State of New Jersey NEW JERSEY DEPARTMENT OF TRANSPORTATION 1035 PARKWAY AVENUE P.O. Box 600 TRENTON, NEW JERSEY

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1 State of ew Jersey EW JERSEY DEPARTMET OF TRASPORTATIO 103 PARKWAY AVEUE P.O. Box 00 TRETO, EW JERSEY STRUCTURE O J ROUTE 7 (BELLEVILLE TURPIKE) OVER CORAIL (EWARK BRACH) TOW OF KEARY HUDSO COUTY TH CYCLE SEPTEMBER 17, 2007 OTE: This Bridge Re-evaluation Report shall be filed immediately after the 13 TH Cycle Inspection. Prepared By Transystems Lichtenstein Paramus, ew Jersey

2 TABLE OF COTETS Page o. 1 Structural Data -1 2 Controlling Ratings -2 3 Conclusions and Recommendations -2 Structural Inventory & Appraisal and Pontis Sheets - Summary of Ratings -7 Drawings and Photos -8 7 Field otes Priority Repairs -82

3 .J.D.O.T. - STRUCTURAL EVALUATIO RE-EVALUATIO BRIDGE SURVEY REPORT CYCLE O. STRUCTURAL DATA: Bridge o.: Year Built: 1937 Widened: /A Route o.: J 7 Length: 1,22 Width: 7. Mile Point: 2.1 Date of this Evaluation: September 17, 2007 ame: J Route 7 (Belleville Turnpike) over Conrail (ewark Branch) By: Transystems Lichtenstein Structure Type: Reinforced concrete slab in Spans 1 to 13 and 3 to 7; Simply supported steel stringers from Spans to 3 (All fascia stringers and all stringers in Span 2 are concrete encased) Date of Previous Evaluation: October 17, 200 By: Special Equipment Used: Transystems Lichtenstein 3 Bucket Truck and 3 Ladder OVERALL CODITIO: Fair WORK DOE: Concrete patches adjacent to the deck joints at Piers, 2, 2, 30, 31, and 33 in the southbound lane, Piers 1, 20, 21, 27, and 29 for full length of joint, asphalt patches at the deck joint at Piers 1 and 33 northbound lane, compression seals replaced at Piers 21, 27, 29 and 33 deck joints, concrete patches and/or timber formwork in the underside of the deck in Span 1, 1, 21, 28, 29, 31, and 32, north and south approaches were repaved with asphalt, concrete patches at Piers,, 9, 10, 13 to 3, 3, 37, 2, and 3 (See Photos -02, and -0 to -1). Inspection Team Leader: Efrain Grajeda, P.E. Initials: Certifying Engineer: Cory Amato, P.E. J P.E. umber: GE I certify that this report is an accurate description of the subject structure, to the extent determinable by visual inspection and testing performed. Original copy signed and sealed Signature: Date: -1

4 Structure o.: J 7 Cycle o.: ame: J Route 7 over Conrail (ewark Branch) COTROLLIG RATIGS: (From 8 th Cycle Report) Computer Program Used: Penn DOT BAR 7 (Version 7.) Based on the Load Factor method of analysis, the following load ratings have been computed: Controlling Member Concrete Slab Rating Type HS-20 (3) Truck Type (Tons) 3 (2) 3S2 (0) 3-3 (0) Inventory Rating Operating Rating COCLUSIOS & RECOMMEDATIOS: The bridge is in overall fair condition due to the condition of the superstructure. The deck is in poor condition due to several large areas of spalls with exposed and corroded rebars, worst in Spans, 8, and 3, many incipient spalls and delaminated concrete, large areas of fine to medium mapcracking with efflorescence, fine to medium transverse and longitudinal cracks with efflorescence in the underside of the deck, deteriorated joints at the underside and top of deck, minor pumping of the deck, moderate wearing of the concrete surfaces, concrete patches and fine to medium cracks typical throughout the wearing surface. The superstructure is in fair condition due to localized web buckling at S7 and S8 over Pier 28 in Span 29, small holes in the web of numerous stringers above the bearings, areas of severe rust and localized material losses of 0% to the web and flanges, anchor bolts with up to 90% material loss and missing anchor bolts and anchor bolt nuts. This inspection revealed the following deficiencies: Holes in the web at the end of Stringers S, S, and S9 over Pier 22 in Span 22 with deteriorated and missing anchor bolts, severe material losses and localized web buckling in Stringers S7 and S8 over Pier 28 in Span 29, wide cracks and leaning temporary timber supports at the east side of Stringer S at Pier 22. Large spall exposing rusted rebars, full depth fracture in the north concrete header at the northbound side and deteriorated compression joint sealer of the deck joint at Pier 30, large spall with exposed rusted rebars and large incipient spall area in the underside of the deck in Span 3 at Bays and respectively with a matching top of deck deteriorated concrete deck repair and settled asphalt patch at Pier 33 deck joint. There are missing access cover plates with exposed wires in the light poles located on top of the east concrete balustrade at Spans 1, 2, 32, and 7 adjacent to the east sidewalk and on top of the west concrete balustrade at Spans 29 and 7. Transystems informed the JDOT of the above deficiencies on October 2, 2007 and October 30, 2007 and recommended repairs on a Priority 1 and Priority 2 basis (See attached Priority Memos). Since the previous inspection, the deck has been upgraded from serious to poor due to concrete patches throughout the underdeck with timber planks left in place, concrete and asphalt patches in several deck joint headers with compression seal replacement, and concrete patches in the wearing surface. The approaches have been upgraded from fair to satisfactory due to repaving of the first 1 LF adjacent to the bridge. The substructure has been upgraded from fair to satisfactory due to concrete repairs throughout the pier columns and caps. There have been no other major changes to the overall condition of the structure. -2

5 Structure o.: J 7 Cycle o.: ame: J Route 7 over Conrail (ewark Branch) Due to the condition of the deck, the structure is classified as structurally deficient. To remove the structure from the structurally deficient category, we recommend replacing the deck. Deck Replacement (includes Removal and Maintenance of Traffic): 122 LF (existing bridge length) x 7. LF (existing bridge width) = 8,22 SF 8,22 SF x $12 / SF = $7,282,70 Approach Roadway Work: 200 LF x $1000 / LF = $200,000 Total = $7,82,70 Preliminary Engineering: $7,82,70 x 10% = $78,27 Say = $8,23,000 In the interim, until the deck is replaced, we recommend that the following Priority repairs be made to retard further deterioration, preserve the structural integrity of the bridge, improve safety and extend its useful life: 1. Install bolted steel plates and angles at the bottom of the Stringers S, S, and S9 over Pier 22 in Span 22 and Stringers S7 and S8 over Pier 28 in Span 29, replace the deteriorated and missing anchor bolts at the stringers over Pier 22, and paint the repaired areas as required on a Priority 1 basis (See Photos -2 to -28 and Priority Memos). 2. Remove all loose and fractured concrete at Pier 30 concrete header, clean the spalled areas, install additional reinforcement as need, patch the area with epoxy concrete and install a new joint sealer on a Priority 1 basis (See Photo -18 and Priority Memos). 3. Remove the large incipient spalls and deteriorated concrete areas from the underside of deck at Span 3, clean any exposed reinforcement, install additional steel reinforcement as needed, patch the spalls with concrete if the spalls are 2 or deeper, and patch the concrete header in the Pier 33 deck joint with concrete on a Priority 1 basis (See Photo -09 and -23 and Priority Memos).. Replace the missing access cover plates in the east and west concrete balustrades on a Priority 2 basis (See Photo -17 and Priority Memos). -3

6 Structure o.: J 7 Cycle o.: ame: J Route 7 over Conrail (ewark Branch) Rated By: Y.G. Dated: 11//9 Checked By: L.M.H Dated: 11/22/9 SUMMARY OF RATIGS The Load Factor ratings were computed in the 8 th Cycle report in accordance with the FHWA directive dated ovember 1993 and AASHTO Manual for Condition Evaluation of Bridges, 199. Based on the load factor method of analysis, the following load ratings have been computed: Computer Program Used: PennDOT BAR 7 (Version 7.) PERCET (%) SECTIO LOSSES: (See load rating calculations in the 8 th Cycle report) Allowable Stresses (psi) Material Compressive Yield (psi) Inventory Operating Strength fc (psi) Concrete 3, ,200 1,0 Reinforcing Steel -- 0,000 20,000 28,000 Structural Steel -- 33,000 18,000 2,00 Member Interior Stringer S3 (0 Approach Span) Concrete slab * Interior Stringer S11 (Track span) Interior Stringer S7A * Controlling Member Truck Type (Tons) Inventory Rating (Tons) Load Factor Operating Type HS-20 (3T) (Tension) Type 3 (2T) (Tension) Type 3S2 (0T). 77. (Tension) Type 3-3 (0T) (Tension) Type HS-20 (3T) (Moment) Type 3 (2T) (Moment) Type 3S2 (0T). 7.1 (Moment) Type 3-3 (0T). 92. (Moment) Type HS-20 (3T) (Tension) Type 3 (2T) (Tension) Type 3S2 (0T) (Tension) Type 3-3 (0T) (Tension) Type HS-20 (3T) (Tension) Type 3 (2T) (Tension) Type 3S2 (0T) (Tension) Type 3-3 (0T) (Tension) -7

