetera, the Engineer may require
daylight and inspection holes at vertical intervals as directed.

\(4\) Bolts or ties shall be used to prevent forms from spreading. All
such bolts or ties shall be arranged so that at least one inch of that
part adjacent to the concrete surface can be removed or broken off.

\(5\) Anchor devices may be cast in the concrete for later use in
supporting forms only if they are detailed on approved formwork or
falsework plans.

\(6\) The inside of all forms shall be coated with a non-staining oil or
other approved material to prevent the concrete adhering to them.
Extreme care shall be exercised to insure that form oil does not come in
contact with structural or reinforcing steel.

\(7\) The forms shall be inspected before placing the concrete and the
interior dimensions carefully checked to insure that the concrete will
be of the form and dimensions shown on the plans. The inside faces of
the form shall be thoroughly examined and any projections, ridges,
depressions, offsets, spaces or other unevenness corrected so that the
surface of the concrete will be smooth, even and true, and mortar tight.
All forms shall be wetted immediately prior to placing the concrete, but
no excess water shall remain in the forms.

\(8\) To permit proper surface finishing, forms shall be removed as soon
after the concrete has set as is practicable and safe; however, forms
shall not be removed without the approval of the Engineer. In the
determination of the time for the removal of forms, except those listed
in Item 501.03(j)2., consideration shall be given to the location and
character of the structure, the weather and other conditions influencing
the setting of the concrete, and the material used in the mixture.
Methods of form removal likely to cause over-stressing of the concrete
shall not be used.

b\. Permanent Steel Bridge Deck Forms.

\(1\) All forms shall be installed in a manner acceptable to the
Engineer.

\(2\) On steel members, form sheets will not be permitted to rest
directly on the top of the stringer or floor beam flanges. Sheets shall
be securely fastened to form supports and shall have a minimum bearing
length of one inch at each end. Form supports shall be placed in direct
contact with the flange of stringer or floor beam. All attachments shall
be made by permissible welds, bolts, clips or other approved means.
However, there shall be no welding of form supports to flanges of steels
not considered weldable or to portions of flanges excluded in Paragraph
501.03(h)2.b.(6). Welding and welds shall be in accordance with the
provisions of Article 836.46 pertaining to fillet welds except that 1/8
inch fillet welds will be permitted. Welders shall be ALDOT qualified
welders when welds are being made to steel beams or girders.

On concrete girders, form supports to be cast into the girders shall be
shown on the shop drawings. All attachments to form supports shall be
made by permissible welds, bolts, clips, or other approved means.
Attachment by welding to form supports may be performed by non-ALDOT
qualified welders with welding electrodes recommended by the form
manufacturer.

All form welds shall be cleaned of slag and wire brushed just prior to
pacing of the deck concrete.

\(3\) Any permanently exposed form metal where the galvanized coating
has been damaged shall be thoroughly cleaned, wire brushed and painted
with two coats zinc oxide-zinc dust primer, Federal Specification
TT-P-641, Type II, no color added, to the satisfaction of the Engineer.
Minor heat discoloration in areas of welds need not be touched up.

\(4\) The Contractor\'s method of construction shall be carefully
observed by the Engineer during all phases of the construction of the
bridge deck slab.

\(5\) Transverse construction joints shall be located at the bottom of a
flute and 3/8 inch weep holes shall be field drilled at not more than 12
inches apart along the line of the joint.

\(i\) FALSEWORK.

1\. DESIGN AND CONSTRUCTION.

a\. General.

For the purpose of this specification, falsework shall be divided into
two classes as follows:

Class 1 ‑ Common or simple falsework such as permanent steel bridge deck
forms, deck overhang supports, screed rail support systems, or
substructure supports attached to permanent parts of the structure (i.e.
drilled shafts, columns, caps, etc.).

Class 2 - Unique or complex falsework such as that required for box
girder construction, RCDG construction, or any falsework used in
connection with steel erection.

The Contractor shall be responsible for designing and constructing safe
and adequate falsework which provides the necessary strength and
rigidity, supports all loads imposed, and produces a finished structure
with lines and grades shown on the plans. Falsework shall be designed
and constructed to withstand all imposed loads during erection,
construction, usage and removal.

The Contractor shall submit to the State Construction Engineer working
drawings and design calculations for falsework in accordance with
Article 105.02.

For both classes of falsework drawings, the Construction Engineer will
verify that the Registered Professional Engineer signature and stamp
requirements of Subarticle 105.02(d) are met. Class 1 drawings will be
stamped for distribution and then distributed. Class 2 drawings will be
forwarded to the Bridge Engineer for review to determine if the results
of the Registered Professional Engineer\'s calculations are in
compliance with design criteria. If the design criteria is met, the
submittal will be returned to the Construction Engineer to be stamped
for distribution and then distributed.

Except where noted in this paragraph, the formal submittal procedure may
be omitted for proposed Class 1 falsework details which have been
previously submitted and distributed for use on a project in Alabama. In
this case the Contractor shall submit a copy of the originally
distributed plans to the Project Engineer for confirmation. The formal
submittal procedure will always be required for permanent steel bridge
deck forms for continuous steel plate girders. The formal submittal
procedure will always be required where screed rail support spacing and
bridge deck overhang support bracket spacing is proposed to exceed the
maximum allowable values given in Subitem 510.03(c)6.c.

All falsework will be inspected by the Project Engineer using the
distributed drawings. For all Class 2 falsework, the Registered
Professional Engineer who signed the falsework submittal shall verify
that the falsework as constructed meets all design criteria prior to any
load being placed thereon. A signed statement from the Registered
Professional Engineer covering the verification shall be furnished to
the Project Engineer by the Contractor.

When falsework of either class is to be used over highway, pedestrian,
or railroad traffic additional details shall provide for special
protection to prevent debris from falling on the traffic below. These
additional details will be required for both removal and construction
work.

All falsework drawings shall include a description and size of all
members, connections and miscellaneous hardware. When pre-manufactured
assemblies are used, all parts shall be easily identified as those shown
on the drawings.

All falsework shall be designed and constructed to provide the necessary
rigidity and to support the loads without appreciable settlement or
deformation. Screw jacks and/or hardwood wedges shall be used to take up
any settlement in the formwork either before or during the placing of
concrete.

Any part of the permanent structure to which falsework will be attached
shall attain a minimum compressive strength of 2400 psi from cylinders
prepared in conformity with AASHTO T 23 prior to the attachment.

Falsework which cannot be founded on a satisfactory footing shall be
supported on piling which shall be spaced, driven and removed in an
approved manner.

All spans shall be given a temporary camber to allow for deflection,
shrinkage and settlement. Bridges shall have a permanent camber only
where so shown on the plans or directed.

b\. Design Criteria.

Falsework shall be designed to withstand all imposed loads during
erection, construction, usage and removal. Designs shall be based on
minimum loads, maximum stresses and deflections, and conditions in the
following paragraphs. Allowable stresses are based on use of undamaged,
high quality materials. Stresses shall be reduced by the Contractor if
lesser quality materials are used.

Design Loads for falsework shall consist of the sum of dead and live
vertical loads and assumed horizontal loads. Minimum total design load
for any falsework shall not be less than 100 pounds per square foot for
the combined live and dead load regardless of slab thickness.

Dead Loads shall include weight of concrete, reinforcing steel, forms
and falsework. Weight of concrete, reinforcing steel and forms shall not
be assumed to be less than 160 pounds per cubic foot.

Live Loads shall consist of the actual weight of any equipment to be
supported by falsework applied as concentrated loads at the points of
contact and a uniform load of not less than 20 pounds per square foot
applied over the area supported plus 75 pounds per linear foot applied
at the outside edge of deck overhangs.

Horizontal Loads applied shall be the sum of the actual horizontal loads
due to equipment, construction sequence or other causes and an allowance
for wind, but in no case shall the design horizontal load to be resisted
in any direction be less than two percent of the total dead load.
Falsework shall be designed of sufficient rigidity to resist the design
horizontal load prior to placement of concrete.

Falsework Foundations shall be designed to carry the loads imposed on
them without exceeding allowable soil bearing values and anticipated
settlements.

