100 general provisions

Reinforcing Steel Tolerances
Description	Box Beam	I Beam
Clear cover	-0 + 1/4(6 mm)	-0 + 1/4(6 mm)
Splice lengths	- 1 1/2” (38 mm)	- 1 1/2” (38 mm)
Stirrup spacing In Anchorage Zone	± 1/4” (6 mm)	± 1/4” (6 mm)
Stirrup spacing outside Anchorage Zone	± 1” (25 mm)	± 1” (25 mm)
Stirrup extension above top flange	+1/4”(6 mm) – 1/2”(13 mm)	+1/4”(6 mm) – 3/4”(13 mm)

515.18 Prestressed Member Acceptance and repair. Throughout the fabrication process reject all prestressed members not meeting specification requirements.

For all rejected members provide the Department with a complete description of the rejection, and unless waived by the Director, an Ohio registered professional engineer’s written evaluation of the criticalness of the rejection and the professional engineer’s proposed repair method that will repair the rejected member to an acceptable condition. The Department will determine the acceptability of the member and the repair procedure. If acceptable, the fabricator will only make repairs witnessed by the Department’s inspector unless waived by Director.

Use the Precast/Prestress Concrete Institute’s Manual for the evaluation and repair of Precast, Prestressed Concrete Bridge Products MNL-137-06 as a general guide.

515.19 Handling Storage, Transportation, and Erection.

Handle, store, transport, and erect the members in an upright position. The direction of support reactions during storage and transportation shall be the same as the member will experience in its in-service position. Do not ship prestressed members until the concrete obtains its 28-day design strength and the inspector’s approval.

Provide at least 30 inches (762 mm) horizontally between each beam for inspection. Provide at least 8 inches (200 mm) of vertical clearance from the bottom. Use storage support locations as close as practical to the in-service support locations. During storage, provide unyielding horizontal supports and bracing capable of maintaining the members in a vertical position.

Transportation support locations shall be the sole responsibility of the fabricator with respect to member stresses and safe delivery to the job site If it is necessary to transport the members in a position other than vertical, obtain the Director’s written approval.

Provide lifting devices capable of withstanding the required loads to lift and erect the members. During erection, accurately place the prestressed beams on their bearings to ensure a uniform load on all bearings. When shifting a member, lift the member up completely off of its bearings. Temporarily brace the first I-beam erected to its substructure support units in the vertical position before releasing the beam from the crane. Tie each subsequent I- beam to the previously braced beam(s). Provide bracing after erection adequate to prevent sliding, tipping, or other movement that may result from high winds, creeping down the grade, or other causes, until placement of the diaphragms. Within any one day erect and brace at least 2 adjacent members in any one span before suspending operations for the day.

Place box beams to ensure a correct fit of the keyways and to ensure proper grouting of the keyways. After placing the beams and installing tie devices, fill the longitudinal keyways using non shrink keyway grouts, 705.22, approved by OMM. Mix, install, and cure the grout according to the manufacturer’s published recommendations to obtain a design compressive strength of 5000 pounds per square inch (34.5 MPa).

Do not allow vehicular load on an individual prestressed concrete box beam until the grout in the keyway obtains the specified design strength of 5000 pounds per square inch (34.5 MPa).

If erection of prestressed members requires placing cranes or launching devices on previously erected spans, submit erection procedures for approval according to Item 501.

At the Director’s discretion, repair or replace members damaged by improper handling, storage, transportation, or erection.

515.20 Safety Requirements. Provide effective safety measures to prevent injuries to personnel due to breakage of strands or failure of anchorage devices during the tensioning operations. Provide adequate protection and assure the OMM inspector can perform inspection of beams and manufacturing processes. The Department inspector will report any inadequate safety precautions to the plant QCS and to OMM if fabricator remedial action is not taken. OMM inspectors will follow safety rules established by the fabricator, at a minimum. Where fabricator safety rules interfere with the inspectors duties, the process should be altered to allow the inspections to be performed while maintaining the required level of safety.

515.21 Method of Measurement. The Department will measure Prestressed Concrete Bridge Members by the number of members.

The Department will measure the intermediate diaphragms by the number of each placed.

515.22 Basis of Payment. Payment for prestressed concrete beams include all inserts, sleeves, fittings, reinforcing steel fully or partially encased in the members, and all transverse tie rods necessary to complete this work.

The Department will pay for concrete diaphragms, steel diaphragms, and bearing plates or pads, or other expansion materials, as separate items.

The Department will not pay for repaired or replaced members damaged by improper handling, storing, transporting, or erecting.