7 Structure o.: J 7 Cycle o.: ame: J Route 7 over Conrail (ewark Branch) Photo o: -01 Location: Description: West elevation, looking east. General view of J Route 7 (Belleville Turnpike) over Conrail (ewark Branch). Photo o: -02 Location: South approach, looking north. Description: General view of the south approach roadway. (ote: Work done: 1 LF of approach roadway adjacent to the bridge was repaved with asphalt, north approach roadway similar) -9

8 Structure o.: J 7 Cycle o.: ame: J Route 7 over Conrail (ewark Branch) Photo o: -03 Location: Span 2, looking south. Description: Typical superstructure at main span consisting of concrete encased rolled steel beams. Photo o: -0 Location: Span 27, looking south. Description: Typical superstructure at Spans to 23 and 2 to 3 consisting of rolled steel beams. -10

9 Structure o.: J 7 Cycle o.: ame: J Route 7 over Conrail (ewark Branch) Photo o: -0 Location: Pier 1 deck joint, looking west. Description: Work done: Concrete patch for the full length of the joint and asphalt patch covering hole in the deck adjacent to the deck joint in the northbound lane. Photo o: -0 Location: Pier 20 deck joint, looking west. Description: Work done: Concrete patches for the full length of deck joint. -11

10 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) Cycle o.: Photo o: -07 Location: Pier 27 deck joint, looking west. Description: Work done: Concrete patches the full length of Pier 27 deck joint and compression seal replaced. Photo o: -08 Location: Pier 30 deck joint, looking west. Description: Work done: Concrete patches the full length of deck joint, looking west. (ote: Edge spalls and fractured concrete header in the northbound lanes with a torn and loose compression seal) -12

11 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) Cycle o.: Photo o: -09 Location: Pier 33 deck joint, looking west. Description: Work done: Concrete patch adjacent at the southbound lane half of the deck joint. (ote: Broken and settled concrete patch in northbound lane is patched with asphalt and settled) Photo o: -10 Location: Span 1, looking north. Description: Work done: Concrete repair at haunch in Bay of Span 1 at Pier

12 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) Cycle o.: Photo o: -11 Location: Span 29, looking north. Description: Work done: Formwork left in place at underside of deck in Bays 2, 3, and adjacent to Pier 29. Photo o: -12 Location: Span 31, looking south. Description: Work done: Formwork left in place at underside of deck in Bays 7 and 8 over Pier 30. -

13 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) Cycle o.: Photo o: -13 Location: Span 31, looking south. Description: Work Done: Formwork left in place at underside of deck at Bays and from midspan to Pier 30. Photo o: - Location: Pier 9 cap, looking west. Description: Work done: Concrete patch at east end. -1

14 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) Cycle o.: Photo o: -1 Location: Pier 1, looking northeast Description: Work done: Concrete patch at east column. Photo o: -1 Location: Span 8, looking north. Description: Clogged scupper at east curb. -1

15 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) Cycle o.: Photo o: -17 Location: Span 2, looking east. Description: Missing light standard access cover plate with exposed wires at east balustrade, Pier 23. Photo o: -18 Location: Pier 30 deck joint at the northbound lane, looking west. Description: Edge spalls and fractured concrete header in the northbound lanes with a torn and loose compression seal. -17

16 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) Cycle o.: Photo o: -19 Location: Span 32, looking north. Description: Damage steel armor at the east curb adjacent to Pier 31 deck joint. Photo o: -20 Location: South approach, looking north. Description: Impact damage to end treatment of the southeast approach guiderail. -18

17 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) Cycle o.: Photo o: -21 Location: Span, looking north. Description: Large spall with exposed rebars and delaminated concrete (± 2 SF) at midspan. Photo o: -22 Location: Haunch over Pier 27, looking south. Description: Deep spall in haunch over end diaphragm in Bay 3 adjacent to Pier 27 deck joint. -19

18 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) Cycle o.: Photo o: -23 Location: Underside of deck in Bays and of Span 3 adjacent to Pier 33, looking south. Description: Large spalls with exposed rebars in Bay, and large incipient spall in Bay adjacent to a concrete repair. (ote: Large spalls approximately match old concrete patches on the top of deck) Photo o: -2 Location: Stringer S over Pier 22 in Span 22, looking northeast. Description: Hole in the web at the bearing area with no temporary timber supports. (ote: Deteriorated anchor bolt) -20

19 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) Cycle o.: Photo o: -2 Location: Stringer S over Pier 22 in Span 22, looking northwest. Description: Hole in the web over the bearing area of the stringer. (ote: Cracked and leaning temporary timber support, and missing anchor bolt and nut in steel bolster bearing) Photo o: -2 Location: Stringer S9 over Pier 22 in Span 22, looking northeast. Description: 12 x area of severe material losses, up to 100%, in the bearing area and missing anchor bolt and nut in steel bearing bolster. (ote: o temporary timber supports at either side of Stringer S9) -21

20 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) Cycle o.: Photo o: -27 Location: Stringer S7 over Pier 28 in Span 29, looking northwest. Description: Severe material losses in the web thickness at the bearing area with localized buckling of the web. (ote: Heavy construction debris accumulation) Photo o: -28 Location: Stringer S8 over Pier 28 in Span 29, looking northwest. Description: Hole at the end of the web with severe material loss in the web thickness and localized buckling of web at the bearing area. (ote: Heavy construction debris accumulation) -22

21 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) Cycle o.: EW JERSEY DEPARTMET OF TRASPORTATIO STRUCTURAL EVALUATIO BRIDGE EVALUATIO CHECK LIST (FIELD OTES) Inspectors: Thomas Enright ame: J Route 7 (Belleville Turnpike) over Conrail (ewark Branch) Jonathan Kuperus Crew Chief: Efrain Grajeda, P.E. Weather: Cloudy Temperature: 0ºF Special Equipment Used: 3 Bucket Truck and 32 Ladder RATIGS: ot applicable Excellent Condition Very Good Condition no problems noted. Good Condition some minor problems. Satisfactory Condition some minor deterioration of structural elements. Fair Condition minor section loss of primary structural elements. Poor Condition advance section loss of primary structural elements. Serious Condition seriously deteriorated primary structural elements. Critical Condition facility should be closed until repairs are made. Imminent Failure Condition facility closed. Study of repairs is feasible. Failed Condition facility is closed and beyond repair. GEERAL Type of Bridge: Year Built: Reinforced concrete slab: Spans 1 to 13 and 3 to 7; Simply supported steel stringers from Spans to 3 (All fascia stringers and all stringers in Span 2 are concrete encased) 1937 o. of Lanes: Year of Widening / Major Repairs: On 2 Vertical Clearances: Under Over Deck: one Unlimited Minimum Under: 23-1 at north track to west fascia at Span 2 Maximum Under (Item 10): /A Horizontal Underclearance: Total Horizontal Clearance: Right 23. from centerline of north track to the Pier 2 Crashwall Left /A Overall Condition of Structure: Work Done: /A 0-0 curb to curb (Item 1) Fair, due to the superstructure and substructure condition Concrete patches adjacent to the deck joints at Piers, 2, 2, 30, 31, and 33 in the southbound lane, Piers 1, 20, 21, 27, and 29 for full length of joint, asphalt patches at the deck joint at Piers 1 and 33 northbound lane, compression seals replaced at Piers 21, 27, 29 and 33 deck joints, concrete patches and/or timber formwork in the underside of the deck in Span 1, 1, 21, 28, 29, 31, and 32, north and south approaches were repaved with asphalt, concrete patches at Piers,, 9, 10, 13 to 3, 3, 37, 2, and 3 (See Photos -02, and -0 to -1). -23