Maximum allowable stresses, loadings, and deflections used in design of
falsework shall be as follows:

Timber:

Compression perpendicular to the
grain\...\...\...\...\...\...\...\...\...\...450 psi

(Dense Select Structural Grade Southern Pine)

Compression parallel to the
grain\...\...\...\...\...\...\...\...\...\.....[480,000]{.underline} psi

(but not to exceed 1,600 psi) (L/D)^2^

Flexural
stress\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\.....
1,800 psi

reduced to 1,500 psi for members with a nominal depth of 8

inches or less

Horizontal
shear\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\...\....
90 psi

Deflection due to weight of concrete\...\...\...\...\.....1/240 of clear
span

irrespective of the fact that the deflection may be compensated for

by camber strips.

Timber piles, maximum
loading\...\...\...\...\...\...\...\...\...\...\...\... 24 tons

(12\" Butt Diameter)

Steel:

Deflection due to weight of concrete\...\...\...\...\.....1/240 of clear
span

irrespective of the fact that the deflection may be compensated for

by camber strips.

Stresses shall not exceed those specified in the Manual of Steel
Construction as published by the AISC. When the grade of the steel
cannot be positively identified, design stresses shall conform to either
those specified in said AISC Manual for ASTM Designation A 36 steel or
the following:

Tension, axial and flexural
\...\...\...\...\...\...\...\...\...\...\...\...\...\... 22,000 psi

Compression,
flexural\...\...\...\...\...\...\...\...\...\...\...\...\...\.....
[12,000,000]{.underline} psi

(but not to exceed 22,000 psi) LD/bt

Compression, axial\...\...\...\...\...\...\...\...\...\...\...\....
16,000 - 0.38(L/r)^2^ psi

(except L/r shall not exceed 120)

Shear on gross section of the web of rolled shapes\...\...\... 14,500
psi

Web crippling for rolled
shapes\...\...\...\...\...\...\...\...\...\...\...\... 27,000 psi

In the foregoing formulas, L is the unsupported member length, D is the
least dimension of rectangular columns, or the width of a square of
equivalent cross sectional area for round columns, or the depth of beam,
b is the width of member, t is the thickness of the compression flange
and r is the radius of gyration of the member. E, modulus of elasticity
used for timber shall be 1.6 x 10^6^ psi and for steel shall be 30 x
10^6^ psi.

Any additional design criteria which may be needed shall be developed by
the Contractor\'s Registered Professional Engineer designer and included
with the calculations of the falsework submittal.

Falsework over or adjacent to roadways or railroads which are open to
traffic during construction shall be designed and constructed such that
it is stable if subjected to vehicular impact or features shall be
provided to protect falsework supports from vehicular impact. Protection
shall be designed such that it does not present a hazard to vehicular
traffic.

Design criteria for permanent steel bridge deck forms shall be as shown
in Subitem 501.03(h)2.b.

2\. REMOVAL OF FALSEWORK.

No falsework supporting concrete shall be removed or wedges loosened
without the consent of the Engineer.

If adequate test cylinders have been made, falsework may be removed when
the cylinders indicate that the concrete has developed a minimum
compressive strength of 2400 pounds per square inch, otherwise falsework
shall be removed according to the following time limitations.

Falsework may be removed after expiration of 14 days exclusive of days
when for four hours or more the temperature is below 40ºF. Falsework
under slabs of less than six foot span may be removed after seven days
with the same temperature limitations.

Falsework shall be gradually and uniformly released in such a manner as
to avoid injurious stresses in any part of the structure. Wedges shall
be removed first under slabs and transverse beams, starting at the
center of the span and working both ways; then wedges under longitudinal
girders and beams shall be removed also starting at the center of the
span and working both ways simultaneously.

All falsework piles, at the time of removal or cleanup shall be pulled
out or cut off at an elevation not more than six inches above the bed of
the stream. Piles not in water shall be removed or cut off flush with or
below the ground surface of stream bed. Piles within roadbed limits
shall be cut off at least three feet below subgrade elevation. Other
piles within roadway limits shall be cut off at least one foot below the
finished surface of the front slope, ditch, or backslope.

\(j\) CURING CONCRETE.

1\. GENERAL.

All concrete shall be cured by an approved method for the period of time
given below:

  ------------------------------------------------ ----------------------
  Concrete with Type III cement                    3 days

  All other concrete                               7 days
  ------------------------------------------------ ----------------------

At all times during and immediately after concrete placement, concrete
shall be protected from premature drying, extremes in ambient air
temperatures, rapid temperature change, mechanical injury and injury
from rain and flowing water for the duration of the curing period. Air
and forms in contact with concrete shall be maintained at a temperature
above 50ºF. for the first 3 days and at a temperature above 32ºF. for
the remainder of the specified curing period. Exhaust fumes from
combustion heating units shall be vented to the outside of the
enclosure, and heaters and ducts shall be placed and directed so as not
to cause areas of overheating and drying of concrete surfaces or to
create fire hazards. All materials and equipment needed for adequate
curing and protection shall be available and at the site prior to
placing concrete. No fire or excessive heat, including welding, shall be
permitted near or in direct contact with the concrete at any time.
Curing shall be accomplished by any of the following methods, or
combination thereof, except as otherwise specified. No matter what
method of curing is to be used, fogging shall be used temporarily
between finishing operations and starting of application of the curing
method to be used.

2\. BRIDGE DECK CURING.

Moist curing shall be used for all bridge deck curing, and shall be used
for curing any other flatwork concrete as designated on the plans or as
approved by the Engineer. Concrete to be moist-cured shall be maintained
continuously wet for the entire curing period, commencing immediately
after finishing operations have been completed. Beginning immediately
after the screeding operations have been completed, the concrete surface
shall be kept continuously moist by fogging, and the fogging operations
shall be maintained continuously until the moist curing procedures have
begun. If water or curing materials stains or discolors concrete
surfaces which are to be permanently exposed, the concrete surfaces
shall be cleaned as approved. When wooden forms are left in place during
curing, they shall be kept wet at all times. If steel forms are used in
hot weather, nonsupporting vertical forms shall be broken loose from the
concrete and curing water continually applied in this void. If the forms
are removed before the end of the curing period, curing shall be carried
out as on unformed surfaces, using suitable materials. Surfaces shall be
moist cured by continuous sprinkling, by continuously saturated burlap
or cotton mats, or by continuously saturated plastic coated burlap.
Burlap and cotton mats shall be clean and free from any contamination
and shall be completely saturated before being placed on the concrete.
Burlap and cotton mat sheets shall extend at least 18 inches beyond the
concrete surface at all edges, and shall be overlapped at least 12
inches where two individual sheets join. All joints between burlap or
cotton mat sheets, and edges of burlap or cotton mat sheets along the
edge of the concrete surface being cured, shall be secured so that the
concrete surface remains covered during the entire curing period. Burlap
or cotton mat sheets shall be immediately repaired or replaced if tears
or holes appear in the sheets during the curing period. The Contractor
shall have an approved work system to ensure that moist curing is
continuous 24 hours per day.

3\. EXPOSED SURFACE CURING.

With the exception of bridge deck concrete, which shall be cured by
moist curing techniques, all concrete surfaces not covered by forms
shall be cured either by moist curing techniques, membrane forming
curing compound, or impervious sheeting. All concrete surface areas
exposed by the removal of forms shall be immediately moistened by water,
followed immediately by application of membrane-forming curing compound,
or by application of impervious sheeting where allowed by the
specifications

a\. Membrane Forming Curing Compounds.

Membrane forming curing compound may be used for curing concrete on any
area designated on the plans or as directed by the Engineer, except that
membrane forming curing compound shall not be used for curing bridge
deck concrete, and shall not be used on surfaces that are to receive any
subsequent treatment depending on adhesion or bonding to the concrete,
including surfaces to which a smooth finish is to be applied or other
concrete to be bonded. However, a styrene acrylate or chlorinated rubber
compound meeting ASTM C 309, Class B requirements, may be used for
surfaces which are to be painted or are to receive bituminous roofing or
waterproofing, or floors that are to receive adhesive applications of
resilient flooring. The curing compound selected shall be compatible
with any subsequent paint, roofing, waterproofing or flooring specified.
Membrane curing compound shall not be used on surfaces that are
maintained at curing temperatures with free steam.

Curing compound shall be applied to formed surfaces immediately after
the forms are removed and prior to any patching or other surface
treatment except the cleaning of loose sand, mortar, and debris from the
surface. All surfaces shall be thoroughly moistened with water before
applying the curing compound. Curing compound shall be applied to slab
surfaces other than bridge deck slabs as soon as the bleeding water has
disappeared, with the tops of joints being temporarily sealed to prevent
entry of the compound and to prevent moisture loss during the curing
period. The curing compound shall be applied in a two-coat continuous
operation by approved motorized power-spraying equipment operating at a
minimum pressure of 75 pounds per square inch, at a uniform coverage of
not more than 400 square feet per gallon for each coat, and the second
coat shall be applied perpendicular to the first coat. Concrete surfaces
which have been subjected to rainfall within three hours after curing
compound has been applied shall be resprayed by the method and at the
coverage specified. Surfaces on which clear compound is used shall be
shaded from direct rays of the sun for the first three days. Surfaces
coated with curing compound shall be kept free of foot and vehicular
traffic, and then from other sources of abrasion and contamination
during the curing period.

b\. Impervious Sheeting.