The Department will pay for accepted quantities at the contract prices as follows:

Item Unit Description

515 Each Prestressed Concrete Non- Composite Box

Beam Bridge Members, Level 1

515 Each Prestressed Concrete Composite Box

Beam Bridge Members, Level 1

515 Each Straight Strand Prestressed Concrete Bridge

I-Beam Members, Level 2

515 Each Draped Strand Prestressed Concrete Bridge

I-Beam Members, Level 3

515 Each Intermediate Diaphragms

ITEM 516 EXPANSION AND CONTRACTION JOINTS JOINT SEALERS AND BEARING DEVICES

516.01 Description

516.02 Fabrication

516.03 Coating

516.04 Materials

516.05 Expansion and Contraction Joints

516.06 Joint Sealers

516.07 Bearing Devices

516.08 Method of Measurement

516.09 Basis of Payment
516.01 Description. This work consists of fabricating, assembling, constructing, coating, and installing expansion and contraction joints, vertical extension of structural expansion joints, joint sealers, or bearing devices of the type and size specified.

516.02 Fabrication. Fabricate metal joint armor and metal bearings according to Items 513. Select a fabricator that is at least pre-qualified at level SF. The Department will base final acceptance of fabricated members on the Engineer’s approval that the fabricated items that can be successfully incorporated into the structures. Submit mill test reports for structural steel, steel castings, bronze, and sheet lead certified according to 501.06.

516.03 Coating. Coat exposed steel bearings according to Items 513 and 514 that are to be attached to structural steel. Galvanize bearings according to 711.02 that are to be attached to concrete beams.

Coat metal parts of expansion joints with metalized 100% zinc wire. Prepare the surface to be coated and apply coating as required by The Society of Protective Coatings SSPC-CS-23.00(1). Apply coating to a minimum thickness of 6 mils.

Repair metalized coatings damaged during fabrication by removal of the damaged coating and reapplication as specified above. Repair metalized or galvanized coatings damaged during shipping, construction, or field welding as specified above or as follows:

A. Clean surface to be repaired using a wire brush, a light grinding action, or mild blasting. Extend the surface cleaning into the surrounding undamaged metalized or galvanized coating.

B. Remove all weld flux residue and weld splatter by mechanical means such as chipping, grinding, or power scaling.

C. Preheat the surface to be repaired to at least 600 F (315 C). Do not overheat the surface above 750 F (400 C) nor allow the surrounding metalized or galvanized coating to be burned. Wire brush surfaces to be repaired during preheating.

D. Apply zinc coating by rubbing with a pure zinc stick or sprinkling pure zinc powder on the preheated surface to achieve a minimum coating thickness of 6 mils.

516.04 Materials. Furnish materials conforming to:

Structural steel 513

Bearing bolts and anchor rods 711.10

Painting 514

Joint sealer, hot applied 705.04

Preformed elastomeric compression stager 705.11

Steel castings 711.07

Sheet copper 711.15

Bronze 711.16, 711.17, 711.18

Sheet lead. 711.19

Preformed bearing pads 711.21

Elastomeric bearings 711.23

Preformed fillers 705.03

Swedged anchor bolts or bars* 711.10

* Fabricated by deforming a minimum of 20 percent of the embedded bolt surface with deformations whose radial dimensions are 15 to 20 percent of the bar diameter.
516.05 Expansion and Contraction Joints. Ensure that expansion joints are completely open for the dimension specified for their full length. Remove stones, forms, or other materials that interfere with expansion.

Finish the surface adjacent to preformed expansion joints to a smooth, uniform surface. Use methods that do not interfere with the free compression of the joint material to anchor the expansion joint materials. The joint material shall neatly fill the space, and have a uniform thickness for the full extent of the joint.

516.06 Joint Sealers. Before applying joint sealer to the surface, clean the concrete of foreign matter, curing compounds, oil, grease, dirt, free water, and laitance and clean steel by sand blasting.

Apply joint sealer with a minimum depth of 1 inch (25 mm) at its thinnest section. Fill joints to within 1/4 inch (6 mm) of the roadway surface.

Separate joint sealer from contact with asphalt concrete using a barrier of foil or other material that is impervious to the joint sealer.

As required to prevent bonding of the joint sealer with a joint surface, place a suitable bond breaker barrier before applying the joint sealer.

Remove joint sealer that did not bond to the joint face as intended within 24 hours after placing. Clean the joint by sandblasting and reseal the joint.

Mix and place joint sealer according to the manufacturer’s instructions. Provide the Engineer with a copy of the manufacturer’s instructions.

Protect joint sealer with an impervious masking tape during the application of concrete protective coatings containing mineral spirits.

516.07 Bearing Devices. For sliding plates, lubricate the sliding surfaces with flake graphite, and superimpose plates on each other with their edges flush.

Accurately set the level and alignment of elastomeric bearings, bearing plates, and bolsters. Set bearing plates and bolsters on 1/8-inch (3 mm) thick sheet lead, conforming to 711.19, or on 1/8-inch (3 mm) thick preformed bearing pads, conforming to 711.21.

