Difference between revisions of "Division 7 Supplemental Information"

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==BRIDGE CONSTRUCTION AND BRIDGE DECK CONSTRUCTION INSPECTION AND DOCUMENTATION==
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==[[Division_7_Supplemental_-_Bridge_and_Bridge_Deck_Construction_Inspection_%26_Documentation|Division 7 Supplemental - Bridge and Bridge Deck Construction Inspection & Documentation]]==
  
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This document clarifies the procedures for bridge construction and bridge deck construction inspection.  It also provides requirements for sampling and testing of bridge concrete, documenting bridge steel reinforcement, wet and dry bridge deck concrete depth measurements, and required documentation for bridge construction inspection.  This document must be coordinated with the Standard Specifications for Construction, Divisions 6 and 7 of the Construction Manual, Special Provision 12SP604B QUALITY CONTROL AND ACCEPTANCE OF PORTLAND CEMENT CONCRETE and the Materials Quality Assurance Procedures Manual.
 
  
 
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===Documentation for Bridge Construction and Bridge Deck Construction Inspection===
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==[https://mdotwiki.state.mi.us/construction/index.php?title=Division_7_Supplemental_-_Hydrodemolition_and_Bridge_Deck_Overlay_Construction_Inspection Division 7 Supplemental - Hydrodemolition and Bridge Deck Overlay Construction Inspection]==
  
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The project engineer (hereinafter referred to as Engineer) is responsible for performing all testing, inspection, and recording on the forms listed below.  See Section 706 of the Standard Specifications for Construction and the contract documents for the Contractor’s responsibilities.
 
  
 
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====Form 1138, Bridge Reinforcing Computations====
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==[https://mdotwiki.state.mi.us/construction/index.php?title=Earth_Retaining_Structures Division 7 Supplemental - Earth Retaining Structures]==
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The Engineer must complete Form [http://mdotjboss.state.mi.us/webforms/GetDocument.htm?fileName=1138.pdf 1138], Bridge Reinforcing Computations, for all structural pours prior to the commencement of the pour.  The Engineer must verify and record bar type, size, number, length, calculate total length, weight per foot, calculate total weight, and add remarks identifying the location of the steel (top mat, bottom mat, transverse, longitudinal, vertical, barrier, etc.).
 
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====Form 1131, Bridge Decks Concrete Depth Measurements (required for bridge decks)====
 
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The Engineer must complete Form [http://mdotjboss.state.mi.us/webforms/GetDocument.htm?fileName=1131.pdf 1131], Bridge Decks Concrete Depth Measurements, for all bridge deck pours.  See Division 706 of the Construction Manual for a sample form and instructions.  Concrete finishing equipment is calibrated by conducting dry runs prior to the pour.  Wet depth checks are taken during the pour to verify the thicknesses as measured during the dry runs.  Wet depth checks are documented on Form 1131.  Note the locations of dry run measurements (ribbon or paint at longitudinal locations) and measure wet depths during the pour at or near the same locations.
 
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====Form 1125, Permit to Place====
 
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The Engineer must complete Form [http://mdotjboss.state.mi.us/webforms/GetDocument.htm?fileName=1125.pdf 1125], Permit to Place, for all substructure and superstructure concrete pours, including bridge barrier railings.  Issue permit to place only after approval of forms, bracing, and temporary works (if required), reinforcing steel layouts, and preparations for casting concrete, which may also include low temperature or cold weather protection requirements.  This includes removing debris from the forms, cleaning forms, and cleaning steel reinforcement, and ensuring all expansion joint bulkheads are properly installed to the correct elevations.  The Contractor must also have prepared a minimum 12-hour soak on the burlap for the bridge deck wet cure (the burlap should be hung out to drain off excess water prior to installation onto fresh concrete deck surface), have appropriate weather monitoring equipment to determine relative humidity and wind speed to verify acceptable evaporation rate prior to pours, have vibrators with rubber coated heads, and a 10-foot straight edge for checking bridge deck trueness (1/8 inch or less deviations per 10 feet).  Ensure that the Contractor has the proper number of curing facilities on site and are properly outfitted to cure the QA test cylinders according to specification requirements.  The curing facilities must be capable of being locked using a Department padlock to ensure that the Engineer maintains sole custody of the QA test cylinders during the initial curing period.
 
