100 general provisions

B. Fabricator Coordination of Shop Drawings for Items 516, 517, and 518. The Contractor and fabricator must coordinate these shop drawings. Ensure that shop drawings meet requirements for materials, field measurements, construction requirements, contract requirements, performance criteria, and similar data. The coordination must also include details of the work to be performed by other fabricators and entities on the project. The Department will not make allowance for additional cost or delays to the Contractor for incorrect fabrication as a result of failure to coordinate or perform this coordination.

Submit two copies of the shop drawings to the Engineer with the materials delivered to the project. Do not incorporate material into the work until after submitting the drawings. Department approval of these shop drawings is not required.

C. Shop Drawing General Requirements. Specific requirements are specified in Item 513, 515, 516, 517, or 518.

Make the prints from tracings, neatly and accurately drawn on 22  34-inch (559  864 mm) sheets.

After all fabrication is completed for Item 513 and 515, furnish, to the Director, a copy of each final Contractor accepted shop drawing on a digital media storage device according to Supplement 1002. For structures carrying railroad traffic, furnish an additional digital media storage device or, at the option of each railroad, furnish a set of full-size drawings on Mylar.

501.05 Submittal of Construction Plans and Calculations. Do not begin work until after complying with the acceptance criteria and work limitations specified below.

Design and perform all procedures as directed by the AASHTO Standard Specifications for Highway Bridges or the AASHTO LRFD Bridge Design Specifications except as modified herein:

A. Prepare and provide plans listed in this section as follows:

Have an Ohio Registered Engineer prepare, sign, seal and date each plan. Submit plans that will be accepted to all involved railway companies at least 50 days before construction begins. Obtain acceptance from all involved railroad company(s). Furnish the Engineer with copies of all correspondence with the railroad, documentation of railroad acceptance and the plans accepted by the railroad. Department acceptance is not required.

This section applies to construction plans for the following:

1. Sheeting and bracing of excavations adjacent to the railroad tracks.

2. Demolition of structures over or within 14 feet of railroad tracks.

3. Erection of structural members over or within 14 feet of railroad tracks or that carry railroad traffic.

B. Prepare and provide plans listed in this section as follows:

Have an Ohio Registered Engineer prepare, sign, seal and date each plan. Have a second Ohio Registered Engineer check, sign, seal and date each plan. The preparer and checker are two different Engineers. Include the following statement on the plans:

“This plan was prepared in compliance with contract documents.”

Submit the plan to the Engineer at least 7 days before construction begins. Department acceptance is not required.

This section applies to construction plans for the following:

1. Sheeting and bracing adjacent to active traffic when required by contract. Perform all work as specified below:

a. Locate sheeting and bracing per contract.

b. Maintain temporary horizontal and vertical clearances per contract.

c. Design sheeting or bracing to support the roadbed including the effects of AASHTO live and dead load surcharges.

2. Demolition of structures over or adjacent to active traffic. Perform all work as specified below:

a. Provide temporary devices or structures necessary to protect traffic during all demolition activities. Provide traffic protection when demolition is located less than 12' horizontally from active traffic on structures of less than 25' vertical clearance. Increase the 12' minimum horizontal distance 1 foot for each 2 feet of additional height greater than 25'.

b. Never lift the portions of structure being removed over active traffic. Before releasing traffic make the remaining structure stable.

c. Design traffic protection devices or structures for a minimum load of 50 pounds per square foot plus the weight of equipment, debris and any other load to be carried. Include any portion of the deck that cantilevers beyond the fascia beams or girders.

d. In lieu of temporary devices or structures required in “a” above, provide a vertical barrier. Design the vertical barrier with rigid or flexible materials specifically designed for demolition containment. Extend the enclosure up to the bottom of the deck and down to the ground. Maintain all materials free of tears, cuts and holes.

e. Maintain temporary horizontal and vertical clearances per contract.

f. Locate structural members to be reused before performing any removal operations.

g. Do not damage structural members being reused during any removal operation.

h. Perform work so that all members are stable during all operation and loading conditions.

i. Perform work per 501.05.B.6.

