STRUCTURES SPECIFICATIONS FOR BRIDGE CONSTRUCTION ISSUES John Westphal, P.E. State Construction Office January 2017
Introduction Discuss Defective Materials, as defined within the Specifications Recent changes related to Defective Materials in Section 6 Engineering Analysis Report (EAR) 2
Think about it How to deal with defects? The reality is they occur Defective Materials must be either Repaired or Removed and Replaced Ultimately, Public Safety most important! 3
EAR Specs 6 CONTROL OF MATERIALS 6-4 Defective Materials Materials not meeting Specification requirements considered Defective Alternative to rejection, Engineering Analysis Initiate within 30 days of rejection 4
EAR Specs 6 CONTROL OF MATERIALS 6-4.1 Engineering Analysis Two-part approach Engineering Analysis Scope Signed & Sealed Engineering Analysis Report (EAR) Respective engineer designation given in affected Specification Sections to perform EAR 5
Pop Quiz Who is designated in the Specs to do repair work? a. The Engineer of Record b. The Specialty Engineer c. The Contractor s Engineer of Record d. Both b and c e. None of the above The Contractor s Engineer of Record and the Specialty Engineer are designations given in the Specifications that grant authority to perform respective categories of work. 6
EAR Specs 6 CONTROL OF MATERIALS Engineering Analysis Scope must contain at a minimum: 1. Description of defective materials 2. Supporting info, testing, photos, drawings, and crack maps 3. Proposed approach of investigation and analysis 4. Specialty Engineer or Contractor s Engineer of Record 5. Testing labs 7
EAR Specs 6 CONTROL OF MATERIALS EAR must be Signed & Sealed and contain at a minimum: 1. Approved Engineering Analysis Scope 2. Investigations and results 3. Analysis and conclusion 4. Performance and durability of proposed repair Provide as appropriate: 1. Previously approved repair of similar deficiency 2. Research showing effectiveness of proposed repair 3. Engineering calculations 8
Engineering analysis who can do what? 9
Construction Specifications Covered by 6-4 Defective Materials Provisions 10
346 PORTLAND CEMENT CONCRETE 346-3.2 Drilled Shaft Concrete Maintain a minimum 5 inch slump throughout elapsed time Elapsed time exceeding slump loss data EAR by Specialty Engineer to address structural adequacy and voids 346-3.3 Mass Concrete Concrete not in compliance with Mass Concrete Control Plan 35 F differential or 180 F max temperature exceeded EAR by Specialty Engineer to address strength and durability 11
346 PORTLAND CEMENT CONCRETE 346-4.2 Chloride Content Limits for Concrete Construction Chloride test results exceed allowable, per Table 4 EAR by Specialty Engineer to address service life of the concrete and address corrosion 346-10.2 Investigation and Determination of Structural Adequacy Concrete greater than 500 psi below minimum strength EAR required with full structural analysis that addresses strength and durability of the concrete 12
400 CONCRETE STRUCTURES 400-21 Disposition of Cracked Concrete Engineer documents cracking Width, length and location documented on crack maps" Cracks monitored for growth throughout construction Engineer classifies cracks as either: nonstructural or structural 13
400 CONCRETE STRUCTURES 400-21.5.1 Nonstructural Cracks, Tables 1 & 2 Disposition of Cracked Concrete: Crack significance Average crack width Environmental classification Elevation relative to Mean High Water (MHW) 14
400 CONCRETE STRUCTURES 400-21.5.1 Nonstructural Cracks, Tables 1 & 2 Repair Methods for treating cracks Treatment not always required Per the Tables either: Repair by EI, M or PS Investigate to Determine Appropriate Repair or Rejection Reject and Replace 15
400 CONCRETE STRUCTURES 400-21.5.2 Structural Cracks EAR required for structural cracks to determine strength and durability Cracks extending deeper than ½ considered structural as are cracks fully or partially underwater 16
450 PRECAST PRESTRESSED CONCRETE CONSTRUCTION 450-12 Noncomplying Prestressed Products Defects defined within Spalls, Chips, Honeycombing and Cracks Minor vs. Major categorization Minor defects and their repair described in the Specification 17
450 PRECAST PRESTRESSED CONCRETE CONSTRUCTION 450-14 Submittal of Proposal to Accept or Repair Deficiencies Major Defects handled through similar process to that of an EAR Non-complying Prestressed/Precast Concrete Component Data Sheet 18
450 PRECAST PRESTRESSED CONCRETE CONSTRUCTION Repair proposal by Contractor s Engineer of Record: 1. Cover Letter 2. Description and proposed repairs 3. Structural and durability evaluation: a. Previous repair use b. Research c. Calculations 4. Proposed credit proportionate to deficiency 5. Documentation and Signed & Sealed evaluation 19
455 STRUCTURES FOUNDATIONS (B. PILING) 455-5.16.5 Deviation From Above Tolerances Tolerances are exceeded: Position Axial Alignment Elevation Redesign by Contractor s Engineer of Record Signed & Sealed drawings and computations 20
455 STRUCTURES FOUNDATIONS (C. DRILLED SHAFTS) 455-21 Drilled Shaft Excavations Constructed out of Tolerance Tolerances not met, per 455-20: Position Axial Alignment Vertical position Concentricity of cage and shaft Redesign by Contractor s Engineer of Record Signed & Sealed drawings and computations 21
455 STRUCTURES FOUNDATIONS (E. STRUCTURES (OTHER THAN BRIDGE) FOUNDATIONS-AUGER CAST PILES) 455-43 Testing Cement Grout Cement grout acceptance strength greater than 500 psi below minimum strength Structural analysis by Contractor s Engineer of Record Strength and durability must be adequate to remain in place 22
460 STRUCTURAL STEEL AND MISCELLANEOUS METALS 460-4.6 Evaluation of Work Corrective procedures in Producer s Department-approved QC Plan Notify Engineer of Nonconforming work beyond scope of QC Plan Nonconforming Steel and Miscellaneous Metal Component Data Sheet (NCR) Cover letter along with supporting documentation submitted with NCR 23
460 STRUCTURAL STEEL AND MISCELLANEOUS METALS Specialty Engineer Signs & Seals supporting information for the NCR: Sketches Documentation Calculations Pictures Signed & Sealed structural and durability evaluation may be required by a Specialty Engineer 24
Questions? 25