Set bearing plates or bolsters on bridge seat areas that are flat and smoothly finished. If the bridge seat area is high or uneven, use a bushhammer or grinder followed by thin film of portland cement mortar or paste to fill the pitted surface to bring the seat area to the proper elevation and provide a level, even surface. If the bridge seat area is low, use steel plate shims of the same bearing area as the bearing plates and bolsters to bring the seat area to the proper elevation.

Set elastomeric bearing pads directly on the concrete surface.

Position rockers, elastomeric bearings, and rollers so that, when the completed bridge is at 60 F (16 C), the rockers and elastomeric bearings are vertical and the rollers are centered on the base.

Set anchor bolts for bearing devices that are clear of the beam or girder flanges, in the concrete after erecting the main structural steel, except as specified below for bearing devices at abutments. Place reinforcing steel in the bridge seat to not interfere with the drilling of anchor holes. Accurately set anchor bolts in the holes and embed the anchor bolts in cement mortar. Until the anchors’ are installed, prevent water from entering and or freezing in the anchor bolt holes.

If structural steel interferes with the setting of the anchor bolts, set the anchor bolts before erecting the steel. The Contractor may determine the location of the bolts by using a template and form holes or embed the bolts when placing concrete or, drilling holes in the hardened concrete.

Install anchor bolts to project at least ¼ inch (6mm) beyond the nut when tightened. Damage or burr the threads on the projecting end of the bolt after the nut is tightened. The bolt threads shall not extend to the planes of the contact surfaces between the connected parts. Include the length of two additional threads to the specified thread length of the bolt to allow for thread runout. Washers no thicker than ¼ (6mm) are permitted under the nut.

Permanently fasten bearing devices to the abutments, steel beams, or girders after backfilling the abutments to within 2 feet (0.6 m) of the top of the bridge seat.

516.08 Method of Measurement. The Department will measure the specified items by the number of each, square feet (square meters), pounds (kilograms), or feet (meters) horizontally along the joint centerline and between the outer limits of the fabricated joint.

For deck resurfacing, the Department will measure Structural Steel Expansion Joints extending vertically by the actual horizontal length of joint.

516.09 Basis of Payment. The Department will pay for accepted quantities at the contract prices as follows:

Item Unit Description

516 Foot or Pound Structural Steel Expansion

(Meter or Kilogram) Joints

516 Foot (Meter) Structural Expansion Joints

Including Elastomeric ___ Seals

516 Foot (Meter) Elastomeric Compression

Seals for Structural Steel Joints, ___ Width

516 Foot (Meter) Folder Copper Strip ___

516 Foot (Meter) Vertical Extension of
Structural Expansion Joints

516 Square Foot ___ Preformed Expansion

(Square Meter) Joint Filler

516 Foot (Meter) Joint Sealer

516 Each, Foot, Bearing Devices
Square Foot, Pound
(Meter, Square Meter,
Kilogram)

516 Each, Square Foot ___ inch (___ mm)

(Square Meter) Elastomeric Bearing Pad

516 Each Elastomeric Bearing with

Internal Laminates Only

516 Each ___  ___  ___ Elastomeric Bearing

with Internal Laminates and
Load Plate ___  ___  ___

516 Square Foot 1/8-inch (3 mm) Preformed

(Square Meter) Bearing Pads
ITEM 517 RAILINGS

517.01 Description

517.02 Fabrication

517.03 Materials

517.04 Construction Methods, General

517.05 Steel and Iron Railings

517.06 Aluminum Railings

517.07 Method of Measurement

517.08 Basis of Payment
517.01 Description. This work consists of furnishing, constructing, coating, and erecting the type of railing specified. This work also consists of providing and galvanizing structural posts, anchors, and connections.

517.02 Fabrication. Fabricate railing according to Items 513. Select a fabricator that is at least prequalified at level SF. The Department will base final acceptance of fabricated members on the Engineer’s approval that the fabricated items that can be successfully incorporated into the structures. Submit mill test reports for structural steel, steel castings, bronze, and sheet lead certified according to 501.06.

517.03 Materials. Furnish materials conforming to:

Concrete, Class S or Class HP 499, 511

Reinforcing steel 509, 709

Structural steel 513

Preformed fillers

(sponge rubber or PVC) 705.03, 711.28

Steel tubing 707.10

Paint 708

Metal deep beam rail 710.06

Ductile iron casings. 711.13

Aluminum 711.20

Timber. 711.26

Stainless steel fasteners. 730.10

Pipe 748.06

Submit mill test reports for structural steel and aluminum according to 501.06.

517.04 Construction Methods, General. Construct railings as shown on the plans. Install posts for metal railings normal to the grade line. Install the tops of railings parallel to the grade line.

Remove or release shoring or falsework supporting the superstructure before placing railing that has no expansion joints or that is on the concrete parapet.