3. Falsework for cast-in-place concrete bridges over 20 feet (6.1 m) in span. Perform all work per 508 and as specified below:

a. Provide a camber table to account for the deflection of the falsework loaded with its self weight and the weight of wet concrete. Also include in the table, the specified camber to compensate for slab deflection after the falsework is released.

b. Maintain temporary horizontal and vertical clearances per contract.

c. As a minimum design falsework over waterways for a five year flood or with 75% of the effective waterway opening of the proposed structure. The Contractor is responsible for any damages caused by upstream flooding due to insufficient temporary structure size or the accumulation of debris or sediment in the channel.

d. Support falsework foundations located within the ten year flood limits on rock, shale or piles driven to a minimum depth of 15 feet, and to sufficient penetration to carry superimposed loads or until refusal on rock.

4. Erection of steel or precast concrete structural members as specified below:

a. Never lift structural members over active traffic. Before releasing traffic make structural members stable.

b. Supply any temporary supports or braces necessary to maintain structural stability and prevent lateral movement until completion of all construction activities.

c. Perform work per 501.05.B.6, 513 or 515.

d. Do not field weld temporary members to permanent steel members.

e. Maintain temporary horizontal and vertical clearances per contract.

5. Jacking and support of existing structures as specified below:

a. Support the structure on temporary supports and brace as necessary to maintain structural stability and prevent lateral movement until completion of the permanent supports. Do not use jacks alone to support the structure except during the actual jacking operation. Remove all temporary supports upon completion of the jacking procedure.

b. Maintain a maximum differential jacking height of 1/4 inch between any adjacent beam lines.

c. Maintain a maximum differential jacking height of 1 inch between any adjacent abutments or piers.

d. Place jacks and any load plates at least 2 inches from the edges of any concrete substructure seats.

e. Do not field weld temporary members to permanent steel members.

f. Maintain temporary horizontal and vertical clearances per contract.

6. Placing or moving equipment having a gross weight in excess of 60,000 pounds (27,000 kg) on or across a structure as follows:

a. Do not allow equipment having a gross weight in excess of the posted limit to be placed on or driven across a structure.

b. Do not allow erection and construction methods, or use or move erection or construction equipment on or across the uncompleted or completed structure, to subject any part of the structure to unit stresses that exceed by more than one-third the allowable unit stresses, as given in AASHTO Standard Specifications for Highway Bridges.

7. Structures for maintaining traffic in accordance with Item 502.

a. For structures located over or within 14 feet of railroad tracks, submit plans in accordance with 501.05.A.

b. Perform work per 501.05.B.6.

C. Welded Attachments. Prepare and provide a detailed request showing weld size, length, type and location for welding permanent or temporary attachments to main structural members not shown or permitted by contract. Submit request to the Office of Structural Engineering for acceptance at least 20 days before construction begins. Perform work per 501.05.B.6 and 513.

501.06 Test Reports.

A. Contractor Acceptance of Materials for Item 513. Submit certified test data to the Director showing compliance with the requirements of Item 711. Accompany all certified test data with copies of mill shipping notices or invoices showing the quantity and size of material being accepted.

Check this material data and provide a letter of written acceptance. Submit the material data and letter of written acceptance to the Director so that the Director receives them at least 7 days before final shop inspection Item 513, Levels 1 through 6 or before final shop inspection Item 513, UF Level.

Submit a single copy of this material data for each structure, except where the structure carries railway traffic. Submit one additional copy to each railway company involved.

Additionally for Item 513, Levels 1 through 6 structural steel members, submit one copy of main material, certified test data with a letter documenting the QCFS acceptance to the QA shop inspector before the material passes check point one.

The Department will not accept materials for final inspection at the fabrication shop until the Director receives the Contractor accepted material data.