Impervious sheeting may be used for curing concrete on any area
designated on the plans or as directed by the Engineer, except that
impervious sheet curing shall not be used for curing bridge deck
concrete, and shall not be used on vertical or near-vertical surfaces.
All surfaces shall be thoroughly wetted and be completely covered with
the sheeting. The concrete surface under the impervious sheeting shall
be maintained in a continuously moist condition at all times during the
curing period. Sheeting shall be at least 18 inches wider than the
concrete surface to be covered. Covering shall be laid with
light-colored side up. Covering shall be lapped not less than 12 inches
and securely weighted down or shall be lapped not less than four inches
and taped to form a continuous cover with completely closed joints. The
sheet shall be weighted to prevent displacement so that it remains in
contact with the concrete during the specified length of curing.
Coverings shall be folded down over exposed edges of slabs and secured
by approved means. Sheets shall be immediately repaired or replaced if
tears or holes appear during the curing period.

4\. PROTECTION OF CONCRETE DURING CURING.

Green concrete shall be protected against jarring or other movement
which might cause damage. No traffic or other superimposed load will be
permitted over bridges or culverts until the concrete has reached the
required minimum 28-day compressive strength.

\(k\) FINISHING CONCRETE.

1\. GENERAL.

The details set forth hereinafter in this Subarticle cover the
requirements for the several classes of surface finishes which shall be
applied to the various parts of concrete structures.

These various classes of surface finishing will be used in accordance
with the following:

Class 1 - required on all concrete surfaces except wearing surfaces and
surfaces placed in direct contact with natural ground or embankment,
except for bridge decks.

Class 2 - required on all exposed concrete surfaces within the
requirements noted in Subitem 501.03(k)3.d. unless another class is
specified, except for bridge decks.

Class 3 - may be used on designated bridge structures when specified by
plan details, except for bridge decks.

Wearing surface finish for bridge deck travelway shall be as specified
in Subitem 510.03(c)6.c. and for sidewalks as specified in Item
510.03(c)7.

Exposed surfaces or sidewalks, driveways, curbs and gutters shall have a
textured finish obtained by the use of a burlap or cotton drag, brush or
broom so that a uniform gritty texture is obtained. Exposed surfaces of
concrete flumes and slope paving shall have a float finish.

2\. CLASS 1 FINISH (ORDINARY SURFACE FINISH).

This class finish will require the concrete surface to be free from
objectionable projections, swells, fins, ridges, depressions, waves,
holes and other defects. This will require that immediately after the
forms are removed, metal ties shall be removed for a minimum depth of
one inch from the face of the concrete. All cavities or depressions
resulting from this removal, or from other causes, shall be carefully
filled and pointed with a mortar of sand and cement, and the surface
left smooth and even. The proportion of cement to sand, measured by
volume, shall be one to two unless otherwise specified. The surface film
of all pointed areas shall be carefully removed before setting occurs.
Any fins, ridges, or projections shall be struck off smooth with the
surface of the concrete. Particular care shall be taken throughout the
progress of this operation to use one of the curing methods covered in
Subarticle 501.03(j).

If a Coated Surface Finish is to be applied in a later finishing
operation, the coating material may be used in lieu of mortar to fill
small air holes in the concrete surface; however, this shall be given
time to take a set prior to applying the Coated Surface Finish.

3\. CLASS 2 SURFACE FINISH.

a\. General.

This class surface finish requires that in addition to a Class 1 finish,
the exposed surfaces of bridges, culverts, headwalls, inlets, etc. as
defined in the Subitem d. below, received an additional surface finish
in accordance with the following:

If only one brand and type of cement from the same mill is used in a
structure or unit (substructure or superstructure), the Contractor may
elect to either apply a Rubbed Surface Finish or apply an approved
coated Surface Finish.

If more than one brand of cement is used in a structure, the Contractor
shall apply a Coated Surface Finish.

The same type of surface finish shall be used throughout the entire
structure unless otherwise authorized in writing by the Engineer.

b\. Rubbed Surface Finish.

The final finish shall be obtained by a complete rubbing with a No. 30
carborundum stone or an abrasive of equal quality. This rubbing shall
continue until the entire surface is of a smooth texture and uniform in
color.

c\. Coated Surface Finish.

Only Departmental approved coated finishing materials may be used. A
list of these coating materials may be obtained from the Materials and
Tests Engineer. Any coating finishes not on the approved list must be
approved by the \"Products Evaluation Board Committee\" before they will
be considered for use.

The application of the coating shall be in an approved manner (normally
in accordance with the manufacturers\' recommendations) by competent and
experienced personnel. The overall coated finish shall be uniform in
coverage, texture and color after the coating material has taken set and
cured. Failure to obtain uniformity of coverage, texture and color shall
be cause for the Engineer to require such remedial action as deemed
necessary to obtain the desired results.

The following actions shall be taken before the application of any
coated finish:

\(a\) A Class 1 surface finish applied and all pointing completely set.

\(b\) Surface clean and free from foreign matter.

If membrane curing compound was used to cure the concrete, the curing
compound shall have weathered for a minimum time period of six weeks.
Special care shall be taken to insure that areas not to be treated are
protected to prevent treatment from overlapping onto these designated
areas.

d\. Exposed Surfaces.

Exposed surfaces for this class finish is defined as all surfaces,
including bottom chamfers and fillets except (1) the wearing surface of
roadway slabs and sidewalks, (2) those surfaces having immediate contact
with embankment or excavation, (3) those surfaces below low water level
and/or below newly established ground line after backfilling excavation
or excavated channels, (4) underside and interior faces of girders,
beams and slabs, and underside of sidewalks where the edge beam extends
three inches or more below the bottom of the sidewalks, (5) top and
bottom surfaces of all type caps, (6) those parts of minor structures,
box culverts, and bridge culverts that are not readily visible from a
travelway.

4\. CLASS 3 SURFACE FINISH.

This class surface finish requires that in addition to the Class 1
surface finish that only the designated exposed surfaces of a bridge
structure noted below be given an additional finish of either a rubbed
or coated finish in accordance with the provisions for such noted in
Item 501.03(k)3.

Exposed surfaces shall be defined as the inside, top, and outside
surfaces of barrier rail to bottom of slab overhang, and all portions of
the bridge abutments outside the edge of the exterior girders which are
not in immediate contact with embankment or excavation. All other
structure surfaces, exposed and unexposed, shall receive a Class 1
finish immediately after the forms are removed.

5\. BRIDGE DECK CONCRETE SLAB FINISHING.

a\. General.

Bridge decks shall be finished in accordance with Subitem 510.03(c)6.c.
except as noted herein. Concrete bridge decks shall be finished after
screeding by performing edging and jointing followed by the application
of texturing. This sequence shall commence immediately after the
concrete has been screeded, and shall proceed in a continuous manner.
Care shall be taken to not perform any of these operations if bleed
water is present on the surface of the plastic concrete. If bleedwater
is present prior to completion of this sequence, it shall be carefully
removed by dragging burlap over the surface of the concrete before the
finishing proceeds any further. The dusting of surfaces with dry cement
or other materials or the addition of any water during finishing will
not be permitted. Bullfloating of deck surfaces will not be permitted.
Overfinishing or overworking water into the surface of a fresh concrete
slab can cause crazing, dusting, or scaling, which is detrimental to the
performance of the bridge deck. Any slabs with surfaces that exhibit
significant crazing shall be removed and replaced at no additional cost
to the Department.

b\. Edging and Jointing.

Edging and jointing shall commence immediately after the screeding
operation has been completed. Edging shall be accomplished with hand
tools against all edge forms and isolation and construction joints.
Jointing by hand tools may proceed simultaneously with edging, but only
in locations as designated on the plans. Minor touch up work to the
concrete surface may be accomplished with a wood float.

c\. Texturing.