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====Form 1174S, Inspector’s Report of Concrete Placed-Structure====
 
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The Engineer must complete Form [http://mdotjboss.state.mi.us/webforms/GetDocument.htm?fileName=1174S.pdf 1174S], Inspector’s Report of Concrete Placed, for all structural concrete pours.  See Division 6 of the Construction Manual for instructions.  Use Contractor-supplied weather equipment to determine and record the evaporation rate for bridge deck pours.  Figure 706-1 of the Standard Specifications for Construction must be used to determine evaporation rate.  The evaporation rate must not exceed 0.20 psf/hour.  Verify and record all concrete test results, cylinder identifications aggregate correction factors supplied from the concrete supplier, quantity of curing compound used, and structural concrete quantities shipped, placed, and overrun/underrun on the form.
 
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====Inspector’s Daily Report (IDR)====
 
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The Engineer must complete IDR’s for all bridge work.  The Engineer must record and verify permanent metal deck form information.  The Engineer must record, verify reinforcement storage, and verify repair to epoxy-coated reinforcement.  The Engineer must also verify the Contractor has validated acceptable evaporation rates with the appropriate weather monitoring equipment.
 
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====MDOT Bridge Deck Construction Inspection Checklist====
 
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This checklist is an aid for documentation and inspection of bridge deck construction.  The checklist identifies important items for testing and inspections, including items to observe during the bridge deck pour operations.  The Engineer must complete the MDOT Bridge Deck Construction Inspection Checklist for each bridge decks constructed on the project which can be found [https://mdotwiki.state.mi.us/construction/index.php/File:Deck_inspection.pdf here]
 
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===Random Number===
 
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The quality index analysis for pay factor determination using Percent-Within-Limits (PWL) does not apply to structural concrete.  The requirements for sampling, testing, and pay factor analysis for structural concrete are according to non-PWL application protocol. Random number sampling method is recommended for larger concrete pours where several loads of concrete will be received, but may not be practical for smaller applications.  For small concrete pours, the Engineer should use judgment when selecting the precise location within the load of concrete to take the QA sample.  However, keep in mind that the sample should be taken from the middle-third of the load.  For larger concrete pours, the following is the required procedure to be used to ensure the random sampling process is uniform, properly documented, and reproducible.  See the Materials Quality Assurance Procedures Manual for more information.
 
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#Prior to the pre-pour meeting, generate random numbers using a computer spreadsheet program or a calculator.  The random numbers will be used for the cubic yardage to determine samples based on the size of the pour.  Generate an excess amount of random numbers to take into account overruns or any situation where another random number is required.
 
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#At the pre-pour meeting, present each page that lists random numbers (cover the numbers with a separate sheet of paper) for signature of the Contractor and Engineer.
 
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#Place the original list in the project file; copies are provided to inspectors for field use.
 
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#Provide the list of random numbers to the contractor when the project is completed, if requested.
 
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#If the concrete is being discharged directly into the forms from the ready mix truck (or by another means other than a pump), a small adjustment in the randomly determined location from where the sample is to be taken may be necessary to ensure the sample is taken from the middle-third of the load of concrete.
 
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===Bridge Construction and Bridge Deck Construction Inspection===
 
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====Permanent Metal Deck Forms====
 
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The Engineer must record and verify the source of the permanent metal deck forms.  The Engineer will verify the Contractor is installing the forms as shown in the approved shop plan drawings.  The approved shop drawings must be retained in the project file.  The Engineer must also verify the Contractor has field drilled ¼ inch diameter weep holes in the forms at 12 inch maximum spacing along the transverse and longitudinal construction joints.  See Section 707 of the Standard Specifications of Construction regarding field welding and welder certifications for connection of forms to bridge beams.  Ensure Styrofoam used in corrugations is secure and will not be displaced by the concrete during placement.  All debris such as nails, dirt, and other trash must be removed from forms prior to placing the Styrofoam and commencing with the deck pour.
 
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Prior to installation of the permanent metal deck forms, ensure the top flange tops and sides are properly cleaned and coated.
 
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====Shear Developers====
 
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See Division 707 of the Construction Manual and Section 707 of Standard Specifications for Construction for installing and testing procedures for shear developers.  Ensure the shear developers are installed in the appropriate orientation given the skew of the bridge.  A list of the approved shear developers is included on the Qualified Products List in section 906.09.
 