22 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) DECK SPA # RATIG SI&A Item 8 Condition Rating: COMPOET Wearing Surface / (LMC overlay) Underside of Deck Median Curbs Sidewalks (east side only) Balustrades Deck Joints Light scaling, isolated fine cracks, few fine longitudinal cracks with efflorescence throughout all spans. Spall (10 SF) and two spalls with exposed rebars (2 SF each) adjacent to the south abutment of the east fascia. Several small spalls with exposed rebars and incipient spalls in Spans 2, 3,, and (30 SF total). umerous small spalls with exposed rebars in Spans and 10 (70 SF total). Span 1: Spall with exposed rebars and hollow areas at west half (± 8 SF); spall up to 3 deep spall with exposed rebars at south end at centerline ( SF). Light scaling at east end ( SF) and medium transverse crack below sidewalk ( LF) at north end. Span 3: Medium longitudinal crack (12 LF) with rust stains on the east face of the slab at the east fascia roadway side with spall (1 SF) at north end and spall (2 SF) at the south end; a spall with exposed rebars (2 SF) under the east sidewalk, spall (2 SF) at west half of slab, and two medium cracks (3 LF) at east end of concrete slab. Span : Medium to wide mapcracking with efflorescence and hollow area (20 SF) between Columns 2 and 3 and hollow area at east end (± 3 SF). Span : Spall with several exposed rebars (± 10 SF) with adjacent hollow area (± SF). Fine to medium cracks with light efflorescence. Span : Spall with exposed rebars (2 SF) at center and incipient spall ( SF) and fine to medium cracks (2 LF) with light efflorescence (See Photo -21). Span 8: Incipient spall with medium longitudinal cracks with efflorescence and rust staining (20 SF). Several longitudinal medium cracks with efflorescence and water staining (± 180 LF) and several short transverse cracks at east fascia (± 3 LF total), spall (12 x 8 ) with exposed rebars at centerline; fine to medium cracks (± 0 LF). ote: There are no superstructure forms for Spans 1 13 since structure is a concrete slab. Few small spalls with exposed reinforcing bars in Spans 3 and 9 of the east and west curbs ( SF total). diameter spall under the steel angle on the west side, Span. Missing joint filler material (2 LF) at Piers and 7 joint. Moderate debris accumulation throughout. Several small spalls with exposed reinforcing on posts at east and west sides, no repair required. Guide Rail 1-13 Cycle o.: Drains and Scuppers Light Stands Utilities Moderate dirt accumulation in both shoulders at joint between Piers and 7 and at Pier 13. Settled and deteriorated compression joint at Pier 13, northbound lane (3 LF). Fully clogged at east curb of Span 8 (See Photo -1). Missing access cover plate at light pole base and vine growth on pole at the beginning of Span 1, east side (See Typical Photo -17). 2 tree against west end of deck slab Span. -2

23 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) DECK SPA # RATIG SI&A Item 8 Condition Rating: COMPOET Wearing Surface / (Concrete) Underside of Deck Median Curbs Sidewalks (east side only) Balustrades Covered in soot from previous car fire. Large areas of fine mapcracking with efflorescence (± 0%), numerous fine transverse cracks with efflorescence, spalls with exposed rusted rebars throughout ( SF total) and patched areas ( SF). Spalled concrete patches in haunches over Pier 13 at Bays 1, 3,,, 7 and 8 (± 13 SF total) and over Pier (3 SF) (See Typical Photos -21 to -23). Spall below curb angle at west side over Pier deck joint (1 SF). Light to moderate accumulation of debris throughout. Several small spalls with exposed shallow reinforcing on both east and west sides. Guide Rail Deck Joints Depressed and deteriorated compression seal material at southbound lane (1 LF). Compression sealer material was replaced with foam material at west end at Pier deck joint. Drains and Scuppers Light Stands Fully clogged at east and west curbs (See Typical Photo -1). Cycle o.: Utilities -2

24 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) DECK SPA # RATIG SI&A Item 8 Condition Rating: COMPOET Wearing Surface / (Concrete) Underside of Deck Large areas of fine mapcracking with efflorescence (0%) and moderate scaling throughout, numerous transverse fine cracks with efflorescence, patched areas with timber formwork still in place, 10% of deck area. Large spall in Bay adjacent to Pier 1 deck joint. Incipient spalls (20 SF) throughout with few located in old concrete patches. Large concrete patch with timber forms left in place at Bay 2 over Pier (work done). End deck haunches exhibit medium to wide cracks with heavy efflorescence and random spalls. Light to medium deflection of concrete deck under heavy live load causing banging noises. (See Typical Photos -21 to -23) Median Curbs Sidewalks (east side only) Balustrades 1 Cycle o.: Typical areas of small spalls with exposed reinforcing on the west side (2 SF total). Typical minor to moderate accumulation of debris throughout. Typical several small spalls with exposed reinforcing on posts on east and west sides. Guide Rail Deck Joints Moderate debris accumulation at Pier 1 and minor depression of joint sealer. Drains and Scuppers Light Stands Utilities -2

25 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) DECK SPA # RATIG SI&A Item 8 Condition Rating: Underside of Deck Large areas of fine map cracking with efflorescence (0%), few fine, transverse cracks with efflorescence, few large spalls with several exposed rebars at both ends of the span (1 SF). End deck haunches exhibit med. to wide cracks with heavy efflorescence and random spalls. Several old concrete patches with timber form work still in place. Large haunch spall at Pier 1, Bay 7 with exposed rebars ( SF) partially covered with timber planks. Several small incipient spalls adjacent to end haunches (± 10 SF total). Large concrete patch in haunch at Bay over Pier 1 (work done). Light to moderate deflection of concrete deck under heavy live load causing a loud banging noise. (See Typical Photos -21 to -23) Median Curbs Several areas of small spalls with exposed reinforcing on the east and west side (10 SF total). Sidewalks (east side only) Balustrades Moderate accumulation of debris throughout. Guide Rail Impact damage on east side (10 LF). Deck Joints Loose and deteriorated compression seal material has been covered with uneven asphalt patch (± 1 SF). COMPOET Wearing Surface / (Concrete) 1 Cycle o.: Several small spalls with exposed reinforcing on posts on both east and west sides. Drains and Scuppers Light Stands Utilities -27

26 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) DECK SPA # RATIG SI&A Item 8 Condition Rating: COMPOET Wearing Surface / (Concrete) Large area of mapcracking with efflorescence (± 0%), few fine, transverse cracks with efflorescence, few spalls and delaminated concrete (1 SF). End deck haunches exhibit medium to wide cracks with heavy efflorescence and random spalls. Several old concrete patches, many with timber form work still in place Light to moderate deflection of deck under heavy live load. (See Typical Photos -21 to -23) Median Curbs Few areas of small spalls with exposed reinforcing on the east and west sides (2 SF total). Sidewalks (east side only) Balustrades Moderate accumulation of debris throughout. 17 Underside of Deck Cycle o.: Several small spalls with exposed reinforcing on posts on both east and west sides. Guide Rail Deck Joints Drains and Scuppers Light Stands Clogged at east and west curbs (See Typical Photos -1). Utilities -28

27 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) DECK SPA # RATIG SI&A Item 8 Condition Rating: COMPOET Wearing Surface / (Concrete) Underside of Deck Mapcracking with efflorescence (± 0%), few fine transverse cracks with efflorescence and a few spalls (1 SF). End deck haunches exhibit medium to wide cracks with heavy efflorescence and random spalls. Several old concrete patches many with timber form work still in place Light to moderate deflection of concrete deck and load banging noises at piers under heavy live load. (See Typical Photos -21 to -23) Median Curbs 18 Cycle o.: Sidewalks (east side only) Balustrades Several areas of small spalls with exposed reinforcing on the west side (10 SF). Concrete patch (1 SF) at Pier 17 joint area. Moderate accumulation of debris throughout. Several small spalls with exposed reinforcing on posts on both east and west sides. Guide Rail Deck Joints Drains and Scuppers Light Stands Utilities -29

28 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) DECK SPA # RATIG SI&A Item 8 Condition Rating: COMPOET Wearing Surface / (Concrete) 19 Underside of Deck Cycle o.: Median Curbs Sidewalks (east side only) Balustrades Moderate wear in traveled lanes. Minor debris accumulation in both shoulders and southbound shoulder has fine mapcracking throughout. Large concrete patch in southbound lane (± 80% of total area). Fine mapcracking with efflorescence (± 0%), few fine transverse cracks with efflorescence, and a few spalls throughout (1 SF). End deck haunches exhibit medium to wide cracks with heavy efflorescence and random spalls with areas of delaminated concrete with exposed rebars (10 SF total). Moderate deflection of deck with load banging noises under heavy live load. (See Typical Photos -21 to -23) Few areas of small spalls with exposed reinforcing on the west side, ( SF total). Moderate accumulation of debris throughout. Several small spalls with exposed reinforcing on posts on both east and west sides. Guide Rail Deck Joints Drains and Scuppers Light Stands Utilities -30

