Blue Book Item 400

PART F – BRIDGE CONSTRUCTION
ITEM 400 – PILING
400.1 Description
400.1.1 Scope
This Item shall consist of piling, furnished, driven or placed, cut and spliced
in accordance with this Specification and in reasonably close conformity with the
Plans.
The Contractor shall furnish the piles in accordance with an itemized list,
which will be provided by the Engineer, showing the number and lengths of all piles.
When cast-in-place concrete piles are specified on the Plans, the Engineer will not
furnish the Contractor an itemized list showing the number and length of piles.
When test piles and load tests are required in conformance with Sub-section
400.1.2 and 400.1.3, respectively, the data obtained from driving test piles and
making test loads will be used in conjunction with other available sub-soil
information to determine the number and lengths of piles to be furnished. The
Engineer will not prepare the itemized list of piles for any portion of the foundation
area until all specified loading tests in the Contract representative of the portion
have been completed.
In determining lengths of piles for ordering and to be included for payment,

the lengths given in the order list will be based on the lengths which are assumed
to remain in the completed structure. The Contractor, shall, without added
compensation, increase the lengths to provide for the fresh heading and for such
additional length as maybe necessary to suit the Contractor’s method of operation.
400.1.2 Test Piles
For his own information, the Contractor may drive at the location of the
regular piles indicated on the Plans such test piles as he may consider necessary
in addition to the test piles specified in the Contract and shall be considered as
regular piles. When called for in the Bill of Quantities, a pile if required to be
subjected to load test shall conform to the provision as provided in Subsection
400.1.3, Load Tests. The Contractor shall furnish and drive test piles of the
dimensions and at the locations designated by the Engineer. They shall be of the
material shown in the Bill of Quantities and shall be driven to refusal or to such tip
elevation or approximate bearing value as the Engineer may request. Test piles
shall be driven with the same hammer that is used for driving foundation piles.
When the Engineer requests a load test to determine a bearing value, the
first load test pile shall be driven to the specified bearing value as determined by
the applicable formula in Subsection 400.1.4 for Timber Pile Bearing Value by
Formula. Subsequent test piles to be load-tested shall be driven to the specified
bearing value as determined by the applicable formula modified by the results of
prior test loads and foundation data. The ground at each test pile shall be
excavated to the elevation of the bottom of the footing before the pile is driven.
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400.1.3 Load Tests
Load tests for files shall be either Static or Pile Testing by Low-Strain
Dynamic Method, High-Strain Dynamic Method and Cross-Hole Sonic Logging.
When load tests are specified, the number and location of piles to be tested
will be designated by the Engineer. Load tests shall be done by methods approved
by the Engineer. The Contractor shall submit to the Engineer for approval detailed
plans of the loading apparatus he intends to use. The apparatus shall be so
constructed as to allow the various increments of the load to be placed gradually
without causing vibration to the test piles. If the approved method requires the use
of tension (anchor) piles, such tension piles shall be of the same type and diameter
as the permanent piles and shall be driven in the location of permanent piles when
feasible. Piling not a part of the structure shall be removed or cut off at least 300mm
below the bottom of the footing or finished elevation of the ground upon completion
of the test load. Permanent piling used as anchor piling which is raised during the
test load shall be redriven to original grade and bearing.
400.1.3.1 Static Testing
Suitable approved apparatus for determining accurately the load on pile and
the settlement of the pile under increment of load shall be supplied by the
Contractor.
Test loading shall consist of the application of incremental static loads to a

pile and measuring the resultant settlement. The loads shall be applied by a
hydraulic jack acting against suitable anchorage, transmitting the load directly to
the pile, or other methods designated by the Plans or approved by the Engineer.
The load shall be applied in increments of 5 or 10 tonnes as directed by the

Engineer. Gross settlement readings, loads and other data shall be recorded by
the Engineer immediately before and after the applications of each load increment.
Each load increment shall be held for an interval of two and one-half minutes.
Each succeeding increment shall be as directed by the Engineer or as shown on
the Plans and shall be applied immediately after the two and one-half minute
interval readings have been made.
When a load-settlement curve obtained from these data shows that the pile
has failed; i.e., the load can be held only by the constant pumping and the pile or
shaft is being driven into the ground, pumping shall cease. Gross settlement
readings, loads and other data shall be recorded immediately after pumping has
ceased and again after an interval of two and one-half minutes for a total period of
five (5) minutes. All loads shall then be removed and the member allowed to
recover. Gross settlement readings shall be made immediately after all loads have
been removed and at each interval of two and one-half minutes for a total period of
five (5) minutes.
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All load tests shall be carried to failure or to the capacity of the equipment,
unless otherwise noted on the Plans.
After the completion of loading tests, the load used shall be removed and the
piles including tension piles, shall be utilized in the structure if found by the Engineer
to be satisfactory for such use. Test piles not loaded shall be utilized similarly. If
any pile, after serving its purpose as a test or tension pile, is found unsatisfactory
for utilization in the structure, it shall be removed if so ordered by the Engineer or
shall be cut off below the ground line of footings, whichever is applicable.
When diesel or other types of hammers requiring calibration are to be used,

the Contractor shall make load tests even though no load tests are called for in the
Bill of Quantities, except that load tests will not be required when the hammer is to
be used only for driving piles to refusal, rock or a fixed tip elevation or the hammer
is of a type and model that has been previously calibrated for similar type, size and
length of pile, and foundation material. Calibration data must have been obtained
from sources acceptable to the Engineer.
400.1.3.2 Pile Testing
Pile testing shall be done by Low-Strain Dynamic Method, High-Strain

Dynamic Method or Cross-Hole Sonic Logging Method as required in the plans or
as directed by the Engineer.
400.1.3.2.1 Low-Strain dynamic Method
Pile integrity testing by Low-Strain Dynamic Method shall conform to ASTM

D-5882-96. It is a so-called Low Strain Method, since it requires the impact of only
a small hand-held hammer, and also referred to as a Non-Destructive Method.
400.1.3.2.2 High-Strain Dynamic Testing
Pile Integrity testing by High-Strain Dynamic Method shall conform to ASTM

D4945-97. High-Strain Dynamic Method shall be applied to confirm the design
parameters and capacities assumed for the piles as well as to confirm the normal
integrity of testing of the piles. It is considered supplemental to the low-strain and
sonic-type integrity testing of the cast-in-place piles. It is a non-destructive relatively
quick test and it is intended that the test shaft be left in a condition suitable fohahr
use in production. The shaft used for the test will be instrumented and tested by the
testing specialist, as approved by the Engineer, meeting requirements in
accordance to ASTM D4945-97.
400.1.3.2.3 Cross-Hole Sonic Logging of Bored Holes
By sending ultrasonic pulses through concrete from one probe to another

(probes located in parallel tubes), the Cross-hole Sonic Logging (CSL) procedure
inspects the drilled shaft structural integrity, and extent and location of defects, if
any. At the receiver probe, pulse arrival time and signal the concrete affects
strength. For equidistant tubes, uniform concrete yields consistent arrival times with
reasonable pulse wave speed and signal strengths. Non – uniformities such as
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contamination, soft concrete, honeycombing, voids, or intrusions of foreign objects
exhibit delayed arrival time with reduced signal strength.
400.1.4 Timber Pile Bearing Value by Formula

`
When load tests are called for in the Bill of Quantities and when diesel or
other hammers to be calibrated are used, the minimum number of hammer blows
per unit of pile penetration needed to obtain the specified bearing value of piles
shall be determined by load tests, as provided in Subsections 400.1.2 and 400.1.3.
In the absence of load tests, the safe bearing value of each timber pile shall be
determined by whichever of the following approximate formulas is applicable:
1000 WH
For gravity hammer, P = ------------- x ---------------
6 S+25.4
For single-action steam or air hammers, and for diesel hammers

having unrestricted rebound of ram,
1000 WH
P = ----------- x -----------------
6 S+2.54
For double-action steam or air hammers, and diesel hammers having

enclosed ram,
1000 E
P = ------------ x -----------------
6 S+2.54
For diesel or steam hammers on very heavy piles,
1000 E
P = ---------- x ------------------------
6 S+2.54 (Wp/W)
Where:
P = Safe load per pile in Newton or kg

W = Weight of the striking part of the hammer in
Newton or kg
H = Height of fall of ram in metres
S = Average penetration per blow in mm for the last 5
to 10 blows for gravity hammers and the last 10
to 20 blows for steam hammers
E = Hammer energy, N.m or kg.m
Wp = Weight of pile
The above formula are applicable only when:
1. The hammer has a free fall.
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2. The head of the pile is free from broomed or crushed wood fiber
or other serious impairment.
3. The penetration is reasonably quick and uniform.
4. There is no measurable bounce after the blow.
5. A follower is not used.
If there is a measurable bounce, twice the height of bounce shall be

deducted from H to determine its value in the formula.
The bearing power as determined by the appropriate formula listed in

this Subsection, will be considered effective only when it is less than the
crushing strength of the pile. Other recognized formulas may be used if
fully detailed in the Special Provisions.
When bearing power is determined by a formula, timber piles shall be

driven until a computed safe bearing power of each is not less than 18
tonnes.
400.1.5 Concrete and Steel Pile Bearing Values
The bearing values for concrete and steel pile will be determined by the
Engineer using the following formulas:
a. Modified Hiley’s Formula or any formula from brochures of the

equipment used, shall be used when the ratio of weight of ram or hammer
to weight of pile is greater than one fourth (1/4).
2WH (W)
Ru = ----------------------------
(S+K) (W+Wp)
Ru
Ra = ---------------
FS
Where:
Ru = ultimate capacity of piles (KN)

Ra = capacity of pile (KN)–shall be greater than the required
W = weight of ram or hammer (KN)
H = height of fall of ram (mm)
Wp = weight of pile (KN)
S = average penetration for the last ten blows (mm)
K = 10 mm (unless otherwise observed/computed during
driving)
FS = factor of safety (min. = 3)
b. Hiley’s Formula shall be used when the ratio of the weight of ram
or hammer to weight of pile is less than one fourth (1/4).
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efWH (W) (W + n2 Wp)
Ru = ------------------------------ x ---------------------------
S+1/2 (C1+C2+C3) (W + Wp)
Ru
Ra = --------------
FS
where:
Ru = ultimate capacity of pile (KN)

Ra = capacity of pile (KN)
ef = efficiency of hammer (refer to table)
W = weight of ram (KN)
Wp = weight of pile (KN)
H = height of fall of ram (mm)
S = average penetration for last ten blows (mm)
C1 = temporary compression allowance for pile head and cap
(refer to table)
C2 = RuL/AEp
C3 = range from 2.54mm to 5.08mm (0.1” to 0.2”) for resilient
soil to 0 for hard pan (rock, very dense sand and gravel)
length of pile
L = cross-sectional area of pile
A = modulus of elasticity of pile
Ep = coefficient of restitution (refer to table)
n = factor of safety (min. = 3)
FS =
Required minimum penetration of all piles shall be six (6)

meters. However, for exposed piles, the embedded length shall be
equal or greater than the exposed length but not less than 6.0m.
Note:
Formula for other pile hammers with suggested factor of safety should
be as provided/recommended by their respective manufacturer.
Values of C1 for Hiley Formula
Temporary Compression Allowance C1 for Pile Head and Cap
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Materials to which Easy Driving: Medium Driving: Hard Driving: Very Hard
blow is applied P1 = 3.45 MPa P1 = 6.90 MPa P1 = 10.34 MPa Driving:
(500 psi) (1000 psi) (1500 psi) P1 = 13.88 MPa
on Pile Butt If on Head or Cap. on Head or Cap. (2000 psi)
no cushion, mm (in.) mm (in.) on Head or Cap.
mm (in.) mm (in.)
Head of timber pile 1.27 (0.05) 2.54 (0.10) 3.81 (0.15) 5.08 (0.20)
76–100mm (3-4 in.)

packing inside cap
on head of precast 1.27 + 1.778b 2.54 + 3.81b 3.81 + 5.588b 5.08 + 7.62b
concrete piles (0.05 + 0.07)b (0.10 + 0.15)b (0.015 + 0.22)b (0.20 + 0.30)b
Concrete Pile 0.635 (0.025) 1.27 (0.05) 1.905 (0.075) 2.54 (0.10)
Steel-covered cap.
containing wood
packing but steel
piling at pipe 1.016 (0.04) 2.032 (0.08) 3.048 (0.12) 4.064 (0.16)
4.76mm (3/16 in.)