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====Epoxy Coated Steel Reinforcement====
 
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Ensure the Contractor is storing the epoxy coated steel reinforcement per the Standard Specifications for Construction, and covering the reinforcement to protect it from ultraviolet rays.  The Engineer must also verify the Contractor’s repair of epoxy coating using a patching/repair material selected from Section 905.03.C, Bar Reinforcement (Epoxy Coating) of the Qualified Products List. 
 
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Pay special attention to those areas near drain castings or joint devices where reinforcement may have been cut.  Exposed steel on bar ends must be repaired.  Note the repair product on IDR.  Complete Form 1138, Bridge Reinforcing Computations. 
 
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Ensure reinforcement is placed as shown on the plans and provides clear cover according to the plans and specifications.  Ensure all reinforcement intersections are tied according to Section 706.03.E.  Verify the Contractor is placing bar chairs as required in the Standard Specifications for Construction to ensure longitudinal and transverse reinforcement is placed at the correct dimensions within the bridge deck per the contract plans.
 
  
 
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====Bridge Deck Pour Sequence====
 
  
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The Engineer must verify the Contractor is following the pour sequence as shown on the contract plans.  Any changes to the sequence must be approved and documented by MDOT Bridge Design, Bridge Field Services, or the MDOT designer, and placed in the project files.  See Section 706.03.P of the Standard Specifications for Construction for requirements and restrictions for removal of vertical forms, including bulkheads at construction joints.  The minimum cure time for the concrete prior to removal of the forms is 15 hours.
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[[Category: Construction Manual]]
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[[Category: Division 7]]
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[[Category: Division 7 Supplemental]]
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====Bridge Deck Pour Sequence====
 
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The Engineer must verify the Contractor is following the pour sequence as shown on the contract plans.  Any changes to the sequence must be approved and documented by MDOT Bridge Design, Bridge Field Services, or the MDOT designer, and placed in the project files.  See Section 706.03.P of the Standard Specifications for Construction for requirements and restrictions for removal of vertical forms, including bulkheads at construction joints.  The minimum cure time for the concrete prior to removal of the forms is 15 hours.
 
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====Bridge Deck Haunches====
 
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During the screed dry run, the Engineer must verify that the haunch depth and the shear developers (studs) protrude from the top of the beams a minimum 2 inches into the bottom side of the deck slab prior to the deck pour; this will ensure composite action of the beams and deck.  Occasionally the haunches will become excessive in height to match existing approach conditions.  In this case, the shear developers must be lengthened (up to a maximum length of 8 inches) to ensure the 2 inch minimum deck slab embedment is achieved.  If the haunch grades become excessive and the 8 inch maximum will no longer provide the required embedment, contact MDOT Bridge Design, Bridge Field Services, or the MDOT designer for guidance.  Additional reinforcement will be required and additional forming materials may be necessary at these locations.
 
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For deck replacements on concrete beams, the 2 inch minimum deck embedment, described above, also applies to the steel shear developers (slab ties) cast into the top flanges.  If the haunch depth on concrete beams becomes excessive, or does not provide the 2 inch embedment into the deck concrete, is not addressed in the design; contact MDOT Bridge Design, Bridge Field Services, or the MDOT designer.  Additional reinforcement will be required and additional forming materials may be necessary at these locations. 
 
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====Changing Night Casting of Bridge Decks====
 
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There are circumstances when the required night casting of a bridge deck may be considered for change to a day pour.  Such circumstances occur primarily when the maximum daytime temperature does not exceed 60 degrees (F) and/or the nighttime temperatures are below 40 degrees (F).  Consult Bridge Field Services prior to engaging in any proposal by the Contractor to change from night casting to day placement.  The Engineer must document the change in the project files.  The following requirements must be followed:
 
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#The concrete mix design generally does not incorporate a set retarding admixture, however, circumstances such as long distances from the readi-mix facility, or large pours may require their use.  Consult Bridge Field Services for assistance in these situations.
 
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#Cold weather precautions are applied, as appropriate.
 
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#MDOT is credited for all cost savings from the appropriate pay items associated with  the deletion for any portion of the night casting:
 
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::*An adjustment to the cubic yard price for the item of “Superstructure Concrete, Night Casting” which was cast during the day (usually a reduction of two dollars per cubic yard.  Consult Bridge Field Services for assistance).
 
