TECHNICAL SPECIAL PROVISION FOR CONCRETE REPAIRS. Financial Project ID , &

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1 TECHNICAL SPECIAL PROVISION FOR CONCRETE REPAIRS Financial Project ID , & The official record of this Technical Special Provision is the electronic file signed and sealed under Rule 61G , F.A.C. Prepared by: Randall C. Wright, P.E. Date: April, 2014 Page 1 of 7

2 SECTION T401 CONCRETE REPAIRS T401-1 Description T General: Perform concrete repairs on the bent caps for bridges and as specified in the plans and as directed by the Engineer. The repairs may consist of large or small areas. T Quantities: Due to the nature of the deterioration present on these bridges, the Engineer may add or delete quantities beyond the limits per Section 4-3 of the Standard Specifications with no adjustment to the contract unit prices. T Deterioration Survey and Report: T Deterioration Survey: A visible and sounding survey of the bent caps for bridges and shall be performed to verify repairs as shown in the plans. All locations identified shall be marked or otherwise delineated, in the presence of the Engineer, and recorded. The Engineer shall verify, modify if needed, and approve the repair limits prior to commencing any repair work. T Report: After the deterioration survey has been done a Deterioration Survey Report shall be prepared identifying the areas, type and limit of each repair and an estimated quantity for the each repair. The report shall be formatted to indicate precise location and limit of each repair, estimated quantity for each repair and calculations for each. This document will be used by the Engineer for preparing the authorization to proceed with repairs and by the Contractor to track quantities. The Contractor shall update the report on a monthly basis to indicate actual limits (length, width and depth) and quantities of repairs and remaining budget available to continue with repairs. T Authorization to Proceed with Repairs: Repair work shall not start until after the Deterioration Survey and Report has been completed and approved by the Engineer. Upon request the Engineer will consider partially approving the Deterioration Survey and Report when the Engineer determines it in the best interest of the Department. The Department shall determine the size of the work assignments. The Work will be assigned by the Department for a specific group of locations at a time. No work shall commence on any new work assignment until the satisfactory completion or substantial progress (more than 40% completion) of previously issued assignments has been confirmed, except when the Engineer determines that such other work is in the best interest of the Department and gives written instructions to proceed. The Contractor will be expected to begin work within 14 calendar days following issuance of the authorization to proceed with work. Repairs performed after exhaustion of budget due to Contractor s failure to track quantities will be at the Contractor s expense. T Work Plan and Schedule: A detailed Work Plan and Schedule shall be submitted for each Work Assignment for approval. The Work Plan shall include, but not be limited to the following, temporary traffic control proposed, type of repair(s) to be performed and type of repair material to be used, concrete removal method and sequence, form work, and metalizing required for the Work Assignment. T Phasing of Work For: T Metalizing; Coordinate and execute work such that metalizing of the repaired areas can be done as specified in Technical Special Provision T459. Page 2 of 7

3 T Structural Integrity: As determined by the Engineer, repairs shall be phased where the structural integrity of the component will be affected due to the amount of concrete removal. Shop drawings, showing how structural integrity will be assured during repair, shall be submitted to the Engineer for approval prior to starting the repair. All shop drawing and backup calculation shall be signed and sealed by a Florida professional engineer. T401-2 Materials T Reinforcing Steel: Reinforcement steel shall conform to ASTM Specification 615 Grade 60. T Welded Wire Reinforcement: Galvanized welded wire reinforcement (WWR) shall conform to ASTM Specification A1064. T Repair/Patching Materials: T Latex Modified (Polymer Concrete); All materials shall be supplied by the same manufacturer and be approved by the Engineer for the specific application. Use a pre-packaged latex modified (polymer concrete) repair materials designed for the specific application and apply in accordance with the manufacturer s recommendations. For underwater repairs, use an approved underwater repair mortar. The selected materials shall have a minimum compressive strength of 5500 psi at 28 days and shall not exceed a maximum chloride content of 0.4 pounds of chloride per cubic yard of material when placed. Patch materials and aggregates shall be kept at a clean, dry location away from contaminants. T Class IV Concrete; Class IV concrete with # 89 aggregate (bent cap repairs deeper than 10 inches) shall be in accordance with FDOT Standard Specifications and properties based on Florida Lime rock aggregate. T Bonding Agent; Bonding compound shall be solvent free; epoxy-cement based, and shall not perform as a vapor barrier. The bonding compound used shall contain corrosion inhibitors and shall be suitable for application over concrete and reinforcement with a minimum application time of 1 hour after mixing. The bonding compound shall be mixed and applied as per manufacturer s specifications. All bonding compounds and inhibitors shall be compatible with the patching material and applied in accordance with the manufacturer's recommendations and these specifications. T Submittals: Manufacture s Technical/Product Data sheets, Specifications, Material Safety Data Sheets (MSDS) and Certification for all repair materials, bonding and corrosion inhibitors to be used shall be submitted for approval. The submittal shall include but not be limited to the following; Pre-packed concrete repair materials including formulation and aggregates; shall include technical data indicating compliance with contract requirements. All aggregates added in the field shall be from an FDOT approved source unless certified satisfactory by the concrete material manufacturer. Concrete bonding compound; data sheet and Material Safety Data Sheets (MSDS). Abrasive blasting material data sheet and MSDS. T401-3 Testing Page 3 of 7