B. Fabricator Certification of Materials for Items 516, 517, and 518. Ensure that a letter of certification accompanies the fabricated material shipped to the job site, in a format approved by the Director, stating all materials conform to contract requirements. For these materials, the fabricator must retain certified test data, copies of mill shipping notices, or invoices showing the quantity and size of material being accepted. This data shall provide complete traceability to the producing mill and proof of domestic origin, as required by ORC 153.011.

Do not deliver materials to the project without the certification letter.

ITEM 502 STRUCTUREs for maintaining traffic

502.01 Description

502.02 Design and Construction

502.03 Maintenance

502.04 Removal

502.05 Basis of Payment
502.01 Description. This work consists of preparing plans, providing, maintaining, and subsequently removing temporary structures.

502.02 Design and Construction. As a minimum, design the temporary structure for a 5-year flood or with 75 percent of the effective waterway opening of the proposed structure. The Contractor is responsible for any damages caused by upstream flooding due to insufficient temporary structure size or the accumulation of debris or sediment in the channel. Provide a clear roadway width of at least 23 feet (7.0 m) measured from face to face of guardrails. If the existing structure or approaches or both have sidewalks provide at least one sidewalk at least 5 feet (1.2 m) wide with adequate connections to existing walks and in compliance with accessibility standards.

Design the temporary structure according to the AASHTO LRFD Bridge Design Specifications except that the design live loading, HL-93 may be reduced by 25 percent.

Submit construction plans in accordance with 501.05.

Drive piling to sufficient penetration to carry the superimposed loads according to Item 507, but not less than 24 tons (24 metric tons) per pile. Perform dynamic load testing to determine required blow count if piles are not driven to rock.

If the plans state that the existing superstructure may be used instead of new construction, do not alter it to meet either the above width or strength requirements. Instead, move or dismantle and re-erect with sufficient care to avoid any reduction of capacity. If the superstructure has been restricted by posting to loads less than permitted by statute, move the posting signs to the temporary road, unless the superstructure is strengthened to a legal load capacity. If planning to use the existing superstructure on the temporary road, notify the Engineer at least 3 days before the superstructure is moved to allow the Department to establish a detour. Complete the bridge within 48 hours after traffic has been routed over the detour.

502.03 Maintenance. Maintain all portions of the temporary structure in good condition with respect to both safety and smoothness for travel as long as it is needed for maintenance of traffic. Satisfactorily maintain the channel and waterway opening.

502.04 Removal. If the temporary structure is no longer needed, take ownership and remove it from the site according to Item 202.

502.05 Basis of Payment. Payment is full compensation for erection, maintenance, performing dynamic load testing, and subsequent removal of temporary structures.

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

Item Unit Description

502 Lump Sum Structure for Maintaining Traffic

ITEM 503 EXCAVATION FOR STRUCTURES

503.01 Description

503.02 Classification

503.03 Cofferdams, Cribs, and Sheeting

503.04 Protection for Excavation

503.05 Footings in Rock

503.06 Approval of Foundations

503.07 Disposal of Excavated Material

503.08 Backfill

503.09 Method of Measurement

503.10 Basis of Payment
503.01 Description. This work consists of designing cofferdams and shoring, and excavating materials not removed under other items of work that must be removed to enable construction of bridges, and other structures. Included in this work are:

A. constructing, maintaining, and subsequently removing cofferdams and shoring;

B. dewatering and backfilling the excavation;

C. protecting the excavation against collapse; and

D. disposing of materials not required or suitable for backfill.

503.02 Classification. Excavation is classified as unclassified excavation, unclassified excavation including rock (or shale), or rock (or shale) excavation.

503.03 Cofferdams, Cribs, and Sheeting. This item includes the preparation of a plan; the construction, maintenance, and subsequent removal of all cofferdams, cribs, sheeting, shoring, bracing, or other materials necessary to safely support the sides of excavations, embankments, adjacent buildings, tracks, or other premises; and all pumping necessary to complete required construction.