red electrical tuber
disk between two
10mm (3/8”) steel
plates, for use with
severe driving on
Monotube pile 0.508 (0.02) 1.016 (0.04) 1.524 (0.06) 2.032 (0.08)
Head of steel piling

of pipe 0 0 0 0
bThe first figure represent the compression of the cap and wood dolly or
packing above the cap, whereas the second figure represent the
compression of the wood packing between the cap and the pile head.
P1 = Ru/A
Values of Efficiency of Hammer, ef
Hammer Type ef
Drop Hammer released by trigger 1.00

Drop Hammer actuated by rope and friction winch 0.75
McKiernan-Terry Single-acting hammers 0.85
Warrington-Vulcan Single –acting hammers 0.75
Differential-acting hammers 0.75
McKiernan-Terry, Industrial B. Ownhoist, National and 0.85
Union double-acting hammers
Diesel Hammers 1.00
Values of Coefficient of Restitution, n

Pile Type Head Condition Drop, Single Double
Acting or Acting
Hammers
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Diesel
Hammer
Reinforced Helmet with composite plastic or
Concrete green heart dolly on top of pile 0.40 0.50
Helmet with Timber dolly, and

packing on top of pile 0.25 0.40
Hammer direct on pile with pad - 0.50

only
Steel Driving cap with Standard plastic
or greenheart dolly 0.50 0.50
Driving cap with Timber dolly 0.30 0.30
Hammer direct on pile - 0.50

Timber Hammer direct on pile 0.25 0.40
The formulas specified in the preceding Subsection for timber piling may be
used in determining a rough approximation for the bearing power of precast and
cast-in-place concrete piles and of steel piles.
In all cases when the bearing power of concrete and steel piles is determined
by formula, the piles shall be driven until the safe bearing power of each is
computed to be not less than 27 tonnes.
400.1.6 Safe Loads
When the safe bearing power of any pile is found by test or computation to
be less than the design load, longer piles or additional piles shall be driven as
ordered in writing by the Engineer.
400.1.7 Jetted Piles
The safe bearing power of jetted piles shall be determined by actual tests or
by the appropriate methods and formulas given in the preceding Subsections. No
jet shall be used during the test blows.
400.2 Material Requirements
The kind and type of piles shall be as specified on the Plans and Bill of
Quantities. No alternative type or kind of piling shall be used.
400.2.1 Untreated Timber Piles
Timber shall conform to the requirements of Item 713, Treated and Untreated
Timber. The specie shall be specified on the Plans. Unless otherwise noted on the
Plans or Special Provisions, only the best grade shall be used. It shall be free from
loose knots, splits, wormholes, decay, warp, ring separation or any defect which will
impair its strength or render it unfit for its intended use. Any specie specified on the
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Plans may be used for untreated timber and if the specie is not available, a specie
of equivalent strength and durability may be used if authorized by the Engineer.
Round piles shall be cut above the ground swell and shall taper from butt to
tip. A line drawn from the center of the tip to the center of the butt shall not fall
outside of the cross-section of the pile at any point more than one percent of the
length of the pile.
In short bends, the distance from the center of the pile to a line stretched
from the center of the pile above the bend to the center of the pile below the bend
shall not exceed four percent of the length of the bend or a maximum of 65mm.
Unless otherwise specified, all piles shall be peeled removing all rough bark
and at least 80 percent of the inner bark. Not less than 80 percent of the surface
on any circumference shall be clean wood. No strip of inner bark remaining on the
pile shall be more than 20mm wide and 200mm long. All knots shall be trimmed
close to the body of the pile.
The pile sizes shall conform to the dimensions shown in Table 400.1.
Table 400.1 – Dimension of Piles
Length of Pile Diameter (1 metre from the Butt) Minimum Tip

Diameter, mm
Minimum Maximum
mm mm
Less than 12 metres 300 450 200
12 to 18 metres 320 450 180
More than 18 metres 350 500 150
The diameter of the piles shall be measured in their peeled condition. When
the pile is not exactly round, the average of three measurements may be used. For
any structure, the butt diameters for the same lengths of pile shall be as uniform as
possible.
Square piles shall have the dimensions shown on the Plans.
400.2.2 Treated Timber Piles
Timber shall conform to the requirements of Item 713, Treated and Untreated
Timber. Treatment shall consist of the forcing of either creosote oil or creosote
petroleum oil mixture into the outer fibers of the timber by a heat and pressure
process. The process shall be in accordance with ASTM D-1760 Standard
Specification for Pressure Treatment of Timber Products, but with such changes as
temperatures, pressures, duration of treatment and other factors affecting the final
treatment that experience has shown to be necessary in the treatment of structural
timbers sawn from woods native to the Philippines. The treatment shall be so
regulated that the curing process will not induce excessive checking. The minimum
penetration of the preservative into the surface of the timber shall be 20 mm. All
piles shall retain the minimum amount of preservative specified in Table 400.2.
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Table 400.2 – Minimum Preservative Per Cubic Metre of Wood
Type of Processing
Use Empty Cell Process Full Cell Process
General Use 195 kg
Marine Use 320 kg
The Engineer shall inspect the timber prior to the treatment to determine
conformance with the Specifications and suitability of conditions for treatment. He
shall be permitted free access to the plant in order that temperatures, pressures
and quantities and type of treatment materials used may be observed. Samples of
the creosote or creosote petroleum mixtures shall be furnished as required for test.
The timber shall be checked to determine penetration of treatment, quantity
of free preservative remaining on the timber and any visual evidence that the
treatment has been performed in a satisfactory manner. The penetration of
treatment shall be determined by boring a sufficient number of well-distributed holes
to determine the average penetration. All such holes shall be plugged with plugs
approximately 2 mm larger in diameter than the bit used in boring the holes.
If the penetration of preservative is less than the required amount, the entire
charge, or such parts thereof shall be retreated. If after treatment the penetration is
still insufficient, the treated pieces shall be rejected.
400.2.3 Concrete Piles
Concrete shall conform to the requirements of Item 405, Structural Concrete.

Concrete shall be Class “C” unless otherwise specified in the Plans.
Concrete shall be proportioned to achieve a range of 6”-8” (150 mm to 200

mm) slump, self-compacting mix.
The use of appropriate plasticizer/additives to assure mix fluidity and

consistency shall be allowed and with the Engineer’s approval. A retardant of
proven adequacy and approved by the Engineer may be used to ensure that early
hardening of concrete during operation will not occur.
Reinforcing steel shall conform to the requirements of Item 404, Reinforcing

Steel. Prestressing reinforcing steel shall be high-tensile steel wire conforming to
AASHTO M 204 or other high-tensile metals conforming to AASHTO Standards.
400.2.4 Steel Shells
1. Shells Driven Without a Mandrel
Unless otherwise called for on the Plans or Special Provisions, shells for
cast-in-place concrete piles shall have a minimum 305mm diameter at cut off and
a minimum 203mm diameter at tip: made from not less than 4.55mm in thickness
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plate stock conforming to AASHTO M 183. Shells may either be spirally welded or
longitudinally welded and may either be tapered or constant in section. Tips shall
be sealed as shown on the Plans.
2. Shells Driven With a Mandrel
The shell shall be of sufficient strength and thickness to withstand driving

without injury and to resist harmful distortion and/or buckling due to soil pressure
after driven and the mandrel removed. Butt and tip dimension shall be as called for
on the Plans or Special Provisions.
400.2.5 Steel Pipes
Filled Steel Pipes (filled with concrete) shall conform to the requirements of
ASTM A 252, Grade 2, Welded and Seamless Pipe Piles. Closure Plates for closed
piles shall conform to the requirements of AASHTO M 183.
Unfilled Tubular Steel Piles shall conform to the requirements of ASTM A

252, Grade 2, with chemical requirements meeting ASTM Designation A 53, Grade
B. The wall thickness shall not be less than 4.76mm.
400.2.6 Steel H-Piles
Steel H-Piles shall be rolled steel sections of the weight and shape called for
on the Plans. They shall be structural steel meeting the requirements of AASHTO
M 183 provided that, where the Special Provisions called for copper-bearing
structural steel, the steel shall not contain less than one-fifth percent nor more than
zero point thirty five percent (0.35%) of copper, except that steel manufactured by
the acid-bessemer process shall not be used.
400.2.7 Sheet Piles
Steel sheet piles shall meet the requirements of AASHTO M 202 (ASTM A
328), or AASHTO M 223. All other sheet piles shall meet the requirements
prescribed above the particular material specified. The joints shall be practically
water-tight when the piles are in place.
400.2.8 Pile Shoes
Pile shoes shall be as called for on the Plans.
400.2.9 Splices
Material for pile splices, when splicing is allowed, shall be of the same quality
as the material used for the pile itself and shall follow the requirements given on
the Plans.
400.2.10 Paint
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It shall conform to Item 709, Paints.
400.3 Construction Requirements
400.3.1 Location and Site Preparation
Piles shall be driven where indicated on the Plans or as directed by the

Engineer.
All excavations for the foundation on which the piles are to be driven shall
be completed before the pile driving, unless otherwise specified or approved by the
Engineer. After driving is completed, all loose and displaced materials shall be
removed from around the piles by hand excavation, leaving clean solid surface to
receive the concrete of the foundation. Any requirement for granular fill and lean
concrete shall be indicated on the Plans or as directed by the Engineer.
400.3.2 Determination of Pile Length
Pile length and bearing capacity shall be determined by the Engineer from
the results of the test piling and load tests.
The criterion for pile length may be one of the following:
1. Piles in sand and gravel shall be driven to a bearing power determined

by the use of the pile driving formula or as decided by the Engineer.
2. Piles in clay shall be driven to the depth ordered by the Engineer.
However, the bearing power shall be controlled by the pile driving formula
if called for by the Engineer.
3. Piles shall be driven to refusal on rock or hard layer when so ordered by
the Engineer.
The Contractor shall be responsible for obtaining the correct pile length and
bearing capacity according to the criteria given by the Engineer.
400.3.3 Pile Driving
All piles shall be driven as shown on the Plans or as ordered in writing by the
Engineer. They shall be driven within an allowed variation of 20mm per metre of
pile length from the vertical or batter as shown on the Plans. The maximum
allowable variation at the butt end of the pile shall be 75mm in any direction from
the location shown on the Plans or as directed by the Engineer. Each pile shall,
after driving, be within 150mm from the theoretical location underneath the pile cap
or underneath the superstructure in case of pile bents. All piles pushed up by the
driving of adjacent piles or any other cause shall be redriven.
Piles shall be used only in places where the minimum penetration of 3m in

firm materials, or 5m in soft materials can be obtained. Whereas soft upper stratum
overlies a hard stratum, the piles shall penetrate the hard materials at sufficient
depths to fix the ends rigidly.
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All pile driving equipment is subject to the Engineer’s approval. The
Contractor is responsible for sufficient weight and efficiency of the hammers to drive
the piles down to the required depth and bearing capacity. Hammers shall be
gravity hammers, single and double acting steam or pneumatic hammers or diesel
hammers. Gravity hammers shall not weigh less than 60 percent of the combined
weight of the pile and driving head but not less than 2,000 kg. The fall shall be
regulated so as to avoid injury to the pile and shall in no case exceed 4.50m for
timber and steel piles and 2.50m for concrete piles unless otherwise specified or
approved by the Engineer.
The plant and equipment furnished for steam hammers shall have sufficient
capacity to maintain, under working condition, the pressure at the hammer specified
by the manufacturer. The boiler or pressure tank shall be equipped with an accurate
pressure gauge and another gauge shall be supplied at the hammer intake to
determine the drop in pressure between the gauges. When diesel hammers or any
other types requiring calibration are used, they shall be calibrated with test piling
and/or test loads in accordance with Subsection 400.1.2, Test Piles.
Water jets shall be used only when permitted in writing by the Engineer.
When water jets are used, the number of jets and the nozzle volume and pressure
shall be sufficient to erode freely the material adjacent to the pile. The plant shall
have sufficient capacity to deliver at all time a pressure equivalent to at least 690
KPa at two 19 mm (3/4 inch) jet nozzles. The jets shall be shut off before the
required penetration is reached and the piles shall be driven solely by hammers to
final penetration as required by the Engineer.
Piles shall be supported in line and position with leads while being driven.
Pile driving leads shall be constructed in such a manner as to afford freedom of
movement of the hammer, and shall be held in position by guys or steel braces to
insure rigid lateral support to the pile during driving. The leads shall be of sufficient
length to make the use of a follower unnecessary and shall be so designed as to
permit proper placing of batter piles. The driving of the piles with followers shall be
avoided if practicable and shall be done only under written permission from the
Engineer.
The method used in driving piles shall not subject them to excessive and
undue abuse producing crushing and spalling of the concrete, injurious splitting,
splintering and brooming of the wood or deformation of the steel. Manipulation of
piles to force them into proper position if considered by the Engineer too excessive
will not be permitted.
The pile tops shall be protected by driving heads, caps or cushions in