Immediately after the edging and jointing has been completed, the
concrete surface shall be carefully textured by pulling a coarse fiber
push-type broom or by dragging burlap across the surface. Texturing
shall be transverse to the direction of traffic. Care shall be taken not
to overlap successive passes of the broom or burlap across the slab;
however, successive passes shall produce surface scores within 1/4 in.
of each other. Moist curing shall proceed immediately after the
texturing has been completed on the slab. Grooving shall be completed on
the hardened slab at the time and procedures described in Subitem
510.03(c)6.c.

\(l\) PRECAST CONCRETE UNITS (NON-PRESTRESSED).

1\. GENERAL.

All concrete furnished for use in any precast Portland cement concrete
section shall comply with requirements of the preceding Articles of this
Section except for modifications provided hereinafter in this
Subarticle, the detailed plans, or special provisions.

2\. CONSTRUCTION DETAILS AND MANUFACTURE.

The method of construction of precast concrete units shall be that of
the fabricator provided such conforms to the following requirements:

\(1\) Units shall be of the size and shape shown on the plans.

\(2\) The reinforcing system shall be rigidly wired or fastened at all
intersections and held to true position in the form by approved devices.

\(3\) Units shall be cast on level, tight platforms that will not settle
during the casting or curing. Forms shall conform to the general
requirements of this Section for concrete form work. The casting
location shall be accessible for vibrating and consolidation of the
concrete. Under normal curing methods, side forms may be removed at any
time after the concrete has taken its initial set (not less than four
hours after casting of the concrete); however, the entire unit shall not
be subjected to any handling stress until the concrete has reached a
strength of 2400 psi.

\(4\) Mixing and placing of concrete shall conform to the preceding
requirements of this Section. Piling shall be cast in a horizontal
position. Casting in tiers will not be permitted. Special care shall be
exercised to vibrate and consolidate the concrete around the
reinforcement and along and against the forms. Concrete shall be placed
continuously in each unit with special care being exercised to avoid
horizontal or diagonal cleavage planes. All reinforcement shall be
accurately placed and rigidly secured at the location shown by the plans
or approved drawings and special care shall be exercised that the
reinforcement is properly imbedded in the concrete in the completed unit
in accordance with the position indicated on the plans.

\(5\) As soon as the forms are removed, the unit shall receive an
ordinary surface finish. No other finish will be required on foundation
piling and that portion of trestle piling which will be required on
foundation piling and that portion of trestle piling which will be below
the ground surface, or piles to be used in sea water or alkali soils.
The completed unit shall be free from honeycomb, porous areas or other
defects. Exposed portions of piling and other exposed surfaces as
defined in Item 501.03(k)1, shall have a Class 2 Surface Finish unless
otherwise specified.

3\. CURING PRECAST CONCRETE UNITS.

After casting, all exposed concrete shall be protected by wet burlap or
other approved material to prevent excessive loss of moisture during the
initial set period. After the concrete has obtained its initial set (not
less than four hours after casting), the side forms may be removed and
the curing continued by one of the following methods. As an exception to
following curing methods, when a compressive strength of 4000 psi is
obtained no further curing will be required. All strength determinations
will be made by concrete cylinder tests.

a\. Standard Curing Method.

After removal of the side forms, the units shall remain on the pallets
and not moved for a minimum period of three days during which they shall
be kept covered with saturated burlap, double thickness, or tarpaulin.
If the unit has not reached a strength of 2400 psi at the end of this
minimum three day period, curing shall be continued for a period of
seven additional days by use of membrane curing compound, covering with
polyethylene sheeting, immersion in water, or by covering with a heavy
layer of sand which is kept wet. Anytime after the first three days if
the concrete reaches 2400 psi strength, curing may be discontinued and
the units moved.

b\. Steam Curing Method.

After precast concrete has obtained its initial set, steam shall be
applied in such a manner as to raise the temperature of the air
surrounding the units at a rate not to exceed 40ºF. per hour to a
temperature not to exceed 160ºF. This raised temperature shall be
maintained for a period of 24 hours; however, if a compressive strength
of 2400 psi has not been obtained at the end of 24 hours, the steam
curing shall be continued until the required strength is obtained. If a
compressive strength of 2400 psi is obtained before the end of the 24
hours noted, the steam curing procedure may be stopped if the units are
covered with polyethylene sheeting for an additional 24 hour period to
compensate for the shorter period of steaming.

4\. HANDLING AND STORAGE.

The method of handling and storage shall be such as to preserve true and
even edges and corners. Any cast unit which becomes chipped, cracked or
marred before or during the process of installation shall be rejected
and ordered removed from the work or if the damage does not affect the
structural integrity of the unit, it may be repaired by approved
methods.

No precast unit shall be transported or installed in the work until the
required strength has been obtained, verified by cylinder test.

**501.04 Inspection.**

\(a\) GENERAL.

The Contractor shall give the Engineer sufficient advance notice before
starting to place concrete in any section of a structure to permit the
inspection of forms, placing of steel reinforcements, and of preparation
for placing. Any defective falsework or forming shall be corrected, or
removed and replaced as necessary to the satisfaction of the Engineer,
all at the expense of the Contractor.

Authorization of the Engineer shall be secured before concrete is placed
in any portion of a structure. Any concrete placed in violation of this
provision or in the absence of the Inspector shall be removed and
replaced at no additional cost to the State.

\(b\) REMOVABLE FORMS.

After the forms have been removed, any defective work discovered shall
be removed and replaced in a satisfactory manner. If the surface of the
concrete is bulged, sagged, uneven or honeycombed to such an extent that
it cannot be satisfactorily repaired, the entire section shall be
removed and replaced, at no additional cost to the State.

\(c\) STAY IN PLACE STEEL FORMS.

After the deck concrete has been in place for a minimum period of two
days, the concrete, if deemed necessary by the Engineer, shall be tested
for soundness and bonding of the forms by sounding with a hammer as
directed by the Engineer. The number and locations of the forms to be
tested shall be as selected by the Engineer. If areas of doubtful
soundness are disclosed by this procedure, the Contractor will be
required to remove the forms from such areas for visual inspection after
the concrete has attained a minimum compressive strength of 2400 psi.
Care will be exercised to distinguish the sound of broken bond from the
sound of defective concrete.

At locations where sections of the forms are removed, the Contractor
will not be required to replace the forms, but the adjacent metal forms
and supports shall be repaired to present a neat appearance and assure
their satisfactory retention. As soon as the forms are removed, the
concrete surfaces will be examined for cavities, honey combing and other
defects. If irregularities are found, and in the opinion of the Engineer
these irregularities do not justify rejection of the work, the concrete
shall be repaired as approved by the Engineer. If the concrete where the
forms are removed is unsatisfactory, additional forms, as necessary,
shall be removed to inspect and repair the slab, and the Contractor\'s
methods of construction shall be modified as required to obtain
satisfactory concrete in the slabs. All unsatisfactory concrete shall be
removed or repaired as approved by the Engineer.

The Contractor shall provide all facilities as are reasonably required
for the safe and convenient conduct of the Engineer\'s inspection
procedures. No additional compensation will be allowed the Contractor
for compliance with the above inspection procedures.

**501.05 Acceptance of Concrete.**

Cast in place concrete, other than drill shaft concrete, will be
accepted in accordance with the following procedures:

\(a\) Concrete will be accepted on the basis of fresh concrete slump and
air content test results and compressive strength test cylinders meeting
the requirements for the class and type of concrete shown in the
Specifications.

\(b\) A core investigation will be used to determine the suitability of
potentially substandard concrete.

\(c\) The core investigation will be conducted as follows:

1\. Delineate the area on the structure representing the set of
cylinders with substandard strength.

2\. The Swiss hammer will be used to select a location for coring within
the affected area of the structure. The procedure to be used is as
follows:

a\. For linear members (columns, bent caps, girders and barriers) the
length of the member affected will be divided into either ten (10) equal
segments or three (3) foot long segments, if the affected length is
greater than thirty (30) feet.

b\. For area members (footings, pile caps and bridge decks) the area of
the member affected will be divided into either sixteen (16) roughly
equal segments or nine (9) square feet segments, if the affected area is
greater than approximately 150 square feet.

c\. Three (3) Swiss hammer readings will be taken in each segment and
averaged. The segment with the lowest average Swiss hammer readings will
be the location for coring.

3\. Four cores shall be obtained, cured and tested within 42 days from
concrete placement. The Contractor shall cut the cores within 35 days
after placement of the concrete to allow for the required curing and
testing to be completed within the above stated 42 days. One set of four
cores shall be obtained for every set of low compressive strength
cylinders. The cores shall be obtained, measured, cured and tested
according to AASHTO T-24. The proper strength correction factor will be
applied to cores having a L/D ratio less than two (2). The average of
the compressive strength of the three highest strength cores will
determine the compressive strength of the member.