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::*Adjust the quantity for cubic yard for the item, “Bridge Ltg, Oper and Maintain,” to that which was actually night cast.
 
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::*Delete the Lump Sum item, “Bridge Ltg, Furn and Rem (Structure No.)” (Delete only if all pours were cast during the day).
 
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::*No adjustment for “Superstructure Concrete, Form, Finish, Cure, Night Casting” is required.
 
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====Concrete Quality Control (QC) and Quality Assurance (QA)====
 
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The Contractor is responsible for QC startup testing and all quality (process) control testing and inspection of the concrete and associated operations.  MDOT is responsible for administering quality assurance (acceptance) of the concrete.  The Contractor and MDOT must correlate field testing of the fresh concrete by conducting side by side temperature and air content testing of the same sampling of concrete representing the first production startup load to verify test results for temperature and air content of the concrete.  For larger concrete pours, it is suggested to also conduct additional side by side correlation tests throughout the production day.  This will ensure that both the Contractor and Engineer’s testing equipment and personnel are in continual correlation. These side by side correlation tests, however, must “in no way” be associated with the normal QA sampling and testing process.  In other words, The Contractor cannot dispute the Engineer’s QA test results by conducting side by side QC tests during normal QA testing; correlation must be conducted independently.  In the event the QC and QA air content tests do not correlate within 0.8 percent by volume of concrete, a third party tester, designated by the Engineer and not directly associated with the project should be brought in to evaluate the dispute in test results.
 
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To verify that excessive air loss is not occurring prior to placing the concrete into the forms, the Contractor must sample and test a representative haul unit of concrete immediately after its discharge from the truck but before the pump hopper.  The contractor must then sample the same load of concrete again after the pump hopper.  If the difference in air content between the two samples is greater than 2.0 percent by volume of concrete, the Contractor must suspend operations and administer corrective action to determine the cause of the excessive air loss through the pump and, thus, make the necessary adjustments to their operations in efforts to reduce the excessive air loss to less than 2.0 percent prior to resuming concrete placement.
 
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The Engineer will also conduct daily QA startup sampling and testing of temperature, slump and air content; QA sampling and testing; monitoring the Contractor’s adherence to the QC plan; and inspection of field placed materials.  QA samples must be taken from the concrete as close to its final placement as practical (after the pump).  A production lot may consist of an individual structural component (footing, column, cap, approach slab, barrier rail, etc…), a single day’s production, or any combination thereof, as determined by the Engineer.  The frequency of QA sampling would then be based on the total volume of concrete included in the production lot. In general, a reasonable volume of concrete representing each test (sublot size) could be approximately 50 cubic yards.  Random numbers could then be used to determine the location for the test within the sublot.  However, keep in mind that the QA sample must be attained within the middle-third of the truckload of concrete.  For smaller concrete pours, the minimum sampling rate must be once per day.
 
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All concrete QC and QA must be in accordance with the requirements for non-PWL applications as described in the Special Provision for QUALITY CONTROL AND ACCEPTANCE OF PORTLAND CEMENT CONCRETE (12SP604B).
 
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====Placing Bridge Deck Concrete====
 
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Verify the concrete is falling less than 6 inches from the discharge chute to the uppermost steel reinforcement for bridge deck pours and that the contractor has mobilized sufficient manpower and equipment to consolidate concrete around reinforcement.  Ensure the Contractor maintains sufficient head of concrete in front of the finishing machine.  When nearing bulkheads or expansion joints, the excess concrete that spills over the form must be collected and disposed of prior to the next pour in sequence. 
 
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====Finishing Bridge Deck Concrete====
 
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Ensure the Contractor verifies the bridge deck trueness with a 10-foot straight edge while the concrete is still plastic.  The Engineer will check the finished deck with a 10-foot straight edge and areas not within 1/8 inch in 10 feet will be corrected while the concrete is plastic, prior to placement of cure materials.  Deviations exceeding a 1/8 inch in any 10-foot length will be considered defective and may require corrective action.
 