29 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) DECK SPA # RATIG SI&A Item 8 Condition Rating: 3 COMPOET Wearing Surface / (Concrete) Underside of Deck Mapcracking with efflorescence (± 0%), few fine, transverse cracks with efflorescence and a few spalls throughout (1 SF). Several old concrete patches few with timber form work still in place. Large concrete repair with formwork left in place in Bay 7 adjacent to Pier 20. There is a concrete patch above this location. End haunches exhibits medium cracks with efflorescence stains, spalls, incipient spalls throughout. Moderate deflection of deck with load banging noises above piers under heavy live load. (See Typical Photos -21 to -23) Median Curbs 20 Cycle o.: Sidewalks (east side only) Balustrades Several areas of small spalls with exposed reinforcing on the west side, (10 SF total). Spall (1 SF) at west side at joint area. Moderate accumulation of debris throughout. Several small spalls with exposed reinforcing on posts on both east and west sides. Guide Rail Deck Joints Drains and Scuppers Light Stands Clogged at both curbs (See Typical Photo -1). Utilities Utility pole has rope tied to the balustrade for lateral support at Pier 20. o signs of movement in the balustrade. -31

30 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) DECK SPA # RATIG SI&A Item 8 Condition Rating: COMPOET Wearing Surface / (Concrete) Underside of Deck Mapcracking with efflorescence (± 0%), few fine transverse cracks with efflorescence and spalled concrete at few locations throughout ( SF total). Several old concrete patches many with timber formwork still in place. Concrete patches at Bays, 7, and 8 near Pier 20, haunches exhibits areas of small spalls and medium cracks with efflorescence stains. (See Typical Photos -21 to -23) Median Curbs 21 Cycle o.: Sidewalks (east side only) Balustrades Several areas of small spalls with exposed reinforcing on the east and west sides ( SF total). Moderate accumulation of debris throughout. Several small spalls with exposed reinforcing on posts on both east and west sides. Guide Rail Deck Joints Drains and Scuppers Light Stands Utilities -32

31 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) DECK SPA # RATIG SI&A Item 8 Condition Rating: Underside of Deck Large areas of fine mapcracking with efflorescence, few fine transverse cracks with efflorescence, and spalled concrete with several exposed rebars at several locations throughout (2 SF). Timber formwork covers approximately 10% of entire area. Deck bounces on stringers S2 through S7 under traffic loading. (See Typical Photos -21 to -23) Median Curbs Sidewalks (east side only) Balustrades Several areas of small spalls with exposed reinforcing on the west side ( SF). Moderate accumulation of debris throughout. Several small spalls with exposed reinforcing on posts on both east and west sides. Spall at east side midspan (1 SF), exposed reinforcement with 100% material loss. Guide Rail Deck Joints COMPOET Wearing Surface / (Concrete) 22 Cycle o.: Sidewalk deck joint filler material is missing at Pier 22. Moderate accumulation of debris in both shoulders at Pier 22. Joint sealer is settled and filled with debris at northbound and west shoulder (± 1 LF). Drains and Scuppers Light Stands Utilities -33

32 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) DECK SPA # RATIG SI&A Item 8 Condition Rating: COMPOET Wearing Surface / (Concrete) Underside of Deck Large areas of fine mapcracking with efflorescence, few fine transverse cracks with efflorescence, and spalled concrete with exposed rebars at Bays and ( SF) at several locations throughout (1 SF). Deck bounces on Stringers S2 through S7 under traffic loading. Haunches at Pier 23 are cracked with heavy efflorescence stains. (See Typical Photos -21 to -23) Median Curbs Sidewalks (east side only) Balustrades 23 Cycle o.: Incipient spall at west side (2 SF). Moderate debris accumulation. Several spalls with exposed reinforcing on posts on both east and west sides (10 SF). 1/8 horizontal through crack on top rail at end of span, east side. Guide Rail Deck Joints Drains and Scuppers Light Stands Fully clogged at both curbs. Vegetation growth at east curb scupper (See Typical Photo -1). Utilities -3

33 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) DECK SPA # RATIG SI&A Item 8 Condition Rating: Underside of Deck Localized areas of fine mapcracking. Few small spalls with exposed rebars throughout ( SF). Few old concrete patches many with timber form work still in place. Medium to wide cracks in Bays 1 to (2 LF total) adjacent to Pier 23 deck joint. Haunches at Piers 23 and 2 are cracked with heavy efflorescence stains and hollow sounding. Deck bounces on Stringers S2 through S7 under traffic loading. (See Typical Photos -21 to -23) Median Curbs Sidewalks (east side only) Balustrades COMPOET Wearing Surface / (Concrete) 2 Cycle o.: Several areas of small spalls with exposed reinforcing on the east and west sides (10 SF total). Moderate debris accumulation. Several small spalls with exposed reinforcing on posts on both east and west sides. Spall with exposed rebars (2 - x 9 x deep) at north end of span, west side, on top rail. 1/8 through crack on top rail at south end of span, east side. Guide Rail Deck Joints Drains and Scuppers Light Stands Missing access cover plate at southeast corner with exposed wires (See Photo -17). Utilities -3

34 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) DECK SPA # RATIG SI&A Item 8 Condition Rating: COMPOET Wearing Surface / (Concrete) Underside of Deck Between S1 and S: Few small spalls at isolated locations with several exposed rebars (2 SF). Between S and S: Fine mapcracking at north end of span. Between S8 and S9: Spall (1 SF) with exposed reinforcing at north end and spalls with exposed reinforcing (1 SF each) on south end. Between S9 and S10: Several fine to medium transverse cracks with efflorescence. Deck bounces on Stringers S2 through S7 under traffic loading. (See Typical Photos -21 to -23) Median Curbs Sidewalks (east side only) Balustrades Several areas of small spalls with exposed reinforcing on the west side ( SF total). Moderate accumulation of debris throughout. Several small spalls with exposed reinforcing on posts on both east and west sides. Guide Rail Deck Joints Compression seal is cover with debris at sidewalk and moderate debris accumulation throughout at Pier 2. Drains and Scuppers Light Stands Both sides are clogged (See Typical Photo -1). 2 Cycle o.: Utilities -3

35 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) DECK SPA # RATIG SI&A Item 8 Condition Rating: Underside of Deck Haunches at both ends are cracked with efflorescence throughout and exposed rebars (10 SF total). Between S9 and S10, spalled concrete above end diaphragm, south end ( SF total). Timber formwork for concrete patches at the following locations: Between S2 and S3 and S3 and S at south end; between S2 and S3 at north end. Deck bounces on Stringers S2 through S7 under traffic loading. (See Typical Photos -21 to -23) Median Curbs Sidewalks (east side only) Balustrades Few areas of small spalls with exposed reinforcing on the west side (2 SF total). Moderate accumulation of debris throughout. Several small spalls with exposed reinforcing on posts on both east and west sides. Guide Rail COMPOET Wearing Surface / (Concrete) Deck Joints 2 Cycle o.: Drains and Scuppers Light Stands Utilities -37

36 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) DECK SPA # RATIG SI&A Item 8 Condition Rating: 27 COMPOET Wearing Surface / (Concrete) Underside of Deck Haunches at both ends are cracked with efflorescence throughout. Between S2 and S3, spalled concrete above end diaphragm, south end ( SF total) (See Photo -22). Timber formwork for concrete patches at several locations. Deck bounces on Stringers S2 through S7 under traffic loading. Large uneven patch between S2 and S3. Several areas of spalled concrete with exposed rebars at Bay 8 (1 SF) and Bay 7 (1 SF). Areas of mapcracking at Bays 3,,,, and 7. (See Typical Photos -21 to -23). Cycle o.: Median Curbs Sidewalks (east side only) Balustrades Few areas of small spalls with exposed reinforcing on the west side (2 SF total). Moderate accumulation of construction debris. Several small spalls with exposed reinforcing on posts on both east and west sides. Guide Rail Deck Joints Drains and Scuppers Light Stands Utilities -38

37 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) DECK SPA # RATIG SI&A Item 8 Condition Rating: 28 COMPOET Wearing Surface / (Concrete) Underside of Deck Haunches at south end are cracked with efflorescence. Few small spalls at north end near haunches. Timber formwork for concrete patches at several locations. Mapcracking in Bays 3 through 8 several areas of spalls with exposed reinforcement in Bays through 8 (± 3 SF). Deck bounces on Stringers S2 through S7 under traffic loading. Large concrete repair in Bay 2 adjacent to Pier 27 (See Typical Photos -21 to -23) Cycle o.: Median Curbs Few areas of small spalls with exposed reinforcing on the west side (2 SF total). Sidewalks (east side only) Balustrades Several small spalls with exposed reinforcing on posts on both east and west sides. Guide Rail Deck Joints Drains and Scuppers Light Stands Utilities -39