4\. Extreme caution shall be taken to ensure that no reinforcing steel
is cut during the coring operation.

5\. The results from the testing of the cores will be used to determine
acceptance of and payment for concrete as follows:

a\. If the average compressive strength of the three highest strength
cores is equal to or greater than 100% of the specified 28-day
compressive strength, the concrete will be accepted with no price
reduction.

b\. If the average compressive strength of the three highest strength
cores is 85% or greater but less than 100% of the specified 28-day
compressive strength, and the State Bridge Engineer deems the
questionable concrete to be structurally acceptable, the concrete will
be accepted with a price reduction applied to the applicable pay item as
follows:

+-----------+----------------------------+----------------------------+
|           | **Average Core**           | **Percent of Pay Item**    |
|           |                            |                            |
|           | **Compressive Strength**   | **Bid Price To Be Paid**   |
+-----------+----------------------------+----------------------------+
|           | 95 % f'c 100 % f'c         | 90 %                       |
+-----------+----------------------------+----------------------------+
|           | 90 % f'c 95 % f'c          | 75 %                       |
+-----------+----------------------------+----------------------------+
|           | 85 % f'c 90 % f'c          | 50 %                       |
+-----------+----------------------------+----------------------------+

c\. If the average compressive strength of the three highest strength
cores is less than 85% of the specified 28-day compressive strength, the
questionable concrete shall be removed; or if the State Bridge Engineer
deems the questionable concrete to be structurally acceptable, the
concrete, at the Contractor's option, may be left in place with no
payment awarded.

SECTION 502

STEEL REINFORCEMENT

**502.05 Basis of Payment.**

***This Article (502.05) shall be deleted as written and the following
substituted in lieu thereof:***

**502.05 Basis of Payment.**

\(a\) UNIT PRICE COVERAGE.

Where the unit of measurement for Steel Reinforcement is pounds, the
weight of Steel Reinforcement determined as provided above shall be paid
for at the Contract Unit Price per pound, which price and payment shall
be full compensation for fabricating, furnishing, placing and butt
welding all materials, and for all labor, equipment, tools, and
incidentals necessary to complete the Item in accordance with Plan
details.

The reinforcement required for a bridge superstructure shall be paid for
at the Contract Unit Price bid per lump sum for Steel Reinforcement For
Bridge Superstructure which shall be full compensation for fabricating,
furnishing, and placing all materials in accordance with Plan details.
The Contract Unit bid price shall also be full compensation for all
labor, equipment, tools and incidentals necessary to complete this item
of work. An increase, or decrease, in the quantity of steel
reinforcement for a bridge superstructure from that shown on the Plans
which is caused by a change in the Plans after the contract has been let
will result in an increase, or decrease, in the compensation due the
Contractor. Changes to the compensation for the superstructure
reinforcing steel will be made by applying the percentage of the
increase or decrease to the contract lump sum price for Pay Item 502‑B,
Steel Reinforcement For Bridge Superstructure.

\(b\) PAYMENT WILL BE MADE UNDER ITEM NO.:

502‑A Steel Reinforcement ‑ per Pound

502‑B Steel Reinforcement For Bridge Superstructure, [\* ]{.underline},
[\*\* ]{.underline}, [\*\*\* ]{.underline}

‑ per Lump Sum

\* Station Number, Bridge Number, Ramp Number, etc.

\*\* Lane, if applicable

\*\*\* Approximate quantity of reinforcing steel in Pounds

SECTION 510

BRIDGES

**510.02 Materials.**

***This Article (510.02) shall be amended by deleting the second
paragraph as written and substituting the following in lieu thereof:***

All steel reinforcement used in a cast‑in‑place concrete bridge deck
shall be ASTM A 615 Grade 60 unless otherwise specified on the plans.

**510.03 Construction Requirements.**

\(c\) SUPERSTRUCTURES.

6\. REINFORCED CONCRETE BRIDGE DECKS.

b\. Placing Concrete.

***This Subitem (510.03(c)6.b.) shall be amended by deleting the fifth
and sixth paragraphs and substituting the following in lieu thereof:***

Simple spans shall be constructed in one pour, except on simple spans
over 50 feet in length transverse slab construction joints will be
permitted. On simple spans over 80 feet, transverse slab construction
joints will be required where longitudinal screeding is to be employed.
Where slab construction joints are used on simple composite spans,
construction joints shall be placed at approximately the quarter points
of the span; after pouring the center portion of the span and when the
concrete has reached a compressive strength of 2400 psi by cylinder
tests, or after four (4) days, the end slab portions of the span may be
poured. Where transverse screeding is to be employed, spans over 80 feet
may be constructed in one pour provided a minimum pour rate of 30 cubic
yards per hour is maintained and an approved retarder is used in the
deck concrete.

c\. Finishing.

***This Subitem (510.03(c)6.c.) shall be amended by deleting the third
paragraph and substituting the following in lieu thereof:***

**Transverse Screeds.**

Transverse screeds shall be of sufficient weight to strike off the
plastic concrete placed in front of the screed without \"riding up\" on
the concrete. Transverse screeds shall be supported by vertically
adjustable rails set a suffi­cient distance from the gutter line to allow
free movement of the screed from gutter line to gutter line. Supports
for the screed rail shall be located a maximum of 18 inches
center‑to‑center with the slab overhang support brackets located a
maximum of 24 inches center‑to‑center. Exceptions to the maximum
allowable screed rail and support bracket spacing will be considered if
the increased spacing is adequately addressed in the design calculations
that are required as a part of the Working Drawings (for falsework).
Satisfactory means of load distribution with minimum rail deflection
shall be provided. The screed rails for any deck pour shall be
completely in place for the full length of the pour and shall be firmly
secured prior to making test runs and subsequently placing deck
concrete. In making the test runs, a \"tell‑tale\" device attached to
the screed carriage may be used to check the proper clearance on the top
mat of the reinforcing steel.

***This Subitem (510.03(c)6.c.) shall be further amended by deleting the
fifth paragraph and substituting the following in lieu thereof:***

Final Finishing.

The final finish behind longitudinal screeds shall be obtained by wood
floating. The final finish behind transverse screeds shall be obtained
by either wood floating or burlap drag. The final texture shall be
obtained by the cutting of transverse grooves in the cured concrete.

The bridge decks shall be grooved perpendicular to the centerline. The
grooving operation shall not be started until the bridge deck has been
cured in accordance with Subarticle 501.03(j).

The grooves shall be cut into the hardened concrete using a mechanical
saw device which will leave grooves 0.125 inches wide and 0.125 inches
deep. The grooves shall be unevenly spaced and randomly varying between
0.625 inches and 1.125 inches using 0.125 inch increments. The grooved
finish shall be at right angles to the centerline of the bridge deck,
regardless of skew, and shall extend across the roadway from two feet
inside the face of the curb or barrier rail to two feet inside the face
of the opposite curb or barrier rail. Each pass of the grooving machine
shall be adjacent to the previous pass without overlapping.

SECTION 513

PRESTRESSED CONCRETE BRIDGE MEMBERS

**513.01 Description.**

\(a\) GENERAL.

This Section shall cover the furnishing of precast‑prestressed members
and the incorporation of these members in any structure to the lines and
grades designated by the plans or directed.

This Section shall also cover the furnishing of precast‑prestressed
members made from high performance concrete (HPC) as specified herein
and the incorporation of these members in any structure to the lines and
grades designated by the plans or directed.

The size, dimension and cross‑section and other details of the members
will be shown in the plan details. All required accessories and fittings
necessary for the incorporation of such members into a structure are
considered incidental to and included as a part of the member furnished.

The Requirements provided for Bridges, Section 510; for Reinforcing
Steel, Section 502; and Structural Steel, Section 508; and for Structure
Concrete, Section 501; shall apply in all respects to precast concrete
bridge members, except where otherwise indicated by specific
requirements given hereinafter in this Section or noted by plan details.

Pretensioned‑Prestressed concrete girders will be classified by \"type\"
according to the current AASHTO Classification, that is, Type I, II,
III, etc.

\(b\) DEFINITION.

The term \"pretensioned‑prestressed concrete\" refers to concrete in
which the prestressing strands or wire are tensioned prior to placing
the concrete and released after the concrete has gained sufficient
strength to retain the prestressing force by bond.