4 In addition to the quality control required by the Standard Specifications for concrete products, compressive strength and plastic testing will also be required for each field batch of the latex modified (polymer concrete) material used for spall repairs. A field batch is defined as each load of the concrete mixer. Six cube samples (2 x 2 x 2 ) will be used for testing. Sampling schedule for field batching may be reduced as directed by the Engineer based on satisfactory previous test results and adequate Contractor s quality control. Produce and test a trial mix with the proposed spall repair materials prior to commencing any concrete work. Test all plastic properties to demonstrate compliance with manufacturer s data. Prepare compressive strength specimens for testing at 7, 14, and 28 days. The QC Plan for concrete, pre-packed material, design mixes and general work plan for the specific tasks shall be approved prior to commencing the specific work for that mix. Failure to obtain approval of any of the above shall not be grounds for granting additional contract time. T401-4 Construction Method T Surface Preparation: Saw cut ¾ to 1" deep along the perimeter of the repair area as delineated in the Deterioration Survey Report. Adjust depth of saw cut if shallow steel is encountered. Feathering of the patch material at the edges is not allowed. Remove all deteriorated concrete within the saw cut limits. Only hand tools, light duty (30 lb max) pneumatic or electric chippers and electric or air saws shall be used for the concrete removal. Exercise extreme caution to avoid cutting or damaging the existing reinforcing steel and/or damaging sound concrete. Should reinforcing steel or sound concrete be damaged, concrete removal work shall stop and a damage report shall be submitted to the Engineer. A repair method for the damaged area(s) shall be submitted for approval by the Engineer prior to continuing the concrete removal work. If in the opinion of the Engineers damage to sound concrete or existing reinforcement was due to carelessness it shall be repaired at no expense to the Department. Remove the concrete adjacent to exposed reinforcement as recommended by the patch material manufacture (1" minimum) or to whatever additional depth is necessary to reach sound concrete. Extend the concrete removal six (6 ) inches beyond the corroded portion of the reinforcing or two (2 ) inches maximum beyond the spalled area. Removal of concrete adjacent to prestressed strands or reinforcing steel shall be done with a 15lb chipping hammer (maximum size) and a 4lb scaling hammer. Unsound concrete extending a depth of two (2 ) inches or more beyond the reinforcement or more than 20% of the cross section area has deteriorated the Engineer shall be notified at once and a revised repair procedure shall be prepared for the Engineers approval. If the bonding is lost between the existing reinforcement and existing concrete or damaged, extend the concrete removal until bonded undamaged steel is reached. Roughen and clean the exposed concrete surfaces, including the saw cut face around the perimeter of the repair area, and clean the reinforcement as per the patch material manufacturer's recommendations. As a minimum clean all reinforcing bars to SSPC SP-10 (near white metal). Special attention shall be observed to ensure proper cleaning and preparation of the backside of the rebars and/or strands. Page 4 of 7

5 All surfaces to receive patch material must be clean, sound and free of surface moisture, oil and grease. Remove dust, residue, marine growth, laitance, grease, curing compounds, waxes, impregnation, foreign particles and other bond inhibiting materials from the surface by sandblasting. Water blasting is not permitted. Chip off areas that have been saturated with oil or grease to a sound non-contaminated concrete. Areas that may trap air shall be vented to prevent air entrapment/voids. T Patch Procedure: If the depth of the repair exceeds 2-inches, place an approved Galvanized welded wire fabric over the area after the existing rebar has been cleaned. Tie the wire fabric at regular intervals, vertically and horizontally, not to exceed eight inches, or as directed by the Engineer. Field bend the welded wire fabric to conform to any changes in the concrete surface profile. Patch material shall be applied to the repair area within 72 hours after the area has been cleaned. If areas become contaminated after initial cleaning, they must be re-cleaned prior to applying the repair material. Just prior to applying the patch material apply a coat of bonding agent to all surfaces within the repair area in accordance with the manufacturer's recommendations. All repairs shall be made using methods to ensure the patch material is carefully worked into the repair area to achieve intimate uniform contact between the repair mortar and the concrete in accordance with manufactures recommendations. T Reinforcement: Existing reinforcement shall be maintained at its original position. If existing reinforcement has been cut or damage during the concrete removal procedure or has lost 20% or more of its cross section, a new bar of equal size shall be drilled and epoxied into place or lapped with a lap splice or embedded length as indicated in the plans. Additional concrete removal may be necessary to provide the lap or embedment length. In place of a signle bar dual bars of equivalent or greater section may be used. T Small Repairs: Smaller spalled or damaged areas of concrete, identified as 20 CF or less, shall be repaired using an approved material mixed, applied and cured in strict accordance with the manufacturer s specifications. The Engineer shall approve the specific material, to ensure that the application is appropriate. Match repair material surface to surrounding concrete surfaces. Provide V -groove construction joints, drip notches, or any other features required to match the existing. T Large Repairs: Large repairs are identified as greater than 20 CF and/or where forming is required. The contractor shall use a repair material for the large concrete repairs approved by the Engineer. Match repair material surface to surrounding concrete surfaces. Provide V -groove construction joints, drip notches and any other features required to match the existing. T Forms: Forms shall be used as required or as directed by the Engineer. All forms shall be removed. Stay-in-place formwork is not allowed. Page 5 of 7