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====Texturing and Curing Bridge Decks====
 
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Ensure the Contractor textures the deck as soon as the concrete has set sufficiently to maintain the texture per Section 706.03.M.3 of the Standard Specifications for Construction.  In colder temperatures, the concrete may not be sufficiently set up to texture and cover with wet burlap within the two hour time limit as directed in Section 706.03.M.3.  For such instances, it is prudent to allow additional time for deck cure prior to texturing and placement of wet burlap.  Contact Bridge Field Services in these situations.  Section 104.01.A of the Standard Specifications for Construction gives the engineer authority in regards to quality and acceptability of the work performed and manner of performance in this scenario.  The Engineer must also ensure the Contractor applies a curing compound at a rate not less than one gallon per 150 square feet of surface, immediately after the sheen of bleed water has left the textured concrete surface.  Ensure the Contractor wet cures the bridge deck per Section 706.03.N.1.B of the Standard Specifications for Construction. 
 
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The Engineer must ensure the Contractor has soaked the burlap a minimum of 12 hours prior to beginning the deck pour, that the burlap is placed (excess water removed from the burlap prior to installation) as soon as the curing compound has dried sufficiently to prevent adhesion, and that the concrete will support it without deformation, but not more than two hours after the deck was cast under normal temperature conditions.  Do not use products such as Burlene, which combine the burlap and vapor barrier, solely for the wet curing.  These products used alone result in the soaker hoses being in direct contact with the fresh concrete.  The hoses must rest on the burlap which is then covered by the appropriate vapor barrier.  The Engineer must ensure the Contractor provides a network of soaker hoses and a system that capable of applying cure water uniformly and continuously for at least the entire seven day wet cure period, and that the entire deck surface is covered with a minimum 4 mil polyethylene film.  The continuous wet cure must be maintained at all times throughout the entire 7-day wet curing period.
 
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====Concrete Delivery Tickets====
 
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The Engineer must collect, verify the mixture proportions (JMF) and record discharge time, and sign each concrete delivery ticket prior to discharge.
 
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====Cold Weather Protection====
 
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Ensure the Contractor follows cold weather precautions in accordance with Section 706.03.J of the Standard Specifications for Construction and note if a pay item is included for this in the plans.  There may also be a monitoring requirement via special provision to assess the effectiveness of low temperature protection measures.  If the National Weather Service forecasts temperatures below 40 degrees (F) during the curing period, preparations for low temperature protection, such as insulated blankets, must be made.  If the National Weather Service forecasts temperatures below 20degrees (F) during the curing period, the Contractor must provide materials and equipment forms and concrete..
 
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Ensure the Contractor does not place superstructure concrete when temperatures are below 40 degrees (F), unless forms, metal surfaces, and adjacent concrete surfaces are preheated to above 40 degrees (F).  However, do not allow placement if the air temperature is below 35 degrees (F).
 
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If temperatures are projected to fall below 40 degrees (F) for eight or more hours after initial placement, ensure the Contractor protects the top of the freshly cast concrete as soon as possible.
 
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Ensure the Contractor maintains a minimum concrete temperature of at least 40 degrees (F) during the curing period.
 
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If temperatures fall below 15 degrees (F) during any time in the curing period, ensure the Contractor circulates heated air in accordance with subsection 706.03.J.2.b of the Standard Specifications for Construction.
 
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====Notification====
 
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Notify Corey Rogers at 517-930-2768 or Scott Hobner at 517-202-4046 of Bridge Field Services one week prior to the commencement of the bridge deck pours
 
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==HYDRODEMOLITION AND BRIDGE DECK OVERLAY CONSTRUCTION INSPECTION==
 
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This document clarifies the procedures for hydrodemolition and bridge deck overlay construction inspection.  It also provides requirements for sampling and testing of bridge deck overlay concrete, documenting bridge steel reinforcement, and documentation for bridge deck overlay construction inspection.  This document must be coordinated with the ''2003 Standard Specifications for Construction'', Divisions 6 and 7 of the ''Construction Manual'', and the ''Materials Quality Assurance Procedures Manual''.
 