The term \"post‑tensioned prestressed concrete\" refers to concrete in
which the stressing steel is installed in voids or ducts cast 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.

The definition of all other terms pertaining to prestressed concrete
shall conform to the latest report of the AASHTO Committee on Bridges
and Structures and Prestressed Concrete Institute Joint Committee.

Requirements for normal strength concrete girders are given in
Subarticle 513.02(c). Requirements for high performance concrete
(**HPC**) girders are given in Subarticle 513.02(d).

**513.02 Materials.**

\(a\) GENERAL.

All materials used in the fabrication and installation of the precast
members shall comply with the appropriate requirements of Division 800,
Materials, and the requirements noted hereinafter in this Section unless
otherwise modified by plan details.

\(b\) REINFORCEMENT.

1\. STRESSING STEEL.

Stressing steel shall be in accordance with the following unless
otherwise specified by plan details:

Stressing Cable ‑ ASTM A 416 ‑ 250 ksi Min. Tensile Strength.

Designs using other strands may be submitted

for consideration by the Bridge Engineer.

Stressing Bars ‑(For Span Sections Only) ASTM A 722 ‑ Type I

with Mill test reports including Supplementary

requirements S1, S2, and S4.

2\. STEEL REINFORCEMENT.

All reinforcing steel and wire fabric for concrete reinforcement shall
meet the requirements of Section 835 unless otherwise specified on the
plans.

\(c\) CONCRETE (FOR NORMAL STRENGTH REQUIREMENTS).

1\. The Contractor shall submit a design to the Engineer for approval of
all concrete to be used in the prestressed members. Prestressed concrete
shall have a minimum 28‑day cylinder strength of 5000 psi or the minimum
28‑day cylinder strength specified by the plans.

2\. An approved air entraining agent shall be used to obtain an air
content of four percent (4%) plus or minus one (1) percentage point.

Other approved admixtures may be used to increase workability of the
concrete. Slump requirements shall be a maximum of three (3) inches plus
1/2 inch tolerance except when a water reducing agent is used, then a
maximum slump of four (4) inches plus 1 inch tolerance may be used. When
a high range water reducing agent is used, a slump requirement greater
than four (4) inches may be requested by the Contractor in the concrete
mix design request submitted to the Engineer for approval.

3\. The size of coarse aggregate shall not be larger than 1/5 of the
narrowest dimension between sides of the forms of the member being cast
nor larger than 3/4 of the minimum clear spacing between individual
reinforcing bars or bundles of bars.

4\. All materials used in manufacturing the concrete shall comply with
the requirements of the Standard Specifications.

\(d\) HIGH PERFORMANCE CONCRETE (HPC) FOR PRESTRESSED HPC CONCRETE
GIRDERS.

1\. REQUIRED STRENGTH.

The minimum strength of the HPC girder concrete at time of release of
the prestressing force shall be 8,000 psi. The minimum 28-day
compressive strength of the concrete shall be 10,000 psi. The concrete
compressive strength shall be determined from test cylinders made
according to AASHTO T 23 and tested according to AASHTO T 22.

2\. PROPORTIONING MATERIALS.

Mix Proportions suitable for achieving the 28-day strength and
performance requirements of the project shall be determined by the
Contractor and confirmed by two full size trial batches of at least 3
cubic yards. A full size test pour to verify the release strength,
28-day strength, and other characteristics of the mix shall also be
required for approval of the mix proportions.

If curing according to AASHTO T 126 is used for test cylinders from full
size trial batches, the required average 28-day strength determined from
two cylinders shall be at least 1500 psi above the required 28-day
strength. If accelerated curing of the test cylinders is achieved by
curing at elevated temperatures matching the anticipated internal
temperature of the girders, the average 28-day strength shall exceed the
required 28-day strength.

The dry weight proportions of the materials shall not be changed after
approval of the mix except that the water content may be decreased and
the fine aggregate content increased to maintain the yield of the mix.
Other changes made necessary by low cylinder strength results shall
require prior approval by the Engineer. Acceptance of a mix design by
the Engineer does not constitute acceptance of low cylinder strengths
resulting from use of the mix.

Permission to change producers for any component material of the mix
including aggregates, cementitious materials, or admixtures shall
require trial batches and/or test pours at the expense of the Contractor
to prove the acceptability of the change. Use of water reducers, water
reducing set retarders, and high range water reducing admixtures is
permissible. Dosage rates and combinations of admixtures may be varied
within the manufacturer's recommended limits as required to meet
seasonal changes in workability and curing requirements. Use of
admixture dosage rates outside ranges approved with the mix design shall
require prior approval by the Engineer.

The Contractor shall select the cement type to be used. The cement
content shall be sufficient to meet the project requirements. The mix
shall also contain fly ash, or microsilica, or a combination of fly ash
and microsilica to provide improved durability. Acceptable ranges of
cement replacement for these mineral admixtures are:

Class "F" fly ash 15 to 25%

Class "C" fly ash 15 to 35%

Microsilica 7 to 15%

When combinations of fly ash and microsilica are used, the fly ash
content shall satisfy the ranges specified above, and the microsilica
shall be considered an addition. The microsilica addition shall be at
least 3% of the total cement plus fly ash content and no more than 15%.

The maximum permissible water to total cementitious material (cement
plus fly ash plus microsilica) ratio shall be 0.32. Water contained in
the aggregates above the amount of absorbed water shall be included in
the calculation of the water to cementitious material ratio.

Coarse aggregate shall be ALDOT No. 7 or No. 67 crushed limestone. The
size of coarse aggregate shall not be larger than 1/5 of the narrowest
dimension between sides of the forms of the member being cast nor larger
than ¾ of the minimum clear spacing between individual reinforcing bars
or bundles of bars.

Fine aggregate shall be a natural sand.

An air entrainment admixture shall be used, and the air content of the
fresh concrete shall be between 3.5 and 6% by volume.

Concrete shall not be placed at a slump exceeding 9 inches.

3\. TEST POUR REQUIREMENTS.

After mix proportions are submitted along with proof from the full size
trial batches of the acceptability of the mix, the Contractor shall make
a full size test pour. Satisfactory performance of test pour shall be a
part of the requirements for acceptance of the mix design. Prior to the
test pour, a prepour conference shall be held with the Engineer. The
test pour shall be made in the casting bed which will be used for
casting the bridge members. The test pour member shall be a full cross
section and at least 10 feet in length.

The test pour shall provide evidence of the Contractor's ability to mix,
handle, place, consolidate and cure the mix properly to meet the release
strength and 28-day strength requirements. Acceptable use and
performance of the match-curing system, as defined below, shall also be
illustrated by the test pour. Sampling, curing, and testing requirements
for cylinders required for the bridge members shall be used for the test
pour except that additional test cylinders shall be required as
described below.

A minimum of eight cylinders shall be made and cured using the
match-curing system, and two cylinders shall be tested to failure at
each of the following concrete ages: release, 7-days, 28-days, and
56-days. A minimum of eight cylinders shall be made and cured using
normal curing, as defined below, and two cylinders shall be tested to
failure at each of the following ages: release, 7-days, 28-days, and 56
days. A minimum of three core samples of the concrete in the test pour
member shall be drilled seven days prior to being tested to failure at
an age of 28 days and three at an age of 56 days.

4\. CURING REQUIREMENTS.

Curing shall be in accordance with BMTP-367, Rev. 3-18-94, except that
intermittent steaming or partial steaming will be allowed only if
required to prevent the internal temperature of the members from
exceeding 160F. If intermittent or partial steaming is used, the
Contractor shall take all necessary steps to prevent cracking of the
members from shrinkage and cooling of the members prior to detensioning.

5\. MATCH-CURING REQUIREMENTS FOR TEST CYLINDERS.

Cylinder test results used for acceptance of the members shall be for
cylinders cured using match-curing. The match-curing system shall
continuously monitor the internal temperature of a member in the line of
production and maintain the internal temperature of the concrete test
cylinders within 5F. of the internal temperature of the member up to the
time of release of the prestressing force. The internal temperature of
all members shall be continuously monitored and recorded at a total of
three points specified by the Engineer based on the configuration of the
casting beds and steam curing equipment. The Engineer will specify the
point inside a specific member that shall be used as a control for the
match-curing system. After release of the prestressing force, the test
cylinders shall be cooled slowly and then cured using normal curing
procedures as outlined below.

At no time shall the internal temperature exceed 160F. at any point
inside any member or test cylinder.