38 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) DECK SPA # RATIG SI&A Item 8 Condition Rating: COMPOET Wearing Surface / (Concrete) Curbs Sidewalks (east side only) Balustrades Spall ( x3 x3 ) with delaminated concrete between S and S7. Large spall ( x x3 ) with delaminated concrete (20 SF total) between S8 and S9 with several exposed and rusted rebars at Pier 28 (matching asphalt patch and spall on top of deck). Spall with exposed rebars between S and S. Timber formwork for concrete patches at the ends of several bays. Large areas of fine mapcracking with efflorescence, few fine transverse cracks with efflorescence. Deck bounces on Stringers S2 through S7 under traffic loading. Several areas of spalled concrete with exposed rebars at Bays 1, 2 and through 9 (± 3 SF). Haunches are cracked and spalled with efflorescence. (See Typical Photos -21 to -23) Several areas of small spalls with exposed reinforcing on the east and west sides (8 SF). Several small spalls with exposed reinforcing on posts on both east and west sides. Guide Rail Deck Joints Drains and Scuppers Light Stands Median 29 Underside of Deck Cycle o.: Missing utility cover with exposed wires at west side light pole at Pier 29 (See Typical Photo -19). Utilities -0

39 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) DECK SPA # RATIG SI&A Item 8 Condition Rating: Underside of Deck Large areas of fine mapcracking with efflorescence, a few fine transverse cracks with efflorescence and a few spalls throughout (1 SF). Several old and new concrete patches many with timber form work still in place and incomplete repairs Bays 2, and. Several spalls with exposed rebars Bays 1 through 3 and through 9 (± 0 SF). Haunches are spalled and cracked with efflorescence; incipient spall Bay 7 (1 SF). Missing 3/ haunch width x deep at Bays and. Deck bounces on Stringers S2 through S7 under traffic loading. (See Typical Photos -21 to -23) Median Curbs Sidewalks (east side only) Balustrades Few areas of small spalls with exposed reinforcing on the east and west sides ( SF total). Several small spalls with exposed reinforcing on posts on both east and west sides. Guide Rail Deck Joints COMPOET Wearing Surface / (Concrete) 30 Cycle o.: Concrete headers along the Pier 30 deck joint is spalled and fractured with several exposed rebars at the compression seal joint material is loose and torn at northbound (20 LF) (See Photo -18). Drains and Scuppers Light Stands Utilities -1

40 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) DECK SPA # RATIG SI&A Item 8 Condition Rating: Underside of Deck Large areas of fine mapcracking with efflorescence in all bays, few fine, transverse cracks with efflorescence and a few spalls throughout. Several new and old concrete patches many with timber form work still in place. Formwork over the center bay between Stringers and. The reminder of the bay (0 SF) is hollow and sagging down 1 ½ and deflects 1-2 under live load. Several spalled areas with exposed rebars at Bays 1 through 8 (± 0 SF). Haunches are spalled and cracked. (See Typical Photos -21 to -23) Median Curbs Several areas of small spalls with exposed reinforcing on the east and west sides (8 SF total). Sidewalks (east side only) Balustrades Several small spalls with exposed reinforcing on posts on both east and west sides. Guide Rail Minor impact damage for 2 LF on the west side. Deck Joints Joint material is settled at the northbound ( LF). Concrete patches in headers are cracked. Shallow reinforcement steel exposed at northbound lane ( x 2 ). Drains and Scuppers Light Stands West side is clogged (See Typical Photos -1). COMPOET Wearing Surface / (Concrete) 31 Cycle o.: Utilities -2

41 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) DECK SPA # RATIG SI&A Item 8 Condition Rating: Underside of Deck Fine map cracking with efflorescence at several locations, few fine transverse cracks with efflorescence near joints and timber forms covering concrete at a few locations. Deck bounces on Stringers S2 through S7 under traffic loading. (See Typical Photos -21 to -23). Median Few areas of small spalls with exposed reinforcing on the east and west sides, section of steel angle is bent upward ( LF) on the east curb, at the beginning of the span. Does not protrude into roadway and is not loose (See Photo -19). Several spalls with exposed rebars areas at Bays 1 through 9 (± 0 SF). Sidewalks (east side only) Balustrades Several small spalls with exposed reinforcing on posts on both east and west sides. Guide Rail East side has 3 LF of minor impact damage. Deck Joints Drains and Scuppers Light Stands COMPOET Wearing Surface / (Concrete) Curbs 32 Cycle o.: East side at Pier 32, utility cover in balustrade is corroded and holed through at bottom 3. Access cover is missing in light pole at east balustrade (See Typical Photo -17). Utilities -3

42 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) DECK SPA # RATIG SI&A Item 8 Condition Rating: Underside of Deck Fine mapcracking with efflorescence at several locations, few fine transverse cracks with efflorescence near joints and timber forms covering concrete at a few locations. Bay : Spall (2 SF) with rebars exposed and delaminated concrete (1 SF). Several small spalls with exposed rebars throughout (± 3 SF). Spall ( x2 x3 ) with exposed rebars near Pier 32. Deck bounces on Stringers S2 through S7 under traffic loading. (See Typical Photos -21 to -23) Median Curbs Sidewalks (east side only) Balustrades Few areas of small spalls with exposed reinforcing on the east and west sides ( SF total). Several small spalls with exposed reinforcing on posts on both east and west sides. Spall (1 SF) at midspan east side with exposed rebars. Guide Rail Deck Joints COMPOET Wearing Surface / (Concrete) 33 Cycle o.: Minor accumulation of debris at both shoulders at Pier 33. Large concrete patches along joint. Broken and settled concrete patch in northbound lane is patched with settled asphalt (See Photo -09). Compression joint was replaced. Drains and Scuppers Light Stands Utilities -

43 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) DECK SPA # RATIG SI&A Item 8 Condition Rating: Underside of Deck Fine mapcracking with efflorescence at several locations, few fine transverse cracks with efflorescence near joints and timber forms covering concrete at a few locations. Several spalls with exposed rebars at Bays 1, 2, 3,,, 7 and 8 (± 2 SF). Haunches have cracks with efflorescence and spalls. Spall ( x 8 x 3 deep) and delaminated concrete in Bay. Spall (3 x 12 x 3 deep) in Bay (See Photo -23). Deck bounces on Stringers S2 through S7 under traffic loading. Median Curbs COMPOET Wearing Surface / (Concrete) 3 Cycle o.: Sidewalks (east side only) Balustrades Few areas of small spalls with exposed reinforcing on the east and west sides ( SF total). Several small spalls with exposed reinforcing on posts on both east and west sides. Guide Rail Deck Joints Drains and Scuppers Clogged scupper (See Typical Photos -1).. Light Stands Utilities -

44 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) DECK SPA # RATIG Cycle o.: SI&A Item 8 Condition Rating: 3 through 7 COMPOET Wearing Surface / (LMC overlay) Moderate wearing in traveled lanes. Moderate debris accumulation in both shoulders throughout all spans. Fine to medium mapcracking throughout both shoulders in Spans 3 0. orthbound lane has 1 longitudinal fine to medium crack throughout Spans 3 38 (0 LF total) appears to go through. One medium longitudinal crack in the southbound lane of Span 38 (1 LF). Fine map cracks in the northbound lane, Span 39, (80 SF). Several fine to medium longitudinal cracks (10 LF). Few concrete patches typical throughout. Tree is leaning over the shoulder and east balustrade in Span 0 and does not obstruct traffic (not considered priority). Underside of Deck A few fine full length longitudinal cracks with efflorescence in Spans 37, 38, 39, 0 and 7. Few small spalls with exposed reinforcement in Spans 3, 37, 38, 39, 0, 2, and 3 (20 SF total). Spall (1 x 8 ) at west fascia over Pier 37. Small spalls with efflorescence at west fascia over Pier 38. Spall (2. x ) at west fascia over Pier 1. Span 3: Shallow spalls with exposed rebars below sidewalk (1 SF). Span : Edge spall with exposed rebars at east end. Span 7: Hollow sounding concrete and light scaling. ote: There are no superstructure forms for Spans 3 7 since structure is a concrete slab. (See Typical Photos -21 to -23) Median Curbs Sidewalks (east side only) Balustrades Few small spalls with exposed reinforcing on posts on both east and west sides. Guide Rail Deck Joints Drains and Scuppers Light Stands East side curb has a few small spalls under the steel angle in Spans 3 37, 0 and 3. Spall ( SF) on east side at the north abutment. West side curb has several small spalls (2 SF total) with exposed reinforcement in Spans and. Partially obstructed at east curb, Span 0. Span 7: Utility cover and one anchor bolt cover missing at the end of the span, east side and west side at the end of the span. Missing access cover plate at east and west balustrade light poles (See Typical Photo -17). Utilities -