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===Documentation for Hydrodemolition Inspection===
 
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The contractor shall submit a hydrodemolition pH control plan for review and acceptance prior to beginning any hydrodemolition work according to the Special Provision for Managing Hydrodemolition Runoff Water, as listed in the proposal.  Attached is an “MDOT Hydrodemolition Projects pH Control Plan Checklist” and a “Sample Hydrodemolition Control Plan” for additional guidance.  The Groundwater Discharge General Permit, 2215-05-7 is available on the Michigan Department of Environmental Quality’s Web site at
 
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Calibrate the hydrodemolition equipment as listed in Section 712 of the Construction Manual. Record the settings (water pressure, cutting head speed, and forward advancement) on the Inspector’s Daily Report, Form [http://mdotjboss.state.mi.us/webforms/GetDocument.htm?fileName=1122B.pdf 1122B].
 
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Ensure the contractor is completing the hydrodemolition log per the special provision. You can locate the pH control plan checklist and the Sample Hydro Control plan [https://mdotwiki.state.mi.us/construction/images/5/5c/Bridge_over.pdf here].
 
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===Documentation for Bridge Deck Overlay Construction Inspection===
 
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The resident/project/delivery engineer (hereinafter referred to as “engineer”) is responsible for performing all testing, inspection, and recording on the forms listed below.  See Sections 706 and 712 of the ''2003 Standard Specifications for Construction'' and the contract documents for the contractor’s responsibilities.
 
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====Form 1138, Bridge Reinforcing Computations====
 
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Complete Form [http://mdotjboss.state.mi.us/webforms/GetDocument.htm?fileName=1138.pdf 1138], Bridge Reinforcing Computations, for all concrete overlay pours prior to the commencement of the pour.  Verify and record bar type, size, number, length, total length, weight per foot, total weight and add any remarks with regards to location (top mat, bottom mat, transverse, longitudinal, vertical, barrier, etc.).
 
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====Form 1125, Permit to Place====
 
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Complete Form [http://mdotjboss.state.mi.us/webforms/GetDocument.htm?fileName=1125.pdf 1125], Permit to Place, for all bridge deck concrete overlays.  See the revised form. Mark “Conc, Bridge Deck Overlay” and select the concrete overlay mixture.  Record the “Structure Number” and “Structure Location” concrete overlay material and any construction stages on the form.  Issue permit to place only after approval of forms, reinforcing steel, and preparations for casting overlay concrete.  This includes removing debris from the deck and forms, cleaning forms and steel reinforcement.  The contractor must be able to provide a minimum 12-hour burlap soak for wet cure for bridge decks, have appropriate weather equipment to determine relative humidity temperature and wind speed for the determination of the evaporation rate, provide vibrators with rubber coated heads, provide ten foot straightedge for checking bridge deck trueness, and provide fogging equipment for the silica fume overlay.
 
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====Form 1131, Bridge Decks Concrete Depth Measurements====
 
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Complete Form [http://mdotjboss.state.mi.us/webforms/GetDocument.htm?fileName=1131.pdf 1131], Bridge Decks Concrete Depth Measurements for all bridge deck overlay pours.  See Division 706 of the Construction Manual for a sample form and instructions.  Verify and record the dry and wet run depth checks.  Note the locations of the dry run measurements, and measure the wet run at or near the same locations.  Measurement of the depth to the top mat of steel is not required for shallow overlays.
 
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====Form 1174A, Inspector’s Report of Concrete Placed====
 
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Complete Form 1174A, Inspector’s Report of Concrete Placed, for all bridge deck overlay concrete pours.  See Division 6 of the ''Construction Manual'' for instructions.  Note the form has been revised to include “Aggregate Correction Factor” and “Evaporation Rate” under “Structure Items Placed.”  Use contractor-supplied weather equipment to determine and record the evaporation rate for bridge deck overlay pours if it is less than 0.15 psf per hour per Figure 706-1 of the ''2003 Standard Specifications for Construction''.  Verify and record all concrete test results, tags, aggregate correction factor supplied from the concrete supplier, and overlay concrete quantities on the form.
 
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====Form 1122B, Inspector’s Daily Report====
 
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Complete Form [http://mdotjboss.state.mi.us/webforms/GetDocument.htm?fileName=1122B.pdf 1122B], Inspector’s Daily Report, for all bridge work.  See the Construction Manual for instructions.  The engineer must also verify that the contractor provided weather equipment to determine the evaporation rate.  Verify the slope and elevation of the expansion joint.  Note any placement delays, inclement weather during the pour or any other factors that may have an adverse affect on the overall quality of the pour.  Record hydrodemolition settings (water pressure, cutting head speed, and forward advancement).
 