Test cylinder moulds for the match-curing system shall be 6 in. by 12
in. or 4 in. by 8 in.

6\. NORMAL CURING REQUIREMENTS FOR TEST CYLINDERS.

For cylinders cured separately from the match-curing system, normal
curing begins with placing the cylinder moulds beside the girder forms
during curing of the members up to time of release. After release, all
test cylinders, including the match-cured cylinders, shall be cured in
the exact same manner as the concrete members they represent. The
cylinders shall be placed in regions representing the average curing
conditions for the members.

**513.03 Construction Requirements For Manufacture and Installation.**

\(a\) GENERAL.

All materials, details and procedures shall be as specified herein,
noted on the plans, or directed by the Engineer.

The manufacture of prestressed concrete items shall be in accordance
with the procedures in BMTP‑367, \"Guidelines For Inspection of
Prestressed and Post‑tensioned Concrete Items.\" The Engineer\'s
interpretation of BMTP‑367 will be final. The suggested and recommended
specifications in the above procedure shall apply and will be used in
the manufacture of prestressed members unless otherwise specified by
plan details or this specification.

The prestressed concrete manufacturing plant shall be certified by the
Precast/Prestressed Concrete Institute Plant Certification Program. The
Manufacturer shall submit proof of certification prior to the start of
production. The plant\'s certification shall be in the appropriate
product group and category for the products being produced by the plant.

\(b\) MANUFACTURE.

The Contractor shall submit to the Bridge Engineer for approval shop
drawings showing complete details of prestressed and post‑tensioned
concrete items as specified in Subarticle 105.02(c) and his proposed
tensioning and de‑tensioning procedure.

Within 30 days after the award of the contract, the Contractor shall
notify the State Bridge Engineer in writing of the name and address of
the fabricator of the bridge members. The notification shall include the
fabricator\'s proposed fabrication schedule.

Each production line shall be equipped with a complete set of forms so
that all members cast can be cast in one operation. Members shall be
cast and cured in one operation and movement of forms from or within a
production line will not be permitted until the next day.

Bearing and anchorage of the prestressed concrete members shall be in
accordance with the plan requirements. Jacks and Gauges, Load Cells,
Dynamometers, etc., used for stressing/tensioning shall be calibrated in
accordance with the procedures in BMTP‑358, JACK CALIBRATION PROCEDURE.

Forms for pretensioning members shall be so designed and aligned that
they will not restrict the longitudinal movement of the casting when the
prestressing force is transferred.

For prestressed I‑shaped bridge beams of depths not more than 4 feet 0
inch, the concrete should be placed in at least two continuous
horizontal layers in the forms and in at least three (3) layers for
prestressed I‑beams of greater depth, unless otherwise specified.

Forms for post‑tensioning members shall be so designed that members will
not be damaged when prestressing force is transferred. Unbal­anced
post‑tensioning will not be permitted.

Forms shall be inspected and approved by the Engineer prior to
authorizing casting operations. Keyways, countersunk keys and other
configurations shown by the plans shall be built into the forms. Tops of
headers shall be in the same plane as the top of side forms. The
dimensional location of the top of the headers and side forms shall be
the same on all forms used in a production of a particular type or size
member. Worn, damaged or otherwise unacceptable forms shall be repaired
before casting operations will be authorized.

The transfer of prestressing force shall be done when the concrete has
reached a strength of 4000 psi, unless otherwise specified by plan
details.

Curing of units shall be in accordance with the provisions of Subarticle
501.03(m).

\(c\) TESTING.

1\. CONCRETE.

a\. Normal Strength Concrete Girders.

At least 12 standard test specimens (6 x 12 cylinders) shall be prepared
for each 50 cubic yards, or fraction thereof, of concrete placed to
determine the concrete strength of the casting at different ages. The
test specimens shall be placed beside the girder forms during curing of
the members up to the time of release of the prestressing force. After
release, all test cylinders shall be cured in the same manner as the
concrete members they represent. The cylinders shall be stored in areas
representing the average curing conditions for the members.

b\. High Performance Concrete Girders.

At least 12 cylinder test specimens shall be prepared for each casting
of 50 cubic yards, or fraction thereof, to determine the concrete
strength of the casting at different ages.

c\. Acceptance of Concrete.

Testing of cylinders for determination of compressive strength shall be
performed according to AASHTO T 22.

Release of the prestressing force for a line of production will be
permitted when cylinder test results for each casting in the line of
production meet the following acceptance criteria. The concrete strength
for a casting is acceptable when the average of two cylinder test
results from the casting obtained at the same age exceeds the required
release strength and neither cylinder test result is below 95% of the
required strength.

The concrete strength will be acceptable for shipping prestressed
members when the average of two cylinder test results obtained at the
same age exceeds the required 28-day strength and neither cylinder test
result is below 95% of the required strength.

The concrete strength at 28-days shall be determined from the average of
two cylinder tests at an age of 28-days even if the concrete strength
has been previously accepted for shipping. If the concrete strength has
been previously accepted, the 28-day compressive strength test results
will be recorded but will not be used to retract acceptance of the
members.

A core investigation as described in Subarticle 501.05(c) will be used
to determine the suitability of concrete having cylinder test results
which do not meet the above acceptance criteria.

2\. STRESSING STEEL AND REINFORCING STEEL.

Sampling and testing shall be in accordance with current Departmental
policy.

3\. MISCELLANEOUS ITEMS AND ACCESSORIES.

Sampling and testing of miscellaneous items and accessories shall be in
accordance with the provisions for the type item provided under the
appropriate Section in Division 800, Materials, and the current
Departmental policy.

Miscellaneous hardware for precast deck span sections such as machine
bolts, nuts, washers, plates, etc. shall be hot dipped galvanized common
stock hardware items unless otherwise specified by plan details.

4\. DIMENSIONAL AND SURFACE TOLERANCES.

In addition to the requirements noted in BMTP-367, roadway surfaces of
span sections shall not vary more than 1/8 inch from a 10‑foot straight
edge.

5\. CAMBER OF MEMBERS.

For span sections at the time of shipment, the total camber shall be
between 0 and + 1/2 inch.

For pretensioned AASHTO girders the camber shall be as indicated by plan
details.

\(d\) SURFACE FINISH OF UNITS.

All units shall receive a Class 1 finish and in addition all outside
AASHTO girders shall receive a Class 2 finish, all in accordance with
the provisions of Subarticle 501.03(l), unless otherwise provided in the
proposal or by plan requirements. When a Class 2 finish is required, it
shall be the same as to be used on the other portions of the bridge
structure, and the final finish shall not be applied until after the
concrete deck is in place on the girders. It will not be necessary to
fill small holes in the surface of the prestressed AASHTO girders caused
by entrapped air where a Class 2 Surface Finish is not required.

The roadway surface of precast span sections shall receive a wood float
finish.

\(e\) HANDLING, STORING AND TRANSPORTING.

The Contractor shall be responsible for the proper handling, storage and
transporting of precast members. While lifting or storing precast
members, the tops of each shall be placed upward. Lifting hooks or
similar devices for lifting shall be placed at points close to each end
of span. They shall be of sufficient strength and embedment to provide
safe handling of the elements. Blocking under units during storage and
handling shall be placed close to ends of span only. Lifting devices
shall be of sufficient size and capacity to insure safe handling during
moving of units.

\(f\) ERECTING AND PLACING.

1\. GENERAL.

Any unit cracked or otherwise damaged in either handling or placing will
be evaluated by the Engineer as to whether the damage is minor and may
be repaired, or whether it will be rejected. Any repair shall be made in
a manner acceptable to the Engineer and the Engineer\'s ruling on the
unit\'s acceptability will be final.

2\. PRE‑TENSIONED ‑ PRESTRESSED GIRDERS.

The moving and placement of the girders shall be such that the units are
lifted and/or supported at the points shown on the plans or at the
supporting points of the unit when it is put into service.

Care shall be taken to insure proper placement on anchor bolts and that
the anchor bolts are tightened and secured as noted in the plan details.

3\. PRESTRESSED CONCRETE SPAN SECTIONS.

In the installation of span sections care shall be taken to match the
units so that the surface differentiation between adjacent units do not
exceed one quarter (1/4) inch. Span sections which do not meet the
surface differentiation requirement will be rejected; however, the
rejected unit may be used in a differ­ent position in the structure or in
another structure provided the surface differen­tiation requirement is
met.