45 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) APPROACHES APPROACH RATIG 7 7 Cycle o.: SI&A Item BA Rating: SI&A Item 72 Rating: 7 South COMPOET Approach Slab / Pavement (Asphalt) Approach Shoulder (Asphalt) Approach Roadway Vertical and Horizontal Alignment Guide Rail Condition (Steel W-beam) Sidewalks Vertical: Upgrade toward bridge Horizontal: Slight horizontal curve towards the west. Moderate collision damage at the end terminal of the southeast approach corner (See Photo -20). Curbs (Concrete) Utilities (Overhead wires at the east side) Approach Roadway Embankment -7

46 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) APPROACHES APPROACH RATIG 7 7 Cycle o.: SI&A Item BA Rating: SI&A Item 72 Rating: 7 orth COMPOET Approach Slab / Pavement (Asphalt) Approach Shoulder (Asphalt) Approach Roadway Vertical and Horizontal Alignment Vertical: Upgrade toward bridge Horizontal: Slight horizontal curve towards the west. Guide Rail Condition (Steel W-beam) Sidewalks Curbs (Concrete) Utilities (Overhead wires at the east side) Approach Roadway Embankment -8

47 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) SUPERSTRUCTURE SPA # Cycle o.: SI&A Item 9 Condition Rating: RATIG COMPOET Stringers (Stringers S1-S10 numbered west to east) Diaphragms / Cross Frames (umbered south to north) Bearings Deflection and Vibration Stringers have heavy peeling paint and surface rust and are covered with soot from previous fire. Timber sheeting under south end diaphragms at Bays 1, 2, and 9. Steel repairs to the ends of stringers S, S, S7, and S8. Stringer ends at Pier 13: S1 and S10 cracked concrete encasement (10 LF total). S2 - Severe loss at bottom of web with a hole in web (3 long x 2 high) under end diaphragm. S3 - Up to 0% material loss of web under end diaphragm (< 1 SF) with small hole in web. S - Approximately 0% material loss in the bottom flange and web (< 1 SF) with two small holes above the bearings. S9 - Moderate laminar rust to bottom flange (±1/8 x 2 LF material loss) and web (1/1 x 2 high x 3 LF) at the bearings. Severe rust with up to 0% material loss of bottom flanges at Bay 2 and 9 at Pier 13. Severe rust of the 1st diaphragm with small holes in bottom flange and up to 7% material loss. Diaphragms at Pier 13 which were previously replaced at Bays 3 to 8 exhibit light surface rust. The Pier end diaphragms exhibit moderate to severe rust with minor material loss. Pier 13: Severe rust and up to 0% material loss of sole plates at S1 to S3, S, S9, and S10. Anchor bolt nuts have 90% material loss at S1, S2, S3, and S. Timber supports have previously been installed at Bays 1, 2, and 9. Pier exhibit moderate to severe rust with up to 2% material loss to anchor bolts and nuts. Light to moderate vibration noted during inspection. FATIGUE DETAILS Category There are no superstructure forms for Spans 1 13 since structure is a concrete slab (See Underside of Deck for Spans 1 13). Estimated percentage of Large trucks in ADT = % Detail Description and Location /A -9

48 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) SUPERSTRUCTURE SPA # Cycle o.: SI&A Item 9 Condition Rating: 1 RATIG COMPOET Stringers Moderate to severe rust at ends of all stringers with paint peeling throughout all stringers. Minor gouge (3 long x 1 high) at bottom flange at midspan of S7 (Stringers S1-S10 numbered west to east) Diaphragms / Cross Frames (umbered south to north) Bearings Deflection and Vibration End diaphragms have severe rust with minor material loss in web and bottom flange. Intermediate diaphragms have paint peeling and moderate rust. Moderate to heavy rust throughout. Completely covered with concrete at Pier 1 at Bays 3 and due to deck repair. Light to moderate deflection noted during inspection under heavy live load. Banging noises at piers due to deck rubbing up against end diaphragm and stringer top flanges FATIGUE DETAILS Category Estimated percentage of Large trucks in ADT = % Detail Description and Location /A -0

49 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) SUPERSTRUCTURE SPA # Cycle o.: SI&A Item 9 Condition Rating: 1 RATIG COMPOET Stringers (Stringers S1-S10 numbered west to east) Diaphragms / Cross Frames (umbered south to north) Bearings Deflection and Vibration Light to moderate rust with paint peeling and flaking at both ends. Heavy rust in bottom flange and bottom of web of stringers at Pier 1. S9 exhibits 2 diameter hole at bottom of web. S1 and S10 concrete encasement cracked and spalled at each end (8 SF total). Steel repairs to ends of Stringers S7, S, S, and S at Pier 1 in good condition with light surface rust. The end diaphragms have severe rust with moderate material losses throughout. Pier 1: Moderate rust and completely covered with concrete debris at Bays 1 and 2 due to deck repair. Pier 1: Heavy rust and up to 0% material loss at edges of plates, anchor bolts corroded up to 0% at both sides of S1, S2, S3, S9 and S10. umerous anchor bolt nuts are severely corroded. Moderate to heavy accumulation of construction debris at Bays 2 to 7. Light to moderate deflection noted during inspection under heavy live load. Banging noises at piers under heavy live load due to deck rubbing up against end diaphragm and stringer top flanges. FATIGUE DETAILS Category Estimated percentage of Large trucks in ADT = % Detail Description and Location /A -1

50 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) SUPERSTRUCTURE SPA # Cycle o.: SI&A Item 9 Condition Rating: 17 RATIG COMPOET Stringers (Stringers S1-S10 numbered west to east) Diaphragms / Cross Frames (umbered south to north) Bearings Moderate rust throughout. Deflection and Vibration Moderate vibration with loud noises under live load due to deck rubbing up against end diaphragm and stringer top flanges Timber shoring is located under the diaphragms at Pier 1 in Bays 3 and 8. Light to moderate rust with paint peeling throughout. S1 and S10: Concrete encasement spalls at both ends of stringers (8 SF total). Steel repairs to stringer ends at S, S, and S7 at Pier 1 exhibit light surface rust. S: Material loss (1/8 ) to web at bearing at Pier 1. Bottom of web exhibits material loss (1 long x 3 high) at bearing. Material loss (1/8 ) to bottom flange at bearing ( long x 2 wide) at edge of bottom flange. S9: Web hole (2 diameter) at bearing and 1/8 thickness remaining ( long x high) at bottom of web around hole Pier 1 exhibits missing anchor bolts at the east side of S2 and east side of S10, and the bearings have severe corrosion. S2 to S8 are covered with heavy construction debris covering the anchor bolts. Pier 17 exhibits moderate rust throughout. FATIGUE DETAILS Category Estimated percentage of Large trucks in ADT = % Detail Description and Location /A -2

51 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) SUPERSTRUCTURE SPA # Cycle o.: SI&A Item 9 Condition Rating: 18 RATIG COMPOET Stringers Light to moderate rust and paint peeling throughout. (Stringers S1-S10 numbered west to east) Diaphragms / Cross Frames (umbered south to north) Bearings Deflection and Vibration Moderate to heavy rust at the intermediate and end diaphragms. Moderate rust throughout. Light to moderate vibration noted during inspection. Banging noises under heavy live load at piers due to deck rubbing up against end diaphragm and stringer top flanges FATIGUE DETAILS Category Estimated percentage of Large trucks in ADT = % Detail Description and Location /A -3

52 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) SUPERSTRUCTURE SPA # Cycle o.: SI&A Item 9 Condition Rating: 19 RATIG COMPOET Stringers (Stringers S1-S10 numbered west to east) Diaphragms / Cross Frames (umbered south to north) Bearings Deflection and Vibration Moderate rust and paint peeling throughout. Small hole (1/2 diameter) at north end at S3. Encasement at both ends of S1 and S10 are cracked and exhibit spalls (± 10 SF total). Moderate rust at the intermediate diaphragms and moderate to heavy rust at the end diaphragms. Moderate deflection noted during inspection under heavy live load. Banging noises at Piers under heavy live load due to deck rubbing up against end diaphragm and stringer top flanges. FATIGUE DETAILS Category Estimated percentage of Large trucks in ADT = % Detail Description and Location /A -