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====MDOT Bridge Deck Overlay Construction Inspection Checklist (attached)====
 
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This checklist is an aid for documenting the inspection of bridge deck overlay construction.  The checklist identifies important documentation items for testing and inspection, and items to observe during the bridge deck overlay operations.  Complete the MDOT Bridge Deck Overlay Construction Inspection Checklist for all bridge deck concrete overlays.  You can find the checklist [https://mdotwiki.state.mi.us/construction/images/2/27/PH.pdf here].
 
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===Bridge Deck Overlay Construction Inspection===
 
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====Epoxy Coated Steel Reinforcement====
 
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Ensure the contractor is storing and covering the epoxy-coated steel reinforcement per the ''2003 Standard Specifications for Construction'' to protect it from the sun’s ultraviolet rays.  The engineer shall verify the contractor’s repair of epoxy coating using a patching/repair material selected from Section 905.03.C, Bar Reinforcement (Epoxy Coating) of the Qualified Products List.  Note the repair product on Form 1122B, Inspector’s Daily Report and complete Form 1138, Bridge Reinforcing Computations.  Ensure reinforcement is placed as shown on the plans and provide clear cover according to the plans and specifications.  Verify the contractor is placing bar chairs as required in the ''2003 Standard Specifications for Construction''.
 
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====Concrete Testing====
 
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Ensure the contractor is performing concrete yield tests as part of the contractor’s concrete quality control.  Subtract the aggregate correction factor from the field air content test results.  Perform sampling of the concrete according to Michigan Test Method 207 at the pump discharge for silica fume modified concrete unless it is correlated to the concrete delivery truck.  Note the correlation on Form 1122B, Inspector’s Daily Report.
 
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====Placing Bridge Deck Overlay Concrete====
 
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Verify that the silica fume modified concrete is falling less than 6 inches from the discharge chute to the uppermost steel reinforcement or existing bridge deck surface.  For latex-modified concrete, the fall height of the mix is dependent on the air content and will vary.
 
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====Texturing and Curing Bridge Deck Overlays====
 
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Ensure that the contractor textures the deck as soon as the concrete has set sufficiently to maintain the texture, per the ''2003 Standard Specifications for Construction''.  For silica fume modified concrete, ensure that the contractor applies a continuous fog to the screeded concrete.  The engineer shall ensure the contractor wet cures the bridge deck per the ''2003 Standard Specifications for Construction''.  Ensure that the contractor has soaked the burlap a minimum of 12 hours prior to beginning the deck pour, and the burlap is placed after the excess water is removed and as soon as the concrete will support it without deformation.  Do not use Burlene directly on the bridge deck overlay concrete.  Ensure that the contractor provides a network of soaker hoses and a system to apply cure water uniformly and continuously for at least 7 days for silica fume concrete and 2 days for latex modified concrete, and that the entire deck surface is covered with a minimum 4 mil polyethylene film.
 
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Do not apply curing compound to latex-modified concrete or silica fume-modified concrete.
 
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====Concrete Delivery Tickets====
 
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Verify and record discharge time on the tickets and sign all of the concrete delivery tickets.  Include any testing results (air, temperature, and slump) on the ticket.
 
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For mobile mixer latex trucks, review the mix calibration and note the meter count on Form 1122B, Inspector’s Daily Report.
 
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====Concrete Trucks and Heavy Equipment====
 
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For deep overlays, do not allow concrete trucks and other heavy equipment (including vacuum trucks) to drive across the thinned bridge deck section and the exposed steel reinforcement.  This prevents damage to the steel reinforcement and the remaining bridge deck concrete.
 
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====Notification====
 
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Notify Eric Burns (517-322-6331) or Scott Hobner (517-322-5120) of the Construction and Technology Division’s Bridge Operations Section, and Elias David (517-322-1222) of the Construction and Technology Division’s Materials Section, one week prior to the commencement of the bridge deck concrete overlays.
 
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[[Category:Construction Manual]]
 

Latest revision as of 16:47, 18 August 2026

Division 7 Supplemental Information


Division 7 Supplemental - Bridge and Bridge Deck Construction Inspection & Documentation

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Division 7 Supplemental - Hydrodemolition and Bridge Deck Overlay Construction Inspection

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Division 7 Supplemental - Earth Retaining Structures

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