Construct cofferdams, cribs, and sheeting such that wales and crossbraces, if practical, clear the top of the footings by at least 1 foot (0.3 m). If this is not practical, construct this bracing using structural steel and leave it in place. If bracing is to be left in place and the ends would not be visible when the structure is completed, burn off the steel ends flush with the concrete surface. If ends would be visible, box back the steel ends at least 6 inches (150 mm) from the concrete face, and burn off the ends at least 3 inches (75 mm) back of the concrete face. Completely fill the resulting holes with concrete.

Where water is not encountered, the Contractor may place sheeting at the plan dimension of the footing and use it as forms for footing concrete. Leave this sheeting in place at least to the top of the footing, or properly separate it from the footing concrete so that it may be removed without damaging the concrete.

Where water is encountered, and cofferdams are necessary, construct them practically watertight before excavating below water level. Make provisions outside the footing to drain, collect, and remove water. When placing concrete, keep the excavation dewatered until the concrete is above the prevailing water level. Effectively protect footing concrete from erosion. If using a concrete seal to stop the flow upward from the bottom of a cofferdam, place the seal below the planned footing and consider it as a part of the cofferdam. The Department will not pay for a seal unless it is shown on the plans.

Design and construct cofferdams, cribs, and sheeting to accommodate a water elevation 5 feet (1.5 m) above the normal water elevation shown on the plans. If the actual water elevation exceeds 5 feet (1.5 m) above the stated normal water elevation, the Department will reimburse the Contractor for any resulting damage to the work protected by the cofferdam provided the Contractor has exercised normal due diligence. If the actual water elevation exceeds 5 feet (1.5 m) above the stated normal water elevation and causes a delay to the project, the Department will grant the Contractor an excusable, non-compensable delay in accordance with 108.06.B.

Cofferdams may be designed and constructed to accommodate a lower water elevation; however, the Department will not reimburse the Contractor for repairs to work damaged nor grant additional time unless the water elevation exceeds 5 feet (1.5 m) above the normal water elevation shown on the plan.

Submit any request for reimbursement for repair to work damaged or for delay to the Engineer with information substantiating that the water elevation was more than 5 feet (1.5 m) above the normal water elevation shown on the plans.

503.04 Protection for Excavation. Cut the sides of all excavations to prevent caving, or protect the excavation from caving. Do not disturb the material below the bottom of footings. Perform blasting in a manner that avoids damage to the material supporting the structure vertically or laterally and that avoids subsequent slides that damage the structure, road, or adjacent property. If the material below the bottom of footings not supported by piles is disturbed, remove it and fill the entire space with concrete at no expense to the Department. Under footings supported on piles, replace and compact the over-excavated or disturbed material as the Engineer directs. If backfilling is necessary to correct caving or slides, backfill according to 503.09.

Excavation adjacent to railroad tracks are subject to the supervision of the involved railway company. Provide sufficient bracing to ensure the proper support of the roadbed and tracks.

503.05 Footings in Rock. Where rock or shale excavation is a separate pay item, fill the portion of the excavation into rock or shale that is below the top of footing with concrete.

If removing rock or shale as part of Unclassified Excavation and the footing is designed to be keyed into the bedrock, confine the excavation into bedrock for the minimum specified depth of keying within the area bounded by the outer edge of the footing. Fill excavation outside these limits and within and below the keyed depth with concrete.

503.06 Approval of Foundations. Notify the Engineer when the excavation is to be completed to the depth shown on the plans. Do not place footings until the Engineer has approved the subfoundation.

503.07 Disposal of Excavated Material. Dispose of excavated material not needed or not suitable according to 105.16 and 105.17. Use other suitable excavation material for backfill.

503.08 Backfill. Backfill under this item includes all replaced excavation and new embankment adjacent to structures. Use backfill embankment materials conforming to 203.02.R, except behind the abutments below the approach slabs use material conforming to Item 203 Granular Material Type B. Place and compact the backfill materials according to 203.06 and 203.07, except as modified by this subsection.