53 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) SUPERSTRUCTURE SPA # Cycle o.: SI&A Item 9 Condition Rating: 20 RATIG COMPOET Stringers Moderate rust at stringer ends and paint peeling throughout. (Stringers S1-S10 numbered west to east) Diaphragms / Cross Frames (umbered south to north) Bearings Moderate rust at the intermediate diaphragms and moderate to heavy rust at the top flanges of the end diaphragms. Deflection and Vibration Moderate rust throughout Pier 19 at Bay 8 is completely covered with concrete debris due to concrete repairs to the deck. Light to moderate vibration noted during inspection FATIGUE DETAILS Category Estimated percentage of Large trucks in ADT = % Detail Description and Location /A -

54 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) SUPERSTRUCTURE SPA # Cycle o.: SI&A Item 9 Condition Rating: 21 RATIG COMPOET Stringers Moderate rust at stringer ends. S1 and S10 concrete encasement is cracked and delaminated (8 SF total) at both ends. Light rust and peeling paint throughout (Stringers S1-S10 numbered west to east) Diaphragms / Cross Frames (umbered south to north) Bearings Moderate to heavy rust at the intermediate diaphragms and moderate to heavy rust at top flange of the end diaphragms. Moderate to heavy rust throughout. Deflection and Vibration Light to moderate vibration noted during inspection FATIGUE DETAILS Category Estimated percentage of Large trucks in ADT = % Detail Description and Location /A -

55 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) SUPERSTRUCTURE SPA # Cycle o.: SI&A Item 9 Condition Rating: 22 RATIG COMPOET Stringers (Stringers S1-S10 numbered west to east) Diaphragms / Cross Frames (umbered south to north) Bearings Deflection and Vibration S1 and S10: Small spalls and cracks in of concrete encasement at both ends (8 SF total). Stringer ends at Pier 22: S: Hole (2 1/2 x 2 ) in web under end diaphragm (See Photo -2). S: Hole (3 x 2 ) in web 1 above bottom flange and from stringer end (See Photo -2). Timber block used as temporary support at each end of S. Timber block at east end of S is cracked and tilted to the north. S: Severe rust and approximately 1/8 material loss ( high x long) of web above the bearing. S7 and S8: Severe rust and material loss (1/8 x 2 long) in the web above the bottom flange to mid-height near the bearing. S8: Hole (1/2 diameter) in bottom of web 10 from stringer end and above bottom flange. S9: 12 by area of severe material losses, up to 100%, in web near the bearing. ± 1/8 material loss to web under end diaphragm (18 long by high) (See Photo -2). Moderate rust at the intermediate diaphragms. Moderate to severe paint peel and minor material loss at the top and bottom flanges of the end diaphragms. Pier 22: Anchor bolts exhibit up to 90% material loss. Anchor bolts missing at east side of S2 and S8, west side of S and S10, and both sides of S, S7 and S9. o signs of lateral or longitudinal movement were noted. Anchor bolt nuts not seated at S3 (2 of 2), S (2 of 2), S (1 of 2), and S8 (1 of 2) with up to 90% material loss to bolts. (See Photos -2 to -2) Light to moderate vibration noted during inspection FATIGUE DETAILS Category Estimated percentage of Large trucks in ADT = % Detail Description and Location /A -7

56 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) SUPERSTRUCTURE SPA # Cycle o.: SI&A Item 9 Condition Rating: 23 RATIG COMPOET Stringers (Stringers S1-S10 numbered west to east) Diaphragms / Cross Frames (umbered south to north) Bearings Deflection and Vibration Stringer ends at Pier 22: S2 through S9 have severe rust with 3/1 material loss to the bottom of the web for high x ± 1 long. Stringer ends at Pier 23: Moderate rust typical at and peeling paint throughout. S3 to S8 exhibit up to (1/8 thick x high x 3 long) material loss to bottom of web. Moderate rust throughout the intermediate diaphragms and severe rust with flaking and minor material loss at the end diaphragms. Severe rust and flaking at Pier 22. 0% to 7% material loss on all anchor bolts and nuts at bearings S3 to S9. Light to moderate vibration noted during inspection. FATIGUE DETAILS Category Estimated percentage of Large trucks in ADT = % Detail Description and Location /A -8

57 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) SUPERSTRUCTURE SPA # Cycle o.: SI&A Item 9 Condition Rating: 2 RATIG COMPOET Stringers All stringers are concrete encased. The concrete encasement at the stringer ends has small spalls and cracks (10 SF total). The exposed bottom flanges at stringer ends exhibit rust. (Stringers S1-S10 numbered west to east) Diaphragms / Cross Frames (umbered south to north) Bearings Deflection and Vibration Moderate rust throughout. Light to moderate vibration noted during inspection. FATIGUE DETAILS Category Estimated percentage of Large trucks in ADT = % Detail Description and Location /A -9

58 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) SUPERSTRUCTURE SPA # Cycle o.: SI&A Item 9 Condition Rating: 2 RATIG COMPOET Stringers (Stringers S1-S10 numbered west to east) Diaphragms / Cross Frames (umbered south to north) Bearings Peeling paint on webs and bottom flanges typical throughout. Stringer ends at Pier 2: S: Hole ( x 3 ) in bottom of web at bearing with timber support at each side of stringer. S and S: 0% material loss of web under diaphragm and S has a hole (1 sq. in). S7: Steel repairs S8: Moderate material loss on web between the end diaphragm and the bottom flange. S10: Spall (20 x 3 x 3 ½ ) of encasement on west side along bottom of web. Concrete encasement is cracked throughout and exhibits spalls at the bottom flange at a few locations including the end diaphragms at Pier 2 (12 SF total). Paint peeling and moderate corrosion with laminar rust on the bottom flanges at the end diaphragms at Pier 2. Pier 2: Corrosion with minor material losses throughout. Pier 2: Missing anchor bolts at east side of S3, both sides S, S, S, west side of S8 and S10. Corrosion with minor to moderate material loss and pack rust on the sole and masonry plates. 90% corroded anchor bolts at the east side of S2 and west side of S3 and S8. Deflection and Vibration Minor pumping of deck noted over Pier 2 under heavy live load. (Timber shoring) Timber shoring previously installed under the diaphragms at Pier 2 between S3-S, S-S, S-S, and S8-S9. Timber blocks exhibit vertical cracks however shim plates are holding timber blocks together. Signs of water leakage through joint. FATIGUE DETAILS Category Estimated percentage of Large trucks in ADT = % Detail Description and Location /A -0

59 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) SUPERSTRUCTURE SPA # Cycle o.: SI&A Item 9 Condition Rating: 2 RATIG COMPOET Stringers Moderate corrosion with minor material loss below the end diaphragms on the web and the bottom flanges near Piers 2 and 2. Cracked concrete encasement at the bottom flanges of S1 and S10 at Piers 2 and 2 (8 SF total). (Stringers S1-S10 numbered west to east) Diaphragms / Cross Frames (umbered south to north) ote: Diaphragms at north end of span are for stringers in Spans 2 and 27. Pier 2: Severe corrosion of top and bottom flanges with moderate material loss between S8 and S9 and minor material loss and rust throughout on all other diaphragms. Pier 2: Moderate to severe rust with up to 1/1 material loss throughout. Bearings Pier 2: 11 ¼ x 10 ½ x 9 high solid steel bolsters. Moderate rust throughout the plates and anchor bolts. Anchor bolt nuts have up to 0% material loss throughout. Pier 2: Light to moderate rust with material loss (up to 1/8 ) to masonry plates. Heavy accumulation of construction debris covering bearings for S to S8. Deflection and Vibration Minor pumping of deck was noted at piers under heavy live load. FATIGUE DETAILS Category Estimated percentage of Large trucks in ADT = % Detail Description and Location /A -1

60 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) SUPERSTRUCTURE SPA # Cycle o.: SI&A Item 9 Condition Rating: 27 RATIG COMPOET Stringers (Stringers S1-S10 numbered west to east) Diaphragms / Cross Frames (umbered south to north) Bearings Deflection and Vibration Concrete encasement at the bottom flange of S1 and S10 is cracked at south end. Concrete encasement spall (1 x ) is at the bottom flange of S10, north end. Paint peeling at bottom flanges of all stringers at isolated locations. Moderate rust at both ends of all stringers below joints. Moderate corrosion on both flanges at north end diaphragms with up to 1/8 material losses in the web. orth end diaphragms are common for Spans 27 and 28. Light to moderate rust with paint peeling throughout both piers. Covered with construction debris at Pier 27. Minor pumping of concrete deck was noted at piers. FATIGUE DETAILS Category Estimated percentage of Large trucks in ADT = % Detail Description and Location /A -2