accordance with the recommendation of the manufacturer of the pile hammer and
to the satisfaction of the Engineer. The driving head shall be provided to maintain
the axis of the pile with the axis of the hammer and provide a driving surface normal
to the pile.
Full length piles shall be used where practicable. Splicing of piles when
permitted, shall be in accordance with the provisions of Subsection 400.3.7 and
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400.3.8. All piles shall be continuously driven unless otherwise allowed by the
Engineer.
Piles shall not be driven within 7 m of concrete less than 7 days old.
400.3.4 Timber Piles
Piles shall be strapped with three metal straps: one about 450mm from the
butt, one about 600mm from the butt, and the third, about 300mm from the tip.
Additional straps shall be provided at about 4.5m on centers between tip and butt.
Strapping should encircle the pile once and be tensioned as tightly as possible.
Straps shall be 38mm wide, 0.8mm thick, cold rolled, fully heat treated, high tensile
strapping, painted and waxed.
Treated piles shall be strapped after treatment.
Point protection shall be considered for all timber piles. Where timber piles
must penetrate dump fill, or may encounter obstructions or be driven to hard strata,
point protection shall be used. A boot that encompasses and utilizes the entire end
area of the pile is preferred.
400.3.5 Timber Pile Bents
Piles for any one bent shall be carefully selected as to size, to avoid undue
bending or distortion of the sway bracing. Care shall be exercised in the distribution
of piles of various sizes to obtain uniform strength and rigidity in the bents of any
given structure.
Cut offs shall be made accurately to insure full being between caps and piles
of bents.
400.3.6 Precast Concrete Piles
Precast concrete piles shall be of the design shown on the Plans.

Prestressed concrete piles shall be prestressed as prescribed in Item 406,
Prestressed Concrete Structures. The piles shall be cast separately and concrete
in each pile shall be place continuously. The completed piles shall be free from
stone pockets, honeycombs, or other defects, and shall be straight and true to the
form specified. The forms shall be true to line and built of metal, plywood or dressed
lumber. A 25mm chamfer strip shall be used in all corners. Form shall be water-
tight and shall not be removed until at least twenty-four (24) hours after the concrete
is placed.
Piles shall be cured and finished in accordance with Items 405, Structural
Concrete and 406, Prestressed Concrete Structures.
Cylinder specimens shall be made and tested in accordance with Item 405.
Piles shall not be moved until the tests indicate that the concrete has attained a
compressive strength of at least 80 percent (80%) of the design 28-day
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compressive strength and they shall not be transported or driven until the design
28-day compressive strength has been attained.
If testing equipment is not available, as in isolated areas, piles shall not be

moved until after fourteen (14) days after casting and shall not be transported or
driven prior to 28 days after casting. If high early strength cement is used, piles
shall not be moved, transported or driven prior to 7 days after casting.
When concrete piles are lifted or moved, they shall be supported at the points
shown on the Plans; if not shown, they shall be supported at the quarter points.
400.3.7 Cast-in-place Concrete Piles
1. Drilled Holes
All holes for concrete piles cast in drilled holes shall be drilled dry to tip
elevation shown on the Plans. All holes will be examined for straightness and any
hole which on visual inspection from the top shows less than one-half the diameter
of the hole at the bottom of the hole will be rejected. Suitable casings shall be
furnished and placed when required to prevent caving of the hole before concrete
is placed.
All loose material existing at the bottom of the hole after drilling operations
have been completed shall be removed before placing concrete.
The use of water for drilling operations or for any other purpose where it may
enter the hole will not be permitted. All necessary action shall be taken to prevent
surface water from entering the hole and all water which may have infiltrated into
the hole shall be removed before placing concrete.
Concrete shall be placed by means of suitable tubes. Prior to the initial

concrete set, the top 3m of the concrete filled pile or the depth of any reinforcing
cage, whichever is greater, shall be consolidated by acceptable vibratory
equipment,
Casing, if used in drilling operations, may be left in place or removed from

the hole as concrete is placed. The bottom of the casing shall be maintained not
more than 1.5m nor less than 0.3m below the top of the concrete during withdrawal
and placing operations unless otherwise permitted by the Engineer. Separation of
the concrete during withdrawal operations shall be avoided by vibrating the casing.
2. Steel Shells and Pipes
The inside of shells and pipes shall be cleaned and all loose materials
removed before concrete is placed. The concrete shall be placed in one continuous
operation from tip to cut-off elevation and shall be carried on in such a manner as
to avoid segregation.
The top 3m of concrete filled shells, or to the depth of any reinforcing cage,
whichever is greater, shall be consolidated by acceptable vibratory equipment.
148
Pipes shall be of the diameter shown on the Plans. The pipe wall thickness
shall not be less than that shown on the Plans but in no case less than 5mm. The
pipe, including end closures, shall be of sufficient strength to be driven by the
specified methods without distortion.
Closure plates and connecting welds shall not project more than 12.5mm
beyond the perimeter of the pile tips.
No shell or pipe shall be filled with concrete until all adjacent shells, pipes,
or piles within a radius of 1.5m or 4 ½ times the average pile diameter, whichever
is greater, have been driven to the required resistance.
After a shell or pipe has been filled with concrete, no shell, pipe or pile shall
be driven within 6m thereof until at least 7 days have elapsed.
3. Drilled Shafts
Drilled shafts are deep foundations formed by boring a cylindrical hole into
soil and/or rock and filling the hole with concrete. Drilled shafts are also commonly
referred to as caissons, bored piles or drilled piers.
Drilled shafts, like driven piles, transfer structural loads to bearing stratum
well below the base of the structure by passing soils having insufficient strength to
carry the design loads.
Drilled shafts are classified according to their primary mechanism for deriving
load resistance either as floating shafts (i.e., shafts transferring load primarily by
side resistance), or end-bearing shafts (i.e., shafts transferring load primarily by tip
resistance). Occasionally, the bases of shafts are enlarged (i.e., belled or
underreamed) to improved the load capacity of end bearing shafts on less than
desirable soils, or to increase the uplift resistance of floating shafts.
Effects of ground and ground water conditions on shaft construction

operations should be considered and delineated, when necessary, the general
method of construction to be followed to ensure the expected performance.
Because shafts derive their capacity from side and tip resistance which are a
function of the condition of the materials in direct contact with the shaft, it is
important that the construction procedures be consistent with the material
conditions assumed in the design. Softening, loosening or other changes in soil
and rock conditions caused by the construction method could result in a reduction
in shaft capacity and an increase in shaft displacement. Therefore, evaluation of
the effects of shaft construction procedure on load capacity must be considered an
inherent aspect of the design.
Drilled shafts are normally sized in 15.24cm (6-inch diameter increments with
a minimum diameter of 45.72cm (18”). The diameter of a shaft socketed into rock
should be a minimum of 15.24cm (6”) larger than the socket diameter. If a shaft
must be inspected by the entry of a person, the shaft diameter shall not be less
than 76.20cm (30”).
149
Drilled shafts constructed in dry, noncaving soils can usually be excavated
without lateral support of the hole. Other ground conditions where caving,
squeezing or sloughing soils are present require installation of a steel casing or use
of a slurry for support of the hole. Such conditions and techniques may result in
loosening of soil around the shaft, or altering of frictional resistance between the
concrete shaft and surrounding soil.
The center-to-center spacing between shafts is normally restricted to a

minimum of 3B to minimize the effects of interaction between adjacent shafts during
construction or in service. However, larger spacings may be required where drilling
operations are difficult or where construction must be completed in very short time
frames.
Particular attention should be given to the potential for deposition of loose

or wet material in the bottom of the hole, or the buildup of a cake of soft material
around the shaft perimeter prior to concrete placement. Adequate cleaning and
inspection of rock sockets should always be performed to assure good contact
between the rock and shaft concrete. If good contact along the shaft cannot be
confirmed, it may be necessary to assume that all load is transferred to the tip. If
the deposition of soft or loose material in the bottom of the hole is expected, the
shaft may have to be designed to carry the entire design load through side
resistance.
A number of methods can be used to prevent caving during the drilling of

holes and the placement of concrete. It is preferred that drilled shafts be
constructed in stable non-sloughing soil without excessive ground water. If
impossible, consider the following three different construction methods:
a. The construction of the pile or shaft in a wet condition while the walls of
the excavation are stabilized by hydrostatic pressure of water or a mineral slurry
until the concrete is placed by tremie methods for the full length of the pile.
Mineral slurry used in the drilling process shall have both a mineral grain size
that will remain in suspension and sufficient viscosity and gel characteristics to
transport excavated material to a suitable screening system. The percentage and
specific gravity of the material used to make the suspension shall be sufficient to
maintain the stability of the excavation and to allow proper concrete placement. The
level of the slurry shall be maintained at a height sufficient to prevent caving of the
hole.
The mineral slurry shall be premixed thoroughly with clean fresh water and
adequate time allotted for hydration prior to introduction into the shaft excavation.
Adequate slurry tanks will be required when specified. No excavated slurry pits will
be allowed when slurry tanks are required on the project without written permission
of the Engineer. Adequate desanding equipment will be required when specified.
Steps shall be taken as necessary to prevent the slurry from “setting up” in the shaft
excavation, such as agitation, circulation, and adjusting the properties of the slurry.
150
Control tests using suitable apparatus shall be carried out by the Contractor
on the mineral slurry to determine density, viscosity, and pH. An acceptable range
of values for those physical properties is shown in the following table.
Range of Values (At 20o [68oF])
Property Time of Slurry Time of Concreting Test

(Units) Introduction (In Hole) Method
Density 10.10 to 10.86 10.10 to 11.79 Density

(KN/m3) 64.3 to 69.1 64.3 to 75.0 Balance
(pcf)
Viscosity 28 to 45 28 to 45 Marsh
(sec. per quart) Cone
pH 8 to 11 8 to 11 pH Paper
or Meter
Note:
a) Increase density values by 0.314 KN/m3 (2 pcf) in salt water.
b) If desanding is required; sand content shall not exceed 4 percent

(by volume) at any point in the shaft excavation as determined by
the American Petroleum Institute sand content test.
Tests to determine density, viscosity and pH values shall be done during the
shaft excavation to establish a consistent working pattern.
Prior to placing shaft concrete, slurry samples shall be taken from the bottom
and at intervals not exceeding 3.05m (10 feet) for the full height of slurry. Any
heavily contaminated slurry that has accumulated at the bottom of the shaft shall
be eliminated. The mineral slurry shall be within specification requirements
immediately before shaft concrete placement.
Excavation Inspection
The Contractor shall provide equipment for checking the dimensions and
alignment of each shaft excavation. The Contractor under the direction of the
Engineer shall determine the dimensions and alignment of the drilled shaft. Final
shaft depth shall be measured after final cleaning.
The base of the shaft excavation may be cleaned using a cleaning bucket
followed by airlifting. Reverse circulation techniques may also be used to clean the
base of the shaft.
The shaft excavation shall be cleaned so that a minimum of 50 percent of

the base will have less than 12.5mm of sediment and at no place on the base more
than 37.5mm of sediment. The Engineer will determine shaft cleanliness.
151
b. The use of steel casing which is installed during drilling operations to hold
the hole open and usually withdrawn during concrete placement.
Casing, if used in operation, shall be metal, smooth, clean, watertight, and

of ample strength to withstand both handling and driving stresses and the pressure
of both concrete and the surrounding earth materials. The outside diameter of
casing shall not be less than the specified size of the shaft. It shall conform to
AASHTO M 270 (ASTM A 709) Grade 36 unless otherwise specified.
Temporary casings shall be removed while the concrete remains workable.