Do not place backfill material against any structural element until the Engineer has approved the element.

In bridge abutment areas compact backfill material to meet the compaction requirements in 203.07. Elsewhere, compact backfill material to 95 percent of the maximum laboratory dry density.

When a test section method is used for compaction acceptance: Use compaction equipment with a total weight or a centrifugal force of least 1 ton (0.9 metric tons). Supply the manufacturers’ information to verify this information. Use at least six passes to construct the production areas. Use at least 97 percent of the test section maximum dry density for acceptance of the production areas.

The Contractor does not have to place backfill material around piers that are not within the embankment area or adjacent to a roadway or a railway in thin layers or compact it, but should leave the backfill material in a neat condition with a compensating allowance made for settlement.

Backfill in front of abutments and around piers to the ground lines shown on the plans.

Backfill all structural foundation units as soon as practical after the required conditions of this subsection are met to avoid the ponding of surface water and the accumulation of debris. Simultaneously backfill in front of and behind abutments, piers, wing walls, and retaining walls.

Carefully backfill against waterproofed surfaces to avoid damage to the waterproofing material.

503.09 Method of Measurement. After the requirements of Items 201, 202, and 203 have been met, the Department will measure excavation by the number of cubic yards (cubic meters) as follows:

A. Bounded on the bottom. Bounded bottom plane of the footing, crossbeam, or wall.

B. Bounded on the top.

1. In cut sections, by the surface of the remaining ground.

2. In fill sections:

a. If excavation is performed before embankment is placed, by the surface of the original ground.

b. If excavation is performed after embankment is placed, by the surface of the embankment.

C. Bounded on the sides.

1. For Unclassified Excavation, 1 foot (0.3 m) outside the outer edge of the footing, crossbeam, or wall.

2. For Rock Excavation or Shale Excavation:

a. If Rock Excavation is included in the Contract, by the outer edge of the footing or wall.

b. If rock or shale is removed as part of Unclassified Excavation Including Rock and/or Shale:

(1) Above the minimum specified depth of keying, the same as described in 503.09.C.1.

(2) For the remainder of the excavation, the same as described in 503.09.C.2.a.

For abutment excavation quantities, the Department will include material removed above the bench (if any), in front of the vertical plane described in 503.09.C.1, and by the finished slope of the cut or embankment.

For keys below footings, the Department will determine the volume of keys by the number of cubic yards (cubic meters) shown on the plans.

The Department will measure Unclassified Excavation on a lump sum basis when shown on the plans.

The Department will measure Cofferdams, Cribs, and Sheeting on a lump sum basis.

503.10 Basis of Payment. If Cofferdams, Cribs, and Sheeting is not included in the Contract, the Department will pay for cofferdams, cribs, and sheeting under the contract unit price for excavation.

The elevations shown on the plans for the bottoms of footings are considered as approximate. When excavation below plan elevation for footings is required, the Department will pay for the 3 feet (0.9 m) immediately below the plan elevation within the lateral limits described in 503.09.C.1 at the unit price bid for the class of excavation.

The Department will consider additional excavation to a maximum depth of 3 feet (0.9 m) within the lateral limits described in 503.09 as incidental to the lump sum price. Excavation deeper than 3 feet (0.9 m) below plan elevation may be provided for as Extra Work, as described in 109.04.

If Cofferdams, Cribs, and Sheeting is a separate pay item, the lump sum price includes any extra cost involved for cofferdams for additional depth up to 3 feet (0.9 m) below plan elevation. Excavation deeper than 3 feet (0.9 m) below plan elevation and the additional cofferdams necessitated by this excavation may be provided for as Extra Work, as described in 109.04.

The Contractor shall provide additional fill material and subsequent excavation to provide the minimum cover over culverts to accommodate heavy earth moving equipment at no expense to the Department.

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