6 No anchoring to the beams will be permitted. No permanent attachments or modifications to the structure for the purpose of supporting the forms will be allowed on any bridge component. All formed concrete corners shall be chamfered ¾ inch in accordance with section of the Standard Specifications unless otherwise noted and properly vented to ensure complete filling of the inside. All forms shall be capable of withstanding internal and/or external vibration and the anticipated head pressure of the repair material. If placing the repair material by pump method start at the bottom of the form to ensure proper air venting. Cap the vents when all air has been removed and maintain pumping pressure until an increase of 3 to 6 psi is observed and close the port. If placing the repair material by pour method, provide shoots and maintain these full to produce a standing head pressure to ensure complete filling of the forms. Remove shoots and excess material after the material has set. After forms are removed, remove all anchors and patch all holes created to support forms, false work, etc. with an approved mortar or epoxy. T Curing: T Formed Areas: The concrete shall be form cured for a minimum of 7 days before removing the forms. Form curing time may be extended by the Engineer based on site conditions. Ambient exposed areas of concrete shall be wet cured for the same amount of time as for form curing. Every effort shall be made to avoid shrinkage cracking of the poured repaired material including, but not limited to: external cooling in the forms, or wet burlap curing after removal of the forms. No curing compounds shall be used on areas to receive metalizing. T Non-Formed Areas: Non-form areas shall be cured as recommended by the repair material manufacturer. T Submittals: Shop drawings shall be submitted for approval indicating type of form system to be used, showing supports system, method of concrete placement, and containment of concrete and waste materials. T401-5 Staging Work T From Water: Concrete repair work performed from the water shall be done using properly size vessels (barge(s) and/or suitable boat(s)) to execute the work and house all the equipment required taking into consideration site conditions, open rough seas, strong currents, and winds at the site. Additional time for work delays will not be allowed due to rough waters if it is determined that the chosen equipment was not adequately suited for the existing conditions at the site. During work hours the vessels can be tied to the piers as long as rubber bumpers or other devices are provided to protect the pier from damage. Therefore, location of equipment on the roadway or on the bridge will not be permitted unless otherwise approved by the Engineer for specific operations. All vessels shall be removed from bridge unless work is in progress. Page 6 of 7

7 T From Deck: Spalls located at elevations on bent caps which require an Under Bridge Inspection Unit (UBIU and/or an under deck access system for repairs. The Contractor shall be responsible for removing all anchors and patching all holes created to support the access system with an approved mortar or epoxy. No anchoring to the beams will be permitted. No permanent attachments or modifications to the structure for the purpose of staging the work will be allowed on any bridge component. Temporary traffic control shall conform to Index 600 and shall be removed from bridge unless work is in progress. T Submittals: Temporary traffic plans, removal of concrete method and sequence shall be submitted with the work plan for each Work Assignment. T401-6 Safety Boat A gasoline or diesel fuel powered emergency boat with communication equipment (phone or radio) shall be at the job site at all times when work is being performed. At no time shall any worker be present at the job site without immediate transportation to shore in the event of an emergency. The emergency boat shall be in addition to the boat provided for FDOT inspectors under SP and shall not be used as a work platform. T401-7 Method of Measurement T Concrete Repair: The quantity of concrete restoration to be paid for under this section shall be the volume in cubic feet of repair material authorized, satisfactorily placed and accepted. The method utilized in determining the volume will be the surface area in square feet multiplied by the average depth of such areas. T Welded Wire Reinforcement and Reinforcing Steel: No additional payment will be made for galvanized welded wire fabric, new steel grid bars or spliced reinforcing bars. These items shall be considered incidental and the cost should be included in the unit price for Restore Spalled Areas. T401-8 Basis of Payment Payment for this work shall include all equipment, labor, concrete removal, surface preparation, temporary shoring where needed, bonding agent, forming, materials, galvanized welded wire fabric, reinforcing steel, and any incidental items necessary to complete the work. No additional payment will be made for galvanized welded wire fabric or spliced reinforcing bars. These items shall be considered incidental and the cost shall be included in the unit price for Restore Spalled Areas. Payment for this work shall be included under the Pay Item Number: Restore Spalled Areas (Latex Modified Mortar-Styrene-Butadiene) - per cubic foot Page 7 of 7

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