Generally the removal of temporary casing shall not be started until concrete
placement in the shaft is at or above ground surface. Movement of casing by
rotating, exerting downward pressure and tapping to facilitate extraction or
extraction with a vibratory hammer will be permitted. Casing extraction shall be at
a slow, uniform rate with the pull in line with the shaft axis.
A sufficient head of concrete shall be maintained above the bottom of the

casing to overcome the hydrostatic pressure of water or drilling fluid outside of the
casing.
c. The use of a permanent casing which is left in place within the portion of
the pile which is in unstable material.
A permanent casing is applied as protection from the presence of surface

water during drilling and as support later for the installation of the rebar cage and
as a concrete form in drilling under water.
Reinforcing Steel Cage Construction and Placement
The reinforcing steel cage consisting of the steel shown on the Plans plus
cage stiffener bars, spacers, centralizers and any other necessary appurtenances
shall be completely assembled and placed as a unit immediately after the shaft
excavation is inspected and accepted and prior to shaft concrete placement.
Where the reinforcing cage length is too long for placement as a single unit
the cage may be placed in separate units such that appropriate means of splicing
the longitudinal steel is provided for. The Contractor shall submit his plans for such
splices to the Engineer for approval.
The reinforcing steel in the hole shall be tied and supported so that the
reinforcing steel will remain within allowable tolerances until the concrete will
support the reinforcing steel. When concrete is placed by suitable tubes, temporary
hold-down devices shall be used to prevent uplifting of the steel cage during
concrete placement. Concrete spacers or other approved noncorrosive spacing
devices shall be used at sufficient intervals not exceeding 1.50 meters along the
shaft to insure concentric location of the cage within the shaft excavation. When
the size of the longitudinal reinforcing steel exceeds 25mm, such spacing shall not
exceed 3.0 meters.
Concrete Placement, Curing and Protection
152
Concrete shall be placed as soon as possible after reinforcing steel cage
placement. Concrete placement shall be continuous in the shaft to the top elevation
of the shaft. Placement shall continue after the shaft is full until good quality
concrete is evident at the top of the shaft. Concrete shall be placed through a
suitable tube.
For piles less than 2.5 meters in diameter, the elapsed time from the
beginning of concrete placement in the shaft to the completion of placement shall
not exceed 2 hours. For piles 2.50 meters and greater in diameter, the concrete
placing rate shall not be less than 9.0 meters of pile height per each 2-hour period.
The concrete mix shall be of such design that the concrete remains in a workable
plastic state throughout the 2-hour placement limit.
When the top of pile elevation is above ground, the portion of the pile above
ground shall be formed with a removable form or permanent casing when specified.
The upper 1.5 meters of concrete shall be vibrated or rodded to a depth of

1.5 meter below the ground surface except where soft uncased soil or slurry
remaining in the excavation will possibly mix with the concrete.
After placement, the temporarily exposed surfaces of the shaft concrete shall
be cured in accordance with the provision in Sub-section 407.3.8 – Curing
Concrete.
For at least 48 hours after pile concrete has been placed, no construction
operations that would cause soil movement adjacent to the shaft, other than mild
vibration, shall be conducted.
Construction Tolerances:
The following tolerances shall be maintained in constructing drilled shaft.
a. The drilled shaft shall be within 7.62cm (6”) of the plan position in the
horizontal plane at the plan elevation for the top of the shaft.
b. The vertical alignment of the shaft excavation shall not vary from the plan
alignment by more than 20.83 mm/m (1/4 inch per foot) of depth.
c. After all the shaft concrete is placed, the top of the reinforcing steel cage
shall be no more than 15.24 cm (6”) above and no more than 7.62 cm
(3”) below plan position.
d. When casing is used, its outside diameter shall not be less than the shaft
diameter shown on the plans. When casing is not used, the minimum
diameter of the drilled shaft shall be the diameter shown on the plans for
diameters 60.96 cm (24”) or less, and not more than 2.54 cm (1 inch) less
than the diameter shown on the plans for diameters greater than 60.96
cm (24”).
153
e. The bearing area of bells shall be excavated to the plan bearing area as
a minimum. All other plan dimensions shown for the bells may be varied,
when approved, to accommodate the equipment used.
f. The top elevation of the shaft shall be within 2.54 cm (1 inch) of the plan
top of shaft elevation.
g. The bottom of the shaft excavation shall be normal to the axis of the shaft
within 62.5 mm/m (3/4 inch per foot) of shaft diameter.
Drilled shaft excavations constructed in such a manner that the concrete

shaft cannot be completed within the required tolerances are unacceptable.
400.3.8 Steel H-Pile
Steel H-Pile shall consist of structural steel shapes of the sections indicated
on the Plans.
When placed in the leads, the pile shall not exceed the camber and sweep
permitted by allowable mill tolerance. Piles bent or otherwise damaged will be
rejected.
The loading, transporting, unloading, storing and handling of steel H-pile

shall be conducted so that the metal will be kept clean and free from damage.
400.3.9 Unfilled Tubular Steel Piles
The tubular steel piles should be or as specified by the Engineer.
The minimum wall thickness shall be as indicated in the following table:
Outside Diameter Less than 355 mm 355 mm and over
Minimum wall thickness 6.5 mm 9.5 mm
Cutting shoes for piles driven open end may be inside or outside of the pipe.
They may be high carbon structural steel with a machined ledged for pile bearing
or cast steel with a ledge, designed for attachment with a simple weld.
400.3.10 Splicing
Splicing when permitted shall be made as shown on the Plans and in

accordance with this Subsection.
1. Precast Concrete Piles
a. By using prefabricated joints mounted in the forms and cast together with
the piles sections and joined together as specified by the manufac-turer
and approved by the Engineer. The joints shall be of the design and type
as specified or shown on the Plans.
154
b. By cutting away the concrete at the end of the pile, leaving the reinforcing
steel exposed for a length of 40 bar diameters for corrugated or deformed
bars and 60 bar diameters for plain bars. The final cut of the concrete
shall be perpendicular to the axis of the pile. Reinforcement of the same
size as that used in the pile shall be spliced to the projecting steel in
accordance with Item 404, Reinforcing Steel, and the necessary
formwork shall be placed, care being taken to prevent leakage along the
pile. The concrete shall be of the same quality as that used in the pile.
Just prior to placing concrete, the top of the pile shall be wetted
thoroughly and covered with a thin coating of neat cement, retempered
mortar, or other suitable bonding material to the satisfaction of the
Engineer. The forms shall remain in place not less than seven (7) days.
The pile shall not be driven until the safe design has been reached.
c. By any other method shown on the Plans or approved by the Engineer.

Curing and finishing of extensions shall be the same as in the original
pile.
2. Prestressed Piles
Splicing of prestressed precast piles will generally not be permitted, but

when permitted, it shall be made in accordance with (1) above, but only after
driving has been completed. Reinforcement bars shall be included in the
pile head for splicing to the extension bars. No additional driving will be
permitted. The Contractor, at his option, may submit alternative plans of
splicing for consideration by the Engineer.
3. Steel Piles, Shells or Pipes
If the length of the steel pile, shell or pipe driven is insufficient to obtain
the specified bearing power, an extension of the same cross-section shall be
spliced to it. Unless otherwise shown on the Plans, splices shall be made
by butt-welding the entire cross-sections to form an integral pile using the
electric arc method. The sections connected shall be properly aligned so
that the axis of the pile shall be straight. Bent and/or damaged piles shall be
rejected.
400.3.11 Cutting Off and Capping Piles
The top of foundation piles shall be embedded in the concrete footing as

shown on the Plans.
Concrete piles shall, when approved by the Engineer, be cut off at such a
level that at least 300mm of undamaged pile can be embedded in the structure
above. If a pile is damaged below this level, the Contractor shall repair the pile to
the satisfaction of the Engineer. The longitudinal reinforcement of the piles shall be
embedded in the structure above to a length equal to at least 40 times the diameter
of the main reinforcing corrugated bars (60 diameters for plain bars). The distance
155
from the side of any pile to the nearest edge of the cap shall not be less than
200mm.
When the cut off elevation for a precast pile or for the steel shell or pile for a
cast in place concrete pile is below the elevation of the bottom of the pile cap, the
pile may be built-up from the butt of the pile to the elevation of the bottom of the cap
by means of reinforced concrete extension constructed in accordance with
Subsection 400.3.10 or as approved by the Engineer.
Cut-offs of structural steel piles shall be made at right angles to the axis of
the pile. The cuts shall be made in clear, straight lines and any irregularity due to
cutting or burning shall be leveled-off with deposits of weld metal prior to placing
bearing caps.
400.3.12 Defective Piles
Any pile delivered with defects, or damaged in driving due to internal defects
or by improper driving, or driven out of its proper location, or driven below the
elevation fixed by the Plans or by the Engineer, shall be corrected at the
Contractor’s expense by one of the following methods approved by the Engineer
for the pile in question:
1. Any pile delivered with defects shall be replaced by a new pile.
2. Additional pile shall be driven/casted at the location as directed by the

Engineer.
3. The pile shall be spliced or built-up as otherwise provided herein on the

underside of the footing lowered to properly embed the pile.
A precast concrete pile shall be considered defective if it has a visible crack,

extending around the four sides of the pile, or any defect which, in the opinion of
the Engineer, affects the strength or life of the pile.
When a new pile is driven or cast to replace a rejected one, the Contractor
at his own expense, shall enlarge the footing as deemed necessary by the
Engineer.
400.3.13 Protecting Untreated Timber Trestle Piles
The heads of untreated piles shall be treated as follows:
The sawed surface shall be thoroughly brush-coated with two (2)

applications of hot creosote oil or other approved preservative.
400.3.14 Protecting Treated Timber Trestle Piles
All cuts and abrasions in treated timber piles shall be protected by a

preservative approved by the Engineer.
156
400.3.15 Painting Steel Piles
Unless otherwise provided, when required steel piles extend above the
ground surface or water surface, they shall be protected by paint as specified for
cleaning and painting metal surfaces in accordance with Item 403, Metal Structures.
This protection shall extend from the elevation shown on the Plans to the top of the
exposed steel.
400.3.16 Pile Records
The Contractor shall keep records of all piles driven or installed. A copy of
the record shall be given to the Engineer within two (2) days after each pile is driven.
The record form to be used shall be approved by the Engineer. The pile records
shall give full information on the following:
Driven Piles Cast-in-Place Piles
1. Pile type and dimension 1. Date of boring or driving (For

steel shell) & casting
2. Date of casting and concrete 2. Pile type and nominal

quality (for concrete piles) dimension
3. Date of driving 3. Length of finished pile and tip

elevation
4. Driving equipment: type, 4. Details of penetration during

weight & efficiency of hammer, boring or driving of steel shell
etc. (driving records as for driven
piles)
5. Description of cushion on pile 5. Concrete quality and consis-

head tency
6. Depth driven and tip elevation 6. Time interval between boring

or driving and concreting
7. Final set for the last 20 blows 7. Volume of concrete placed in