After placing the units in a structure they shall be bolted together as
shown by plan details to provide a snug tight fit, if the flat washers,
bolt heads or nuts do not indicate uniform bearing on each other and the
concrete, an appropriate sized beveled washer shall be provided. Snug
tight is defined as the tightness such as can be produced by one or two
solid blows from an impact wrench or by full effort of a man using an
ordinary two (2) foot spud wrench. After obtaining the proper bolt fit,
the threads shall be burred to prevent removal.

Upon satisfactory completion of the bolting up operation, the con­crete
keyway shall be poured using a 4000 psi concrete (the Contractor shall
have a design mix for the concrete, approved in the same manner noted in
Subarticle 513.02(c)) which has been retempered. This pouring operation
requires the following sequence: 1. Standard mixing of the concrete
shall be completed a minimum of 45 minutes in advance of placing; 2. The
mix shall be retempered by remixing the concrete without additional
water just prior to placing; 3. The concrete mix shall be placed in the
keyway, tamping and packing the mix as necessary to insure complete
filling of the joint; 4. The exposed surface of the joint shall be
struck to the same elevation of the adjoining deck sections and the
surface given a wood float finish.

\(g\) ACCEPTANCE OF UNITS.

Preliminary acceptance of units will be based on compliance with plan
dimensions, the details noted hereinbefore and concrete cylinder tests.

Final acceptance of the units will be based on the preliminary appro­val
and the satisfactory installation of the units in the structure in
accordance with the plan requirements.

**513.04 Method of Measurement.**

\(a\) ITEM NO. 513‑A.

The number of pretensioned‑prestressed concrete girders of each length
and type measured for payment will be the actual number of girders of
each length and type ordered, installed and accepted.

\(b\) ITEM NO. 513‑B.

The linear footage of pretensioned‑prestressed concrete girders measured
for payment will be the ordered length of each type ordered, installed
and accepted. The length measured for payment will be the casting length
shown on the approved shop drawings minus any allowances for elastic
shortening and shrinkage for each girder. This will be the length
recorded on the Shipping Notice (BMT‑139) prepared by the Department\'s
Plant Inspector and shipped with the girders.

\(c\) ITEMS 513‑C and 513‑D.

The number of precast (post‑tensioned or pretensioned) concrete span
sections of each type and dimension complete in place and accepted will
be the actual number of units ordered and accepted completed in place in
a bridge structure.

\(d\) RELATED ITEMS.

Items not specifically covered by the unit price coverage noted in
Subarticle 513.05(a) necessary to complete the bridge structure will be
measured and paid for under the appropriate item of work noted elsewhere
in Sections 501, 502, 508 and 510 of the Standard Specifications.

**513.05 Basis of Payment.**

\(a\) UNIT PRICE COVERAGE.

1\. ITEMS 513‑A and 513‑B.

The accepted pretensioned‑prestressed concrete girders, measured as
noted above, will be paid for at the respective unit price bid for each
of the type girders designated on the plans or proposal. Said price
shall be full compensation for furnishing all materials, manufacturing,
and installation of the girders, including premolded bituminous filler,
and all necessary accessories; for all items cast into the concrete,
including metal bearing plates, and studs welded to these plates; for
obtaining a Class 2 surface finish on the outside of all exterior
girders; and for all other materials, equipment, tools, labor, and
incidentals necessary to complete and place the girders into the proper
position in the bridge.

The placement of the concrete slab and other related items of work which
are to be measured for payment separately will be paid under their
respective items of work.

2\. ITEMS 513‑C and 513‑D.

Accepted pretension concrete deck span sections measured as noted above
will be paid for at the respective contract unit prices each, for the
respective type member of the depth, width and length desired. Said unit
price shall be full compensation for the manufacturing and furnishing of
the member complete in place in the bridge, for necessary accessories,
for all items cast into the concrete, for the tie bolts, for expansion
and bearing materials, for cover concrete over fittings, for grout and
grouting, for placement of keyways, for surface finishing and for all
other materials, equipment, tools, labor and incidentals required to
complete the bridge, except structural steel and handrail.

3\. PARTIAL PAYMENT.

Partial payments will be made in accordance with the following schedule:

Fabrication and Delivery to Approved Storage Site \*

Erected and the Required Finish Applied to

Girder Units or the Bolting Up and Casting of

Keyway on Deck Units 100%

\* Reference is made to Article 109.07 concerning approved

storage sites and partial payment for stored material.

Any unit that fails to meet the contract requirements or is damaged
prior to acceptance of the project will be rejected by the Department
and any partial payments made on the unit prior to its rejection will be
recovered by the Department on the next monthly estimate or final
estimate, whichever is applicable.

\(b\) PAYMENT WILL BE MADE UNDER ITEM NO.:

513‑A Length Pretensioned‑Prestressed Concrete Girders, Type
[\*]{.underline}

(SPECIALTY ITEM) ‑ per Each

513‑B Pretensioned‑Prestressed Concrete Girders, Type [\*]{.underline},
( [\*\*]{.underline} )

(SPE­CIALTY ITEM) ‑ per Linear Foot

513‑C Prestressed Concrete Interior Span Sections,
[\_\_\_\_]{.underline}\_ Wide by

[\_\_\_\_]{.underline}\_ Deep by [\_\_\_\_]{.underline}\_ Long
(SPECIALTY ITEM) ‑ per Each

513‑D Prestressed Concrete Exterior Span Sections,
[\_\_\_\_]{.underline}\_ Wide by

[\_\_\_\_]{.underline}\_ Deep by [\_\_\_\_]{.underline}\_ Long
(SPECIALTY ITEM) ‑ per Each

\* Type I, II, III, etc., as per AASHTO Classification.

\*\* Specify "HPC" if required.

SECTION 806

MINERAL ADMIXTURES

**806.01 Mineral Admixtures.**

***This Article (806.01) shall be deleted as written and the following
substituted in lieu thereof:***

**806.01 Mineral Admixtures.**

\(a\) GENERAL.

The Department has established a list of Mineral Admixtures For Use In
Portland Cement Concrete, List I‑3, \"Materials, Sources, and Devices
With Special Acceptance Requirements\" Manual. Refer to Subarticle
106.01(f) and BMTP-355 concerning this list.

\(b\) FLY ASH.

Fly ash shall consist of the finely divided residue or ash that remains
after burning finely pulverized coal at high temperatures and shall meet
the requirements of AASHTO M 295, including the optional requirements in
Table 2.

\(c\) MICROSILICA.

Microsilica for use as a mineral admixture in Portland cement concrete
shall meet the requirements of AASHTO M 307.

\(d\) GROUND GRANULATED BLAST FURNACE SLAG.

Ground granulated blast furnace slag for use as a mineral admixture in
Portland cement concrete shall meet the requirements of AASHTO M 302,
Grade 100 or 120. The total cementitious material (the ground granulated
blast furnace slag and the cement) shall meet the total alkali content
requirement in Article 815.07. See Item 501.02(c)7. for additional
requirements.

If ground granulated blast furnace slag is used as a mineral admixture
in soil-cement stabilization, the ground granulated blast furnace slag
shall meet the requirements of AASHTO M 302, Grade 100 or 120, and the
content shall be 50 % of the weight of the total cementitious material.

SECTION 815

CEMENT

**815.04 Type IS Portland Blast Furnace Cement.**

***This Article (815.04) shall be deleted as written and the following
substituted in lieu thereof:***

**815.04 Type IS Portland Blast Furnace Slag Cement.**

Type IS Portland blast furnace slag cement (for use in soil-cement
stabilization) shall meet the requirements of AASHTO M 240, *Blended
Hydraulic Cement*.

**815.05 Type IP Portland ‑ Pozzolan Cement.**

***This Article (815.05) shall be deleted as written and the following
substituted in lieu thereof:***

**815.05 Type IP Portland ‑ Pozzolan Cement.**

Type IP Portland ‑ Pozzolan Cement shall meet the requirements of ASTM C
595 with the following modifications:

1\. The fly ash content shall be limited to a maximum of 20% by weight.

2\. The Pozzolan shall be limited to fly ash meeting the require­ments of
Section 806, Mineral Admixtures.

3\. Attention is directed to the fact that the final blend of the IP
Cement shall comply with Article 815.07.

SECTION 835

STEEL REINFORCEMENT

**835.06 Prestressing Steel.**

\(a\) STRESSING CABLE.

***This Subarticle (835.06(a)) shall be deleted as written and the
following substituted in lieu thereof:***

\(a\) STRESSING CABLE.

Unless otherwise shown by plan details, stressing cables shall meet the
requirements of ASTM A 416 for the appropriate design strength.