61 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) SUPERSTRUCTURE SPA # Cycle o.: SI&A Item 9 Condition Rating: 28 RATIG COMPOET Stringers S10, north end has a spall (2 x 9 ) in the bottom of the concrete encasement. S1, north end has a spall (1 SF) in the bottom of the concrete encasement. Moderate rust to stringer ends S2 to S9 at Piers 27 and 28. S7 and S8 exhibit 1/8 material remaining at end of web, beyond bearing area at Pier 28 (3 high x long) (Stringers S1-S10 numbered west to east) Diaphragms / Cross Frames (umbered south to north) Bearings Deflection and Vibration Peeling paint, rusting of top flanges throughout. Moderate rust to end diaphragms below joints. Light to moderate concrete debris accumulation on top of Pier 27. Pier 28 bearings exhibit moderate rust and the sole and masonry plates are partially covered with construction debris Minor deck pumping noted under live load. FATIGUE DETAILS Category Estimated percentage of Large trucks in ADT = % Detail Description and Location /A -3

62 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) SUPERSTRUCTURE SPA # Cycle o.: SI&A Item 9 Condition Rating: 29 RATIG COMPOET Stringers (Stringers S1-S10 numbered west to east) Diaphragms / Cross Frames (umbered south to north) Bearings Deflection and Vibration S10: At both ends, the bottom flange concrete encasement has wide cracks and delaminated concrete for approximately 2 ( SF total). Stringer ends at Pier 28: Stringers S2 through S9 exhibit severe rust with up to 2% localized loss on webs under diaphragm connections. S7: 1/8 diameter hole in web at Pier 28 with heavy material losses (up to ¼ remaining) with localized buckling of web under end diaphragm. (See Photo -27). S8: 1 ½ diameter hole at end of web and localized buckling of web under end diaphragm (See Photo -28). Stringer ends at Pier 29: The exposed flanges exhibit moderate rust. Pier 28: Moderate corrosion on entire member with up to 0% loss in localized areas of bottom flange. Between S7 and S8, the top and bottom flange has approximately 7% loss with knifed edges. Pier 29: Moderate to severe rusting of top and bottom flanges with minor losses. Diaphragm is common at Pier 29 for Spans 29 and 30. Severe rust at sole plate and masonry plate edges at Pier 28. Peeling paint with corrosion at S2, S3, S7 and S8. Moderate construction debris accumulation on Pier 28 at Bay 1 and Pier 29 at Bays 2 to 8. Minor pumping of deck noted at midspan and Pier 29. Construction debris partially covers bearings at S3, S and S7 at Pier 29. FATIGUE DETAILS Category Estimated percentage of Large trucks in ADT = % Detail Description and Location /A -

63 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) SUPERSTRUCTURE SPA # Cycle o.: SI&A Item 9 Condition Rating: 30 RATIG COMPOET Stringers Moderate rust at bearings with minor losses to web and top and bottom flanges. Light rust and peeling paint typical throughout. (Stringers S1-S10 numbered west to east) Diaphragms / Cross Frames (umbered south to north) Bearings At Pier 30 (common for Spans 30 and 31): Rust with minor material loss of the top and bottom flanges. Deflection and Vibration Deck between S3 and S8 exhibits minor pumping at Pier 29. Deck between S and S9 exhibits minor pumping at Pier 30. Light to moderate construction debris on pier seats. FATIGUE DETAILS Category Estimated percentage of Large trucks in ADT = % Detail Description and Location /A -

64 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) SUPERSTRUCTURE SPA # Cycle o.: SI&A Item 9 Condition Rating: 31 RATIG COMPOET Stringers (Stringers S1-S10 numbered west to east) Diaphragms / Cross Frames (umbered south to north) Bearings Deflection and Vibration S2 to S9: Moderate corrosion at the top flanges at Pier 30. Stringer ends at Pier 31 (from above the bearing to 18 inches from the stringer end): S1 and S10: Cracking of concrete encasement with moderate corrosion of web. S1, S2, S, S, S8 and S9: Severe rust and flaking with moderate material loss of web and minor material loss of the bottom flange. S3, S, S and S7: Severe rust with flaking and minor material loss to the bottom of web. Partially cover with construction debris. Moderate rust at the intermediate diaphragms. Severe rust with flaking and minor material loss; spall of the concrete encasement on the interior side at the north end diaphragms. Diaphragms in Bays, 7 and 8 are concrete encased. Severe rust of bearings with flaking and minor material loss at both piers. At Pier 31: Anchor bolts missing at east side of S2, both sides of S3 to S7, S8, and S9, and west side of S10. Anchor bolts severely corroded at S1 and S2. Some bearings are not visible due to construction debris. Minor pumping noted in deck at piers. Light to moderate concrete debris on top of pier caps. FATIGUE DETAILS Category Estimated percentage of Large trucks in ADT = % Detail Description and Location /A -

65 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) SUPERSTRUCTURE SPA # Cycle o.: SI&A Item 9 Condition Rating: 32 RATIG COMPOET Stringers (Stringers S1-S10 numbered west to east) Diaphragms / Cross Frames (umbered south to north) Bearings Deflection and Vibration End of stringers at Pier 31: S2 to S and S7 to S10: Severe rust and minor material loss to bottom of web. S2 to S: 3/1 material loss to web for high S and S: Steel repairs at stringer ends. Severe rust with moderate material loss of bottom and top flanges and flaking of web plate at the end diaphragms. Moderate rust throughout the intermediate diaphragms. Anchor bolt nuts have 2%-0% material loss throughout at Pier 31 except S and S. Bearing plates have severe rust with flaking and material loss. Moderate vibration with minor pumping of concrete deck under heavy live load. Timber shoring was placed under the end diaphragm at S3 at Pier 31 to support the stringer reactions. Light to moderate debris on top of pier caps. FATIGUE DETAILS Category Estimated percentage of Large trucks in ADT = % Detail Description and Location /A -7

66 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) SUPERSTRUCTURE SPA # Cycle o.: SI&A Item 9 Condition Rating: 33 RATIG COMPOET Stringers Moderate rust at all stringer ends with light rust and paint peeling throughout. (Stringers S1-S10 numbered west to east) Diaphragms / Cross Frames (umbered south to north) Bearings Minor rust at intermediate diaphragms and severe rust with efflorescence at the end diaphragms. Moderate rust throughout. Deflection and Vibration Minor pumping of concrete deck noted at piers. Moderate water leakage marks on Pier 33. Light to moderate construction debris on top of pier caps. FATIGUE DETAILS Category Estimated percentage of Large trucks in ADT = % Detail Description and Location /A -8

67 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) SUPERSTRUCTURE SPA # Cycle o.: SI&A Item 9 Condition Rating: 3 RATIG COMPOET Stringers (Stringers S1-S10 numbered west to east) Diaphragms / Cross Frames (umbered south to north) Bearings Deflection and Vibration FATIGUE DETAILS Category Stringer ends at Pier 3: S1 & 10: Moderate rust with cracks in the concrete encasement. S2, S3, S, S9, and S10: Severe rust 3/1 material loss x high to web. S: Similar to S2 with additional severe material loss behind end diaphragm and hole (2 x 1 ) in the web at mid-height at stringer end. S9: Hole (1 sq inch) in the web below the diaphragm. Steel repairs to stringer ends at S, S7 and S8. Severe rust with flaking and moderate material loss at the top and bottom flanges of the end diaphragms. At Pier 3: Severe rust with flaking throughout. All anchor nuts have 2% to 7% material loss, except for S, S7 and S8. Moderate pumping of deck noted at piers. Timber blocking at stringers S2, S3, S, S, and S9. Light to moderate debris accumulation on top of pier cap. There are no superstructure forms for Spans 3-7 since structure is a concrete slab (See Underside of Deck for Spans 3-7). Estimated percentage of Large trucks in ADT = % Detail Description and Location /A -9

68 Structure o.: ame: J 7 J Route 7 over Conrail (ewark Branch) PAIT ISPECTIO 8. *Environment: 3A Date of Last Painting: 1. Rural or Industrial, Mild exposure 2. Industrial, Severe Exposure 3A. Marine, Mild Exposure 3B. Marine, Severe Exposure *Ref. JDOT Design Manual Sec Cycle o.: Unknown 7... ote: Blistered Paint areas are counted as rust % 0.1% 0.3% 10 = 0% Rust 0 = 100% Rust ote: Use the closest rating to the actual field condition based on the average for the bridge. Indicate any areas of severe rusting in remarks. 1% 3% 10% % 33% 0% FIG. 1 Examples of Area Percentages ISPECTIO RATIGS (0 THROUGH 10 OR /A) Fascia Beam: Interior Beam: Bracing: Bearings: /A 1 1 Fascia Bottom Flange: Interior Bottom Flange: /A Substructure: /A Above Deck Superstructure Remarks 1: Remarks 2: -70 Beams Ends: Connections: 1 3 Railings/Fence: /A /A