(for every 10 piles and when the concrete
Engineer so requires the
penetration along the whole
depth driven shall be recorded)
8. For gravity and single-acting

hammers: the height of drop
9. For double acting-hammers ---

the frequency of blows
157
10. Details of any interruption in
driving
11. Level of pile top immediately

after driving and the level
when all piles in the group are
driven
12. Details of re-driving
400.4 Method of Measurement
400.4.1 Timber, Steel and Precast Concrete Piles
1. Piles Furnished
The quantity to be paid for will be the sum of the lengths in metres of the
piles of the several types and lengths ordered in writing by the Engineer,
furnished in compliance with these Specifications and stockpiles in good
condition at the project site by the Contractor and accepted by the Engineer.
The length to be paid for will include test and tension piles ordered by the
Engineer, but not those furnished by the Contractor at his option. No
allowance will be made for piles, including test piles, furnished by the
Contractor to replace piles previously accepted by the Engineer that are
subsequently lost or damaged while in stockpile, or during handling or
driving, and are ordered by the Engineer to be removed from the site of work.
In case extensions of piles are necessary, the extension length will be

included in the length of pile furnished, except for cut off lengths used for
extensions and already measured for payment.
2. Piles Driven
The quantity to be paid for will be the sum of the lengths in metres of the
piles driven in the completed work measured from the pile tip elevation to the
bottom of pile caps, footings or bottom of concrete superstructure in the case
of pile bents. Measurement will not include additional piles or test piles
driven that may be necessary to suit the Contractor’s method of construction
and were driven at his option.
Unless otherwise provided for, preboring, jetting or other methods used

for facilitating pile driving operations will not be measured directly but will be
considered subsidiary to pay items.
400.4.2 Cast-In-Place Concrete Piles
The quantity to be paid for will be the sum of actual lengths in meters of the
piles cast and left in-place in the completed and accepted work. Measurements will
be from the pile tip to the bottom of cap or footing. Portions of
158
piles cast deeper than the required length through over-drilling will not be measured
for payment.
400.4.3 Pile Shoes
The quantity to be paid for, including test pile shoes, will be the number of
pile shoes driven shown on the Plans or ordered in writing by the Engineer,
furnished by the Contractor in accordance with these Specifications and accepted
by the Engineer. Pile shoes furnished by the Contractor at his option or to replace
those that are lost or damaged in stockpile or handling will not be measured for
payment.
400.4.4 Load Tests
The quantity of the load tests to be paid for will be the number of tests
completed and accepted except that load tests made to calibrate different types of
hammers, if not included in the Bill of Quantities, will not be measured for payment.
Anchor and test piling which are not part of the completed structure, will be
included in the unit bid price for each “Load Test”. Anchor and test piling or anchor
and test shafts which are a part of the permanent structure will be paid for under
the appropriate Item.
400.4.5 Splices
The quantity to be paid for will be the number of splices which may be
required to drive the pile in excess of the estimated length shown on the Plans for
cast-in-place steel pipes or shells or in excess of the order length furnished by the
Engineer for all other types of piling. Splices made for the convenience of the
Contractor or to fabricate piles cut offs will not be paid for.
400.5 Basis of Payment
The accepted quantities, measured as prescribed in Section 400.4 shall be

paid for at the contract unit price for each of the particular item listed below that is
included in the Bill of Quantities, which price and payment shall be full compensa-
tion for furnishing and placing all materials, including all labor, equipment tools and
incidentals as well as temporary works, staging areas or craneway necessary to
complete the work prescribed in this Item.
Payment will be made under:
Pay Item Description Unit of

Number Measurement
400 (1) Untreated Timber Piles, furnished Meter

400 (2) Treated Timber Piles, preservative, furnished Meter
400 (3) Steel H-Piles, furnished Meter
400 (4) Precast Concrete Piles, furnished Meter
400 (5) Precast, Prestresssed Concrete Piles, furnished Meter
159
400 (6) Structural Steel Sheet Piles, furnished Meter
400 (7) Precast Concrete Sheet Piles, furnished Meter
400 (8) Untreated Timber Piles, driven Meter
400 (9) Treated Timber Piles, driven Meter
400 (10) Steel H-Piles, driven Meter
400 (11) Steel Pipes Piles Meter
400 (12) Structural Steel Sheet Piles, driven Meter
400 (13) Precast Concrete Sheet Piles, driven Meter
400 (14) Precast Concrete Piles, driven Meter
400 (15) Precast, Prestresssed Concrete Piles, driven Meter
400 (16) Test Piles, furnished and driven Meter
400 (17) Concrete Piles cast in Drilled Holes Meter
400 (18) Concrete Piles cast in Steel Shells Meter
400 (19) Concrete Piles cast in Steel Pipes Meter
400 (20) Pile Shoes Each
400 (21) Splices Each
400 (22) Load Tests Each
400 (23) Bored Piles (dia. __m) Meter
400 (24) Permanent Casing (dia. ___m) Meter
ITEM 401 – RAILINGS
401.1 Description
This Item shall consist of furnishing or fabricating and/or placing railings, for
bridges and other structures of the material or combination of materials shown on
the Plans, constructed in reasonably close conformity with this Specification and to
the lines, grades and dimensions shown on the Plans. Railings shall be classified
as concrete, steel, aluminum or timber in accordance with the predomi-nating
material contained in each.
401.2.1 Concrete
It shall conform to the applicable requirements prescribed in Item 405,

Structural Concrete.
401.2.2 Reinforcing Steel
It shall conform to the requirements of Item 710, Reinforcing Steel and Wire
Rope.
401.2.3 Steel
160
Structural steel consisting of steel and iron plates, shapes, pipes, fittings and
castings shall conform to the requirements of Item 403, Metal Structures.
401.2.4 Aluminum
It shall conform to the requirements of AASHTO M 193, ASTM B 221 or

ASTM B 308 or as called for on the Plans.
401.2.5 Timber
It shall conform to the requirements of Item 713, Treated and Untreated

Timber.
401.2.6 Stones and Bricks
These shall conform to the requirements of Item 505, Stone Masonry and
Item 704, Masonry Units.
401.2.7 Paint
It shall conform to the requirements of Item 709, Paints.
401.3.1 General
Railings shall be constructed to the lines and grades shown on the Plans and
shall not reflect any unevenness in the structure. All railing posts shall be set plumb
in hand or mechanically dug holes, unless driving is permitted. In the latter case,
the manner of driving shall be such as to avoid battering or distorting of post. Post
holes shall be backfilled with acceptable material placed in layers and thoroughly
compacted. When it is necessary to cut post holes in existing pavement, all loose
materials shall be removed and the paving replaced in kind. Bridge railings shall
not be placed on a span until centering or falsework has been removed, rendering
the span self-supporting.
Rail elements shall be erected according to Plans and in a manner resulting

in a smooth, continuous installation with laps in the direction of traffic flow. All bolts
except adjustment bolts shall be drawn tight. Bolts shall be of sufficient length to
extend beyond the nuts by more than 25 mm.
Where painting of railing component is specified, any damage to the shop

coat of paint shall be corrected by an application of an approved rust-inhibitive
primer prior to painting. Ungalvanized surfaces inaccessible to painting after
erection shall be field painted before erection. The railing components shall be
given the specified number of coats of paint uniformly applied by thorough brushing
or by approved pressure spray.
161
Galvanized surfaces which have been abraded so that the base metal is
exposed, threaded portions of all fittings and fasteners and cut ends of bolts shall
be painted with two (2) coats of zinc-dust and zinc oxide paint.
401.3.2 Metal Railing
Fabrication and erection shall be done in accordance with the requirements

of Item 403, Metal Structures. In the case of welded railings, all exposed joints shall
be finished by grinding or filing after welding to give a neat appearance.
Metal railing shall be carefully adjusted prior to fixing in-place to insure proper
matching of abutting joints, correct alignment and camber throughout their length.
Holes for field connection shall be drilled with the railing in-place in the structure at
proper grade and alignment. Welding may be substituted for rivets or bolts in field
connections with the approval of the Engineer.
401.3.3 Concrete Railing
1. Railing Cast-In-Place
The portion of the railing or parapet which is to be cast-in-place shall be

constructed in accordance with the requirements of Item 405, Structural
Concrete. Special care shall be exercised to secure smooth and tight fitting
forms which can be rigidly held in line and grade and removed without injury
to the concrete.
Forms shall either be of single width boards or shall be lined with suitable
material to have a smooth surface which shall meet the approval of the
Engineer or as shown on the Plans.
All moldings, panel work and bevel strips shall be constructed according
to the detailed Plans with metered joints, and all corners in the finished work
shall be true, sharp and clean-cut and shall be free from cracks, spalls and
other defects.
2. Precast Railings
Moist tamped mortar precast members shall be removed from the molds
as soon as practicable and shall be kept damp for a period of at least ten
(10) days. Any member that shows checking of soft corners of surfaces shall
be rejected.
Expansion joints shall be constructed as to permit freedom of movement.

After all work is completed, all loose or thin shells of mortar likely to spall
under movement shall be carefully removed from all expansion joints by
means of a sharp chisel.
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401.3.4 Wooden Railing
Wooden railing shall be constructed in accordance with the requirements of

Item 402, Timber Structures.
401.3.5 Stone and Brick Railing
The materials used in masonry brick railing and parapet and the work to be
done shall conform to the requirements of this Specification. The workmanship
shall be first class and the finished construction shall be neat in appearance and
true to line and grade.
The quantity to be paid for shall be the number of linear meters of specified
railing actually completed and accepted measured from center to center of end
posts.
The accepted quality, measured as prescribed in Section 401.4, shall be paid

for at the contract unit price for Railing, which price and payment shall be full
compensation for furnishing and placing all materials including all labor, equipment,
tools and incidentals necessary to complete this Item.
Pay Item Description Unit of Measurement

Number
401 Railing Meter
ITEM 402 – TIMBER STRUCTURES
402.1 Description
This Item shall consist of the construction of timber structures to the

dimensions, lines and grades as shown on the Plans or as ordered by the Engineer
in accordance with these Specifications. The timber shall be treated or untreated
as called for on the Plans or Special Provisions.
163
402.2.1 Timber
It shall conform to the requirements of Item 713, Treated and Untreated

Timber.
402.2.2 Hardware
All hardware shall be of the kind and size specified on the Plans. All bolts,
including drift bolts, shall be either wrought iron or medium steel. Washers shall be
either ogee gray iron casting or malleable cast iron unless cut washers are specified
on the Plans.
Bolts shall have square heads and nuts, unless otherwise specified. Nails
shall be cut or round wire of standard form. Spikes shall be cut wire or spikes, or
boat spikes, as specified. All hardware shall be galvanized in conformity with
AASHTO M 232 or cadmium plated per ASTM M 165 Type OS, unless otherwise
specified on the Plans or Special Provisions.
402.2.3 Paint
It shall conform to the requirements of Item 709, Paints or Item 411, Paint.
402.2.4 Structural Steel
It shall conform to the applicable requirements of Item 712, Structural Metal.
402.2.5 Preservatives
The preservative shall be creosote oil or creosote petroleum oil blend as

called for on the Plans or by the Special Provisions, and shall conform to the
Specifications for timber preservatives of the AASHTO M 133.
When timber is intended for marine use, creosote petroleum oil blend shall
not be used.
402.3.1 Storage of Materials
All timber which is to be stored on the job for any length of time prior to its
use in the structure shall be neatly stacked in piles to prevent warping or distortion.
Untreated timber shall be open-stacked at least 300mm above the ground and the
stack shall be sloped so as to shed water. Creosote-treated timber shall be close-
stacked and piled to prevent warping. The ground under-neath and in the vicinity
of all material piles shall be cleared of all weeds and rubbish.
402.3.2 Treated Timber
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All treated timber shall be framed prior to treating. Care shall be exercised
in handling all treated timber so as not to break or penetrate the treatment with any
tool or handling equipment. Any piece of timber that has been damaged by the
Contractor shall be replaced by him without extra compensation.
Any cut made or hole bored in treated timber that shall expose untreated
wood shall be given three coats of hot creosote or carbolineum before the exposed
part is assembled.
402.3.3 Timber Treatment
Treatment shall consist of the forcing of either creosote oil or a creosote-

process. The treatment shall be so regulated that the curing process will not induce
excessive checking.
The minimum penetration of the preservative with the surface of the timber
shall be 20mm. The minimum retention of preservative per cubic metre of timber
shall be as follows:
For general use, 195 kg by empty cell process
For marine use, 320 kg by full cell process
The Engineer shall be notified at least ten (10) days in advance of the date
that the treating process will be performed in order that the untreated timber, the
treatment process, and the finished treated timber may all be inspected. The
Engineer will inspect the timber prior to treatment to determine conformance with
the Specifications and suitability of conditions for treatment. He shall be permitted
free access to the plant in order that temperatures, pressures and quantities and
types of treatment materials used may be observed. Samples of the creosote or
creosote-petroleum mixture shall be furnished as required for tests.
After completion of the treatment, the timber shall be checked to determine

penetration of treatment, amount of checking, quantity of free preservative
remaining of the timber and any other visual evidence that the treatment has been
performed in a satisfactory manner. The penetration of treatment shall be
determined by boring a sufficient number of well-distributed holes to determine the
average penetration. All such holes shall be plugged with plugs approximately 2mm
larger in diameter than the bit used in boring the holes.
charge, or such parts thereof as are determined by the Engineer or his authorized
representative to be unsatisfactory, may be retreated. If after retreatment, the
penetration is still insufficient, the retreatment pieces shall be rejected.
Any excessive checking caused by the treating process shall be cause for
rejection of the pieces in which the excessive checking occurs.
165
The treating plant shall be equipped with adequate thermometers and
pressure gages so that the process can be accurately controlled and a continuous
record made of stages of the treating process. If requested by the Engineer,
records shall be furnished showing the duration, maximum and minimum
temperatures and pressures used during all stages of the process.
402.3.4 Untreated Timber
In structures of untreated timber, all of the following surfaces shall be coated

thoroughly with two (2) coats of hot creosote oil or carbolineum before the timber
are assembled: ends, tops and all contact surfaces of posts, sills, caps, floor beams
and stringers, all ends, joints and contact surfaces of bracing. The back surface of
all bulkheads and any other timber in direct contact with earth shall be similarly
treated.
402.3.5 Bolts and Washers
Washers of the size and type specified shall be used under all bolt heads
and nuts that would otherwise be in contact with wood. Cast iron washers shall
have a thickness equal to one fourth the diameter of the bolt and the diameter of
the washer shall be four times its thickness. For malleable or plate washers, the
diameter or side size of the square shall be equal to four times the diameter of the
bolt. Cap washers shall be used when the timber is in contact with earth. All nuts
shall be checked effectively after being finally tightened.
402.3.6 Pile Bents
The pile shall be driven as indicated on the Plans, with a variation of the
portion above the ground of not more than 6mm per 300mm from the vertical or
batter indicated, or so that the cap may be placed in its proper location without
inducing excessive stresses on the piles. Excessive manipulation of piles will not
be permitted and the Contractor will be required to redrive or use other satisfactory
methods to avoid such manipulations. No shimming on tops of piles will be
permitted.
The piles for any one bent shall be carefully selected as to size and quality
to avoid undue bending or distortion of the sway bracing. However, care shall be
exercised in the distribution of piles of various sizes to secure uniform strength and
rigidity in the bents of any given structure. Cut offs shall be accurately made to
insure perfect hearing between caps and piles.
402.3.7 Frame Bents
Concrete pedestal for the support of framed bents shall be finished carefully
so that sills or posts will take even bearing on them. Dowels for anchoring sills or
posts shall be set the concrete is cast and shall project at least 150mm above the
tops of the pedestals.
Sills shall have true and even bearing on piles or pedestals. They shall be
drift-bolted with bolts extending into the piles or pedestals at least 150mm. When
166
possible, all earth shall be removed from contact with sills so that there will be free
circulation of air around the sills.
402.3.8 Caps
Timber caps shall be placed to obtain even and uniform bearing over the
tops of the supporting posts or piles with their ends in alignment. All caps shall be
secured by driftbolts, set approximately at the center extending at least 230mm into
the post or piles.
402.3.9 Bracing
Bracing shall be bolted through at intersections to the pile, posts, caps or

sills.
402.3.10 Stringers
Stringers shall be sized at bearings and shall be placed in position so that

knots near the edges will be in the top portions of the stringers. Outside stringers
may have butt joints but interior stringers shall be lapped to take bearing over the
full width of the floor beam or cap at each end. The lapped ends of untreated
stringers shall be securely fastened to caps by driftbolts. When stringers are two
panels in length, the joints shall be staggered. Cross-bridging between stringers
shall be neatly and accurately framed and securely toe-nailed with at least two nails
at each end. All cross-bridging members shall have full bearing at each end against
the sides of stringers. Unless otherwise specified, cross bridging shall be placed at
the center of each span.
402.3.11 Plank Floors
Roadway and sidewalk floor planks, unless otherwise stipulated, shall be

surfaced one side and one edge (SISIE). The planks shall be laid heartside down,
with 7mm openings between them for seasoned materials and with tight joints for
unseasoned material. Each plank shall be spiked securely to each joint or
supporting member. The planks shall be graded carefully as to thickness, and so
laid that no two adjacent planks shall vary in thickness by more than 1.6mm.
402.3.12 Laminated or Strip Floors
Planks for laminated or strip floors shall have a nominal thickness of 50mm
and shall be surfaced to a uniform width (SIE), and when so specified, to a uniform
thickness (SIS). Unless otherwise stipulated, no splicing of planks will be allowed.
Planks shall be laid with the surfaced edge down and each plank shall be
toe-nailed to each alternative stringer. The nailing of successive planks shall be
staggered so that the spacing of nails along each stringer shall not be less than
100mm. In addition, each piece shall be nailed horizontally to adjacent pieces at
450mm centers, and staggered both horizontally and vertically with nails in adjacent
pieces. All floors shall be cut to a straight line along the sides of the roadway.
167
402.3.13 Railing and Rail Posts
Railing and rail posts shall be built as shown on the Plans and shall be
constructed in a workmanlike and substantial manner. All railing and rail post
materials shall be surfaced on four sides (S4S). All rails shall be continuous and
squarely butt-joined at the post.
402.3.14 Wheel Guards
Wheel guards shall be accurately constructed true to line and grade in

accordance with the Plans.
Unless otherwise specified, wheel guards shall be surfaced on one side and
one edge (SISIE). Wheel guards shall be laid in sections not less than 3.60mm
long.
Timber structures shall be measured by the completed span and shall

include all materials, equipment and labor used to finish the structure as called for
in the Bid, Plans and Specifications.
Payment for the timber structure measured in Section 402.4, Method of

Measurement, shall constitute full compensation for furnishing all materials,
preservative treatment, if called for in the Contract, equipment, hardware and other
metal parts, tools and labor necessary for the completion of the structure and
painting, if required in a satisfactory manner and all incidentals necessary to
complete the Item.
Pay Item Number Description Unit of Measurement
402 (1) Timber Structure Span
ITEM 403 – METAL STRUCTURES
403.1 Description
This work shall consist of steel structures and the steel structure portions of
composite structures, constructed in reasonably close conformity with the lines,
grades and dimensions shown on the Plans or established by the Engineer.
168
The work will include the furnishing, fabricating, hauling, erecting, welding
and painting of structural metals called for in the Special Provision or shown on the
Plans. Structural metals will include structural steel, rivet, welding, special and
alloy steels, steel forgings and castings and iron castings. This work will also
include any incidental metal construction not otherwise provided for, all in
accordance with these Specifications, Plans and Special Provisions.
Materials shall meet the requirements of Item 712, Structural Metal; Item
409, Welded Structural Steel, and Item 409, Welded Structural Steel; and Item 709,
Paints.
403.3.1 Inspection
The Contractor shall give the Engineer at least fifteen (15) days notice prior
to the beginning of work at the mill or shop, so that the required inspection may be
made. The term “mill” means any rolling mill, shop or foundry where material for
the work is to be manufactured or fabricated. No material shall be rolled or
fabricated until said inspection has been provided.
The Contractor shall furnish the Engineer with copies of the certified mill
reports of the structural steel, preferably before but not later than the delivery of the
steel to the job site.
The Contractor shall furnish all facilities for inspection and the Engineer shall
be allowed free access to the mill or shop and premises at all times. The Contractor
shall furnish, without charge, all labor, machinery, material and tools necessary to
prepare test specimens.
Inspection at the mill or shop is intended as a means of facilitating the work

and avoiding errors and it is expressly understood that it will not relieve the
Contractor from any responsibility for imperfect material or workmanship and the
necessity for replacing same. The acceptance of any material or finished member
at the mill or shop by the Engineer shall not preclude their subsequent rejection if
found defective before final acceptance of the work. Inspection of welding will be
in accordance with the provision of Section 5 of the “Standard Code for Arc and
Gas Welding in Building Construction” of the American Welding Society.
403.3.2 Stock Material Control
When so specified in the Contract, stock material shall be segregated into

classes designated as “identified” or “unidentified”. Identified material is material
which can be positively identified as having been rolled from a given heat for which
certified mill test can be produced. Unidentified material shall include all other
general stock materials. When it is proposed to use unidentified material, the
Engineer shall be notified of such intention at least fifteen (15) days in advance of
commencing fabrication to permit sampling and testing. When so indicated or
169
directed, the Contractor shall select such material as he wishes to use from stock,
and place it in such position that it will be accessible for inspection and sampling.
The Contractor shall select identified material from as few heat numbers as
possible, and furnish the certified mill test reports on each of such heat numbers.
Two samples shall be taken from each heat number as directed, one for a tension
test and one for a bend test.
In the case of unidentified stock, the Engineer may, at his discretion, select
any number of random test specimens.
Each bin from which rivets or bolts are taken shall subject to random test.
Five rivets or bolts may be selected by the Engineer from each bin for test purposes.
Structural material, either plain or fabricated, shall be stored above the

ground upon platforms, skids, or other supports. It shall be kept free from dirt,
grease, or other foreign matter, and shall be protected as far as practicable from
corrosion.
403.3.3 Fabrication
These Specifications apply to riveted, bolted and welded construction. The

Contractor may, however, with approval of the Engineer, substitute high tensile
strength steel bolts equivalent to the rivets in any connection.
Workmanship and finish shall be in accordance with the best general

practice in modern bridge shops. Portions of the work exposed to view shall be
finished neatly. Shearing, flame cutting, and chipping shall be done carefully and
accurately.
Structural material, either plain or fabricated, shall be stored above the

ground upon platforms, skids or other supports. It shall be kept free from dirt,
grease or other foreign matter, and shall be protected as far as practicable from
corrosion.
Rolled material before being laid off or worked must be straight. If

straightening is necessary, it shall be done by methods that will not injure the metal.
Sharp kinks and bends will be cause for rejection of the material.
Preparation of material shall be in accordance with AWS (American Welding

Society) D 1.1, paragraph 3.2 as modified by AASHTO Standard Specification for
Welding of Structural Steel Highway Bridges.
403.3.4 Finishing and Shaping
Finished members shall be true to line and free from twists, bends and open
joints.
1. Edge Planing
170
Sheared edges of plates more than 15.9 mm in thickness and
carrying calculated stresses shall be planed to a depth of 6.3 mm. Re-
entrant cuts shall be filleted before cutting.
2. Facing of Bearing Surfaces
The surface finish of bearing and based plates and other bearing
surfaces that are to come in contact with each other or with concrete
shall meet the American National Standards Institute surface
roughness requirements as defined in ANSI B-46.1-47, Surface
Roughness Waviness and Lay, Part I:
Steel slabs ANSI 2,000

Heavy plates in contact in shoes to
Be welded ANSI 1,000
Milled ends of compression
members, ANSI 500
stiffeners and fillers
Bridge rollers and rockers ANSI 250
Pins and pin holes ANSI 125
Sliding bearings ANSI 125
3. Abutting Joints
Abutting joints in compression members and girders flanges, and in

tension members where so specified on the drawings, shall be faced
and brought to an even bearing. Where joints are not faced, the
opening shall not exceed 6.3 mm.
4. End Connection Angles
Floor beams, stringers and girders having end connection angles

shall be built to plan length back to back of connection angles with a
permissible tolerance of 0 mm to minus 1.6 mm. If end connections
are faced, the finished thickness of the angles shall not be less than
that shown on the detail drawings, but in no case less than 9.5 mm.
5. Lacing Bars
The ends of lacing bars shall be neatly rounded unless another form
is required.
6. Fabrication of Members
Unless otherwise shown on the Plans, steel plates for main

members and splice plates for flanges and main tension members, not
secondary members, shall be cut and fabricated so that the primary
direction of rolling is parallel to the direction of the main tensile and/or
compressive stresses.
171
Fabricated members shall be true to line and free from twists, bends
and open joints.
7. Web Plates (Riveted or Bolted)
In girders having no cover plates and not to be encased in concrete,

the top edges of the web shall not extend above the backs of the flange
angles and shall not be more than 3.2 mm below at any point. Any
portion of the plate projection beyond the angles shall be chipped flush
with the backs of the angles. Web plates of girders having cover plates
may not be more than 12.7 mm less in width than the distance back to
back of flange angles.
Splices in webs of girders without cover plates shall be sealed on

top with red lead paste prior to painting.
At web splices, the clearance between the ends of the plates shall
not exceed 9.5 mm. The clearance at the top and bottom ends of the
web slice plates shall not exceed 6.3 mm.
8. Bent Plates
Cold-bent load-carrying rolled-steel plates shall conform to the

following:
a. They shall be so taken from the stock plates that the bendline will
be at right angles to the direction of rolling, except that cold-bent ribs
for orthotropic deck bridges may be bent in the direction of rolling if
permitted by the Engineer.
b. The radius of bends shall be such that no cracking of the plate

occurs. Minimum bend radii, measured to the concave face of the
metal, are shown in the following table:
ASTM THICKNESS, t in mm
DESIG- Up to Over 6.3 Over 12.7 Over 25.4 Over 38.1
ATION 6.3 To 12.7 To 25.4 to 38.1 to 50.08
A36 1.5t 1.5t 2t 3t 4t
A242 2t 3t 5t a--- a---
A440 2.5t 3.5t 6t a--- a---
A441 2t 3t 5t a--- a---
A529 2t 2t ---- ---- ----
Gr.42 2t 2t 3t 4t 5t
Gr.45 2t 2t 3t 4t ----
Gr.50 2.5t 2.5t 4t a--- ----
Gr.55 3t 3t 5t a--- ----
Gr.60 3.5t 3.5t 6t ---- ----
172
Gr.65 4t 4t ---- ---- ----
A572
A588 2t 3t 5t a--- a---
A514b 2t 2t 3t 3t
2
t
a
It is recommended that steel in this thickness range be bent hot. Hot bending
however, may result in a slight decrease in the as-rolled mechanical
properties.
b
The mechanical properties of ASTM A 514 steel results from a quench-and-
temper-operation. Hot bending may adversely affect these mechanical
properties. If necessary to hotbend, fabricator should discuss procedure with
steel supplier.
c. Before bending, the corners of the plate be rounded to a radius of

1.6 mm throughout that portion of the plate where the bending is to
occur.
9. Fit of Stiffeners
End stiffeners of girders and stiffeners intended as supports for

concentrated loads shall have full bearing (either milled, ground or on
weldable steel in compression areas of flanges, welded as shown on
the Plans or specified) on the flanges to which they transmit load or
from which they receive load. Stiffeners not intended to support
concentrated loads shall, unless shown or specified otherwise, fit
sufficiently tight to exclude water after being painted, except that for
welded flexural members, the ends of stiffeners adjacent to the tension
flanges shall be cut back as shown on the Plans. Fillers under
stiffeners shall fit within 6.3 mm at each end.
Welding will be permitted in lieu of milling or grinding if noted on the

Plans or in the Special Provisions. Brackets, clips, gussets, stiffeners,
and other detail material shall not be welded to members or parts
subjected to tensile stress unless approved by the Engineer.
10. Eyebars
Pin holes may be flame cut at least 50.8 mm smaller in diameter

than the finished pin diameter. All eyebars that are to be placed side
by side in the structure shall be securely fastened together in the order
that they will be placed on the pin and bored at both ends while so
clamped. Eyebars shall be packed and matchmarked for shipment and
erection. All identifying marks shall be stamped with steel stencils on
the edge of one head of each member after fabrication is completed so
as to be visible when the bars are nested in place on the structure. The
eyebars shall be straight and free from twists and the pin holes shall be
173
accurately located on the centerline of the bar. The inclination of any
bar to the plane of the truss shall not exceed 1.6 mm to 305 mm.
The edges of eyebars that lie between the transverse centerline of

their pin holes shall be cut simultaneously with two mechanically
operated torches abreast of each other, guided by a substantial
template, in such a manner as to prevent distortion of the plates.
11. Annealing and Stress Relieving
Structural members which are indicated in the Contract to be

annealed or normalized shall have finished machining, boring and
straightening done subsequent to heat treatment. Normalizing and
annealing (full annealing) shall be in accordance with ASTM E 44. The
temperatures shall be maintained uniformly throughout the furnace
during heating and cooling so that the temperature at no two points on
the member will differ by more than 37.80C at any one time.
Members of A514/A517 steels shall not be annealed or normalized

and shall be stress relieved only with the approval of the Engineer.
A record of each furnace charge shall identify the pieces in the

charge and show the temperatures and schedule actually used. Proper
instruments including recording pyrometers, shall be provided for
determining at any time the temperatures of members in the furnace.
The records of the treatment operation shall be available to and meet
the approval of the Engineer.
Members, such as bridge shoes, pedestals, or others which are built

up by welding sections of plate together shall be stress relieved in
accordance with the provisions of Subsection 403.3.11 when required
by the Plans, Specifications or Special Provisions governing the
Contract.
12. Tests
When full size tests of fabricated structural members or eyebars are

required by the Contract, the Plans or Specifications will state the
number and nature of the tests, the results to be attained and the
measurements of strength, deformation or other performances that are
to be made. The Contractor will provide suitable facilities, material,
supervision and labor necessary for making and recording the tests.
The members tested in accordance with the Contract will be paid for in
accordance with Subsection 403.3.5.1. The cost of testing, including
equipment handling, supervision labor and incidentals for making the
test shall be included in the contract price for the fabrication or
fabrication and erection of structural steel, whichever is the applicable
item in the Contract, unless otherwise specified.
403.3.5 Pins and Rollers
174
Pins and rollers shall be accurately turned to the dimensions shown on the
Plans and shall be straight, smooth, and free from flaws. Pins and rollers more
228.6 mm or less in diameter may either be forged and annealed. Pins and rollers
228.6 mm or less in diameter may either be forged and annealed or cold-finished
carbon-steel shafting.
In pins larger than 228.6 mm in diameter, a hole not less than 50.8 mm in
diameter shall be bored full length along the axis after the forging has been allowed
to cool to a temperature below the critical range under suitable conditions to prevent
injury by too rapid cooling and before being annealed.
Pin holes shall be bored true to the specified diameter, smooth and straight,
at right angles with the axis of the member and parallel with each other unless
otherwise specified. The final surface shall be produced by a finishing cut.
The distance outside to outside of holes in tension members and inside to

inside of holes in compression members shall not vary from that specified more
than 0.8 mm. Boring of holes in built-up members shall be done after the riveting
is completed.
The diameter of the pin hole shall not exceed that of the pin by more than
0.51 mm for pins 127 mm or less in diameter, or 0.8 mm for larger pins.
The pilot and two driving nuts for each size of pin shall be furnished, unless
otherwise specified.
403.3.6 Fastener Holes (Rivets and Bolts)
All holes for rivets or bolts shall be either punched or drilled. Material forming
parts or a member composed of not more than five thickness of metal may be
punched 1.6 mm larger than the nominal diameter of the rivets or bolts whenever
the thickness of the material is not greater than 19 mm for structural steel, 15.9 mm
for high-strength steel or 12.7 mm for quenched and tempered alloy steel, unless
subpunching and reaming is required for field connections.
When there are more than five thicknesses or when any of the main material
is thicker than 19 mm for structural steel, 15.9 mm for high-strength steel, or 12.7
mm for quenched and tempered alloy steel, all holes shall either be subdrilled or
drilled full size.
When required for field connections, all holes shall either be subpunched or
subdrilled (subdrilled if thickness limitation governs) 4.8 mm smaller and, after
assembling, reamed 1.6 mm larger or drilled full size 1.6 mm larger than the nominal
diameter of the rivets or bolts.
When permitted by design criteria, enlarged or slotted holes are allowed with
high-strength bolts. For punched holes, the diameter of the die shall not exceed
175
the diameter of the punch by more than 1.6 mm. If any holes must be enlarged to
admit the fasteners, they shall be reamed. Holes shall be clean cut, without torn
or ragged edges. Poor matching of holes will be cause for rejection.
Reamed holes shall be cylindrical, perpendicular to the member, and not

more than 1.6 mm larger than the nominal diameter of the fasteners. Where
practicable, reamers shall be directed by mechanical means. Drilled holes shall be
1.6 mm larger than the nominal diameter of the fasteners. Burrs on the outside
surfaces shall be removed. Poor matching of holes will be cause for rejection.
Reaming and drilling shall be done with twist drills. If required by the Engineer,
assembled parts shall be taken apart for removal of burrs caused by drilling.
Connecting parts requiring reamed or drilled holes shall be assembled and securely
held while being reamed or drilled and shall be matchmarked before disassembling.
Unless otherwise specified, holes for all field connections and field splices of
main truss or arch members, continuous beams, towers (each face), bents, plate
girders and rigid frames shall be subpunched (or subdrilled if subdrilling is required)
and subsequently reamed while assembled in the shop in accordance with
Subsection 403.3.7.
All holes for floor-beam and stringer field end connections shall be
subpunched and reamed to a steel template reamed while being assembled.
Reaming or drilling full size of field connection through templates shall be

done after templates have been located with the utmost care as to position and
angle and firmly bolted in place. Templates used for the reaming of matching
members, or of the opposite faces of one member, shall be exact duplicated.
Templates for connections which duplicate shall be so accurately located that like
members are duplicates and require no matchmarking.
If additional subpunching and reaming is required, it will be specified in the

Special Provisions or on the Plans.
Alternately, for any field connection or splice designated above in lieu of sub-
sized holes and reaming while assembled, or drilling holes full-size while
assembled, the Contractor shall have the option to drill bolt holes full-size in
unassembled pieces and/or connections including templates for use with matching
sub-sized and reamed holes means of suitable numerically-controlled (N/C) drilling
equipment subject to the specific provisions contained in this Subsection.
If N/C drilling equipment is used, the Engineer, unless otherwise stated in

the Special Provisions or on the Plans, may require the Contractor, by means if
check assemblies to demonstrate that this drilling procedure consistently produces
holes and connections meeting the requirements of conventional procedures.
The Contractor shall submit to the Engineer for approval a detailed outline of
the procedures that he proposes to follow in accomplishing the work from initial
drilling through check assembly, if required, to include the specific members of the
structure that may be N/C drilled, the sizes of the holes, the location of common
176
index and other reference points, composition of check assemblies and all other
pertinent information.
Holes drilled by N/C drilling equipment shall be drilled to appropriate size

either through individual pieces, or any combination of pieces held tightly together.
All holes punched full size, subpunched or subdrilled shall be so accurately

punched that after assembling (before any reaming is done), a cylindrical pin 3.2
mm smaller in diameter than the nominal size of the punched hole may be entered
perpendicular to the face of the member, without drifting, in at least 75 percent of
the contiguous holes in the same plane. If the requirement is not fulfilled, the badly
punched pieces will be rejected. If any hole will not pass a pin 4.8 mm smaller in
diameter than the nominal size of the punched holes, this will cause for rejection.
When holes are reamed or drilled, 85 percent of the holes in any continuous
group shall, after reaming or drilling, show no offset greater than 0.8 mm between
adjacent thickness of metal.
All steel templates shall have hardened steel bushings in holes accurately
dimensioned from the center lines if the connections as inscribed on the template.
The center lines shall be used in locating accurately the template from the milled or
scribed ends of the members.
403.3.7 Shop Assembly
1. Fitting for Riveting and Bolting

Surfaces of metal in contact shall be cleaned before assembling.
The parts of a member shall be assembled, well pinned and firmly
drawn together with bolts before reaming or riveting is commenced.
Assembled pieces shall be taken apart, if necessary, for the removal
of burrs and shavings produced by the reaming operation. The
member shall be free from twists, bends and other deformation.
Preparatory to the shop riveting of full-sized punched material, the
rivet holes, if necessary, shall be spear-reamed for the admission of
the rivets. The reamed holes shall not be more than 1.6 mm larger
than the nominal diameter of the rivets.
End connection angles, and similar parts shall be carefully

adjusted to correct positions and bolted, clamped, or otherwise firmly
in place until riveted.
Parts not completely riveted in the shop shall be secured by bolts,

in so far as practicable, to prevent damage in shipment and handling.
2. Shop Assembling
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The field connections of main members of trusses, arches,
continuous beam spans, bents, towers (each face), plate girders and
rigid frames shall be assembled in the shop with milled ends of
compression members in full bearing, and then shall have their sub-
size holes reamed to specified size while the connections are
assembled. Assembly shall be “Full Truss or Girders Assembly”
unless “Progressive Chord Assembly” or “Special Complete Structure
Assembly” is specified in the Special Provisions or on the Plans.
Check assemblies with Numerically-Controlled Drilled Fields

Connections shall be in accordance with the provision of 2 (f) of this
Subsection.
Each assembly, including camber, alignment, accuracy of holes

and fit of milled joints, shall be approved by the Engineer before
reaming is commenced or before an N/C drilled check assembly is
dismantled.
The fabricator shall furnished the Engineer a camber diagram

showing the camber at each panel point in the cases of trusses or
arch ribs and at the location of field splices and fractions of span
length (0.25 points minimum, 0.10 points maximum) in case of
continuous beam and girders or rigid frames. When the shop
assembly is Full Truss or Girder Assembly or Special Complete
Structure Assembly, the camber diagram shall show the camber
measured in assembly. When any of the other methods of shop
assembly is used, the camber diagram shall show calculated camber.
Methods of assembly shall be described below:
a. Full of Truss or Girders Assembly shall consist of assembling

all members of each truss, arch rib, bent, tower face,
continuous beam line, plate girder or rigid frame at one time.
b. Progressive Truss or Girder Assembly shall consist of

assembling initially for each truss, arch rib, bent, tower face,
continuous beam line, plate girder, or rigid frame all members
in at least three continuous shop sections or panels but not less
than the number of panels associated with three continuous
chord lengths (i.e., length between field splices) and not less
than 45.72 m in case of structures longer than 45.72 m. At
least one shop section or panel or as many panels as are
associated with a chord length shall be added at the advancing
end of the assembly before any member is removed from the
rearward end so that the assembled portion of the structure is
never less than that specified above.
c. Full Chord Assembly shall consist of assembling with

geometric angles at the joints, the full length of each chord or
each truss or open spandrel arch, or each leg of each bent or
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tower, than reaming their field connection holes while the
members are assembled; and reaming the web member
connections to steel templates set at geometric (not cambered)
angular relation to the chord lines. Field connection holes in
web members shall be reamed to steel templates. At least
one end of each web member shall be milled or shall be scribed
normal to the longitudinal axis of the member and the
templates of both ends of the member shall be accurately
located from one of the milled ends or scribed line.
d. Progressive Chord Assembly shall consist of assembling

contiguous chord members in the manner specified for Full
Chord Assembly, and in the number and length specified for
Progressive Truss or Girder Assembly.
e. Special Complete Structure Assembly shall consist of

assembling the entire structure, including the floor system.
(This procedure is ordinarily needed only for complicated
structures such as those having curbed girders, or extreme
skew in combination with severe grade or camber). The
assembly including camber, alignment, accuracy of holes and
fit of milled joints shall be approved by the Engineer before
reaming is commenced.
A Contractor shall furnished the Engineer a camber

diagram showing the camber at each panel point of each truss,
arch rib, continuous beam line, plate girder or rigid frame.
When shop assembly is Full Truss or Girder Assembly or
Special Complete Structure Assembly, the camber diagram
shall show the camber measured in assembly. When any of
the other methods of shop assembly is used, the camber
diagram shall show calculated camber.
f. Check Assemblies with Numerically-Controlled Drilled Field

Connections. A check assembly shall be required for each
major structural type of each project, unless otherwise
designated on the Plans or in the Special Provisions, and shall
consist of at least three contiguous shop sections or, in a truss,
all members in at least three contiguous panels but not less
than the number of panels associated with three contiguous
chord lengths (i.e., length between field splices). Check
assemblies should be based on the proposed order erection,
joints in bearings, special complex points, and similar
considerations. Such special points could be the portals of
skewed trusses, etc.
Use of either geometric angles (giving theoretically zero secondary

stresses under deadload conditions after erection) or cambered angles
(giving theoretically zero secondary stresses under no-load conditions)
should be designated on the Plans or in the Special Provisions.
179
The check assemblies shall be preferably be the first such sections of
each major structural type to be fabricated.
No matchmaking and no shop assemblies other than the check

assemblies shall be required.
If the check assembly fails in some specific manner to demonstrate

that the required accuracy is being obtained, further check assemblies
may be required by the Engineer for which there shall be no additional
cost to the contracting authority.
403.3.8 Rivets and Riveting
The size of rivets called for on the Plans shall be the size before heating.
Rivet heads shall be of standard shape, unless otherwise specified, and of uniform
size for the same diameter of rivet. They shall be full, neatly made, concentric with
the rivets holes, and in full contact with the surface of the member. Sufficient rivets
for field connections shall be furnished to rivet the entire structure with an ample
surplus to replace all rivets burned, lost or cut out.
Rivets shall be heated uniformly to a “light cherry red color” and shall be
driven while hot. Any rivet whose point is heated more than the remainder shall
not be driven. When a rivet is ready for driving, it shall be free from slag, scale and
other adhering matter. Any rivet which is sealed excessively, will be rejected.
All rivets that are loose, burned, badly formed, or otherwise defective shall
be removed and replaced with satisfactory rivets. Any rivet whose head is defective
in size or whose head is driven off center will be considered defective and shall be
removed. Stitch rivets that are loosened by driving of adjacent rivets shall be
removed and replaced with satisfactory rivets. Caulking, recapping, or double
gunning of rivets heads will not be permitted.
Shop rivets shall be driven by direct-acting rivet machines when practicable.

Approved bevelled rivet sets shall be used for forming rivet heads on sloping
surfaces. When the use of a direct-acting rivet machine is not practicable,
pneumatic hammers of approved size shall be used. Pneumatic bucking tools will
be required when the size and length of the rivets warrant their use.
Rivets may be driven cold provided their diameter is not over 9.5 mm.
403.3.9 Bolted Connections, Unfurnished, Turned and Ribbed Bolts
1. General
Bolts under this Subsection shall conform to “Specifications for

Carbon Steel Externally and Internally Threaded Standard
Fasteners”, ASTM A 307. Specifications for high strength bolts are
covered under Subsection 403.3.10.
180
Bolts shall be unfinished, turned or an approved form of ribbed
bolts with hexagonal nuts and heads except that ribbed bolts shall
have button heads. Bolted connections shall be used only as
indicated by the Plans or Special Provisions. Bolts not tightened to
the proof loads shall have single self locking nuts or double nuts.
Bevel washers shall be used where bearing faces have a slope or
more than 1:20 with respect to a plane normal to the bolt axis. Bolts
shall be of such length that will extend entirely through their nuts but
not more than 6.3 mm beyond them.
Bolts shall be driven accurately into the holes without damage to

the threads. A snap shall be used to prevent damage to the heads.
The heads and nuts shall be drawn tight against the work with the full
effort of a man using a suitable wrench, not less than 381 mm long for
bolts of nominal diameter 19 mm and over. Heads of bolts shall be
tapped with a hammer while the nuts are being tightened.
2. Unfinished Bolts
Unfinished bolts shall be furnished unless other types are

specified. The number of bolts furnished shall be 5 percent more
than the actual number shown on the Plans for each size and length.
3. Turned Bolts
The surface of the body of turned bolts shall meet the ANSI
roughness rating value of 125. Heads and nuts shall be hexagonal
with standard dimensions for bolts of the nominal size specified or the
next larger nominal size. Diameter of threads shall be equal to the
body of the bolt or the nominal diameter of the bolt specified. Holes
for turned bolts shall be carefully reamed with bolts furnished to
provide for a light driving fit. Threads shall be entirely outside of the
holes. A washer shall be provided under the nut.
4. Ribbed Bolts
The body of ribbed shall be of an approved form with continuous

longitudinal ribs. The diameter of the body measured on a circle
through the points of the ribs shall be 1.98 mm greater than the
nominal diameter specified for the bolts.
Ribbed bolts shall be furnished with round heads conforming to

ANSI B 18.5 unless otherwise specified. Nuts shall be hexagonal,
either recessed or with a washer of suitable thickness. Ribbed bolts
shall make a driving fit with the holes. The hardness of the ribs shall
be such that the ribs do not mash down enough to permit the bolts to
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turn in the holes during tightening. If for any reason the bolt twists
before drawing tight, the holes shall be carefully reamed and an
oversized bolt used as a replacement. The Contractor shall provide
and supply himself with oversize bolts and nuts for this replacement
in an amount not less than ten percent (10%) of the number of ribbed
bolts specified.
403.3.10 Bolted Connections (High Tensile-Strength Bolts)
1. Bolts
Bolts shall be AASHTO M 164 (ASTM A 325 or AASHTO M

253) tensioned to a high tension. Other fasteners which meet the
chemical requirements of AASHTO M 164 or M 253 and which meet
the mechanical requirements of the same specification in full size
tests and which have body diameter and bearing areas under the
head and nut, or their equivalents, not less than those provided by a
bolt and nut of the same nominal dimensions prescribed above, may
be used subject to the approval of the Engineer.
Bolts lengths shall be determined by adding the grip-length values

given in Table 403.1 to the total thickness of connected material. The
values of Table 403.1 compensate for manufacturer’s tolerance, the
use of heavy semi-finished hexagon nut and a positive “stick-through”
at the end of the bolt. For each hardened flat washer that is used
and 4 mm to the tabular value and for each bevelled washer add 7.9
mm. The length determined shall be adjusted to the next longer 6.3
mm.
Table 403.1 – Grip-Length Values
Bolts Size (mm) To determine required

bolt length, add grip
(mm) *
9.5 17.5
12.7 22.2
19.0 25.4
22.2 28.6
25.4 31.7
28.6 38.1
31.7 41.3
34.9 44.4
38.1 47.6
* Does not include allowance for washer thickness
2. Bolted Parts
The slope of surface of bolted parts in contact with the bolt head
and nut shall not exceed 1:20 with respect to a plane normal to the
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bolt axis. Bolted parts shall fit solidly together when assembled and
shall not be separated by gaskets or any other interposed
compressible material. When assembled, all joint surfaces, including
those adjacent to the bolt head, nuts or washers, shall be free of scale,
except tight mill scale, and shall also be free of burrs, dirt and other
foreign material that would prevent solid seating of the parts. Paint
is permitted unconditionally in bearing-type connections.
In friction-type connections, the Class, as defined below, indicating

the condition of the contact surfaces shall be specified on the Plans.
Where no Class is specified, all joint surfaces shall be free of scale,
except tight mill scale and shall not have a vinyl wash.
a. Classes A, B and C (uncoated). Contact surfaces shall be free of

oil, paint, lacquer or other coatings.
b. Class D (hot-dip galvanized and roughened). Contact surfaces

shall be tightly scored by wire brushing or blasting after
galvanizing and prior to assembly. The wire brushing treatment
shall be a light application of manual or power brushing that marks
or scores the surface but remove relatively little of the zinc coating.
The blasting treatment shall be a light “brush-off” treatment which
will produce a dull gray appearance. However, neither treatment
should be severed enough to produce any break or discontinuity
in the zinc surface.
c. Classes E and F (blast-cleaned, zinc rich paint). Contact surfaces

shall be coated with organic or inorganic zinc rich paint as defined
in the Steel Structures Painting Council Specification SSPC 12.00.
d. Classes G and H (blast-cleaned, metallized zinc or aluminum).

Contact surfaces shall be coated in accordance with AWS C2.2,
Recommended Practice for Metallizing with Aluminum and Zinc
for Protection of Iron and Steel, except that subsequent sealing
treatments, described in Section IV therein shall not be used.
e. Class I (vinyl wash). Contact surfaces shall be coated in

accordance with the provisions of the Steel Structure Painting
Council Pretreatment Specifications SSPC PT3.
AASHTO M 164 (ASTM A 325) Type 2 and AASHTO M

253 bolts shall not be galvanized nor shall they be used to connect
galvanized material.
3. Installation
a. Bolt Tension. Each fastener shall be tightened to provide, when

all fasteners in the joints are tight at least the minimum bolt tension
shown in Table 403.2 for the size of fastener used.
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Threaded bolts shall be tightened with properly calibrated
wrenches or by the turn-of-nut method. If required, because of
bolt entering and wrench operation clearances, tightening by
either procedure may be done by turning the bolt while the nut is
prevented from rotating. Impact wrenches, if used, shall be of
adequate capacity and sufficiently supplied with air to perform the
required tightening of each bolt in approximately ten seconds.
AASHTO M 253 and galvanized AASHTO M 164 (ASTM A

325) bolts shall not be reused. Other AASHTO M 164 (ASTM A
325) bolts may be reused, but not more than once, if approved by
the Engineer. Retightening previously tightened bolts which may
have been loosened by the tightening of adjacent bolts shall not
be considered as a reuse.
b. Washers. All fasteners shall have a hardened washer under the

element (nut or bolt head) turned in tightening except that
AASHTO M 164 (ASTM A 325) bolts installed by the turn of the
nut method