517.05 Steel and Iron Railings. Unless specified to paint according to Item 514, galvanize all parts of steel and iron railings.

Erect metal deep beam rail elements according to Item 606.

517.06 Aluminum Railings. Use alloy conforming to 711.20 for aluminum railings.

Give the extreme outer surfaces of cast railing posts a 40-grit finish. The Contractor is not required to provide a special finish for other portions of railings. Do not scratch, dent, or cause other damage to railings that may affect the durability or appearance of the railing.

Use galvanized steel anchor bolts and hexagon nuts conforming to 711.02. Coat the entire projecting portion of anchor bolts and fill the space between the bolts and post base with an aluminum-impregnated caulking compound.

Where aluminum contacts concrete or stone masonry, thoroughly coat the contact surfaces with an aluminum-impregnated caulking compound or with a heavy asphalt material paint pigmented with aluminum powder or paste thereby providing an aluminum appearance. Where aluminum or aluminum shims contacts different metal, thoroughly coat the contact surface with an aluminum-impregnated caulking compound or place a synthetic rubber impregnated fabric gasket between the metals.

Weld only where shown on the plans using inert gas shielded metal-arc or tungsten-arc method without flux, or by other approved methods.

517.07 Method of Measurement. The Department will measure Railing by the number of feet (meters) of railing including end posts. If deep beam guardrail is used, the Department will measure the length of railing between the first posts off the bridge excluding the first posts off the bridge. If hand rails or tubular backup rails are used, the Department will not measure any portions extending beyond the first posts off the bridge. If twin steel tube bridge railing is used, the Department will measure the length of the railing between the second post off the bridge including the second post.

517.08 Basis of Payment. The cost of hand rails or tubular backup rails extending beyond the measured limits are included for payment in the unit price bid for the measured length.

The Department will pay for accepted quantities at the contract price as follows:

Item Unit Description

517 Foot (Meter) Railing (___)

ITEM 518 DRAINAGE OF STRUCTURES

518.01 Description

518.02 Fabrication

518.03 Materials

518.04 General

518.05 Porous Backfill

518.06 Pipe

518.07 Scuppers

518.08 Excavation

518.09 Method of Measurement

518.10 Basis of Payment
518.01 Description. This work consists of constructing drainage systems.

518.02 Fabrication. Fabricate scuppers according to Item 513. Select a fabricator that is at least pre-qualified at level SF. The Department will base final acceptance of all fabricated members on the Engineer’s approval that the fabricated items can be successfully incorporated into the structures. Submit mill test reports for structural steel, steel castings, bronze, and sheet lead certified according to 501.06.

518.03 Materials. Furnish materials conforming to:

Scuppers, structural steel and cast steel 513

Metal pipe 707

Plastic pipe 707.33, 707.45

Other metals 711

Filter fabric, Type A 712.09

Furnish pipe specials of a grade at least as high as the type of pipe specified.

Furnish porous backfill consisting of gravel, stone, or air-cooled blast furnace slag, with a NO. 57 size gradation as per Table 703.01-1 The sodium sulfate soundness loss shall not exceed 15 percent.

Furnish ACBF slag conforming to Supplement 1027.

518.04 General. As shown on the plans, connect all parts to new or existing sewers or other outlets.

When installing to superstructure, take into account the deflection of spans under full dead load.

518.05 Porous Backfill. Place porous backfill as shown on the plans. When not shown on the plans place at least 18 inches (0.5 m) thick behind the full length of abutments, wing walls, and retaining walls. Measure the thickness of porous backfill normal to the abutment or wall face. The Contractor may leave undisturbed rock or shale within 18 inches (0.5 m) of the abutment or wall. Place sufficient coarse aggregate or other material adjacent to, but not more than 6 inches (150 mm) below, the bottom of the weep hole to retain the porous backfill. Compact porous backfill according to Item 603.11 D.

518.06 Pipe. For drain pipe leading down from the superstructure, use either galvanized steel pipe, 748.06; or plastic pipe, 707.45. Provide specials, elbows, tees, wyes, and other fittings essential for a complete and satisfactory installation of the same material and quality as the pipe. Construct watertight joints of adequate strength. In steel pipe, weld joints or use clamp-type couplings having a ring gasket. In plastic pipe, make joints according to the applicable ASTM standard. Securely fasten the pipe to the structure with hanger or clamp assemblies that are galvanized according to 711.02.

Place subsurface pipe according to Item 603. If the plans require drainage pipe in the porous backfill, provide plastic pipe conforming to 707.33.

For corrugated metal pipe, perforated specials are not required and the Contractor may make bends with adjustable elbows conforming to the thickness requirements of the pipe specifications.

518.07 Scuppers. Construct secure and watertight connections, including the connections to adjacent concrete. Provide castings, true to form and dimension. Weld the joints of structural steel scuppers. Galvanize scuppers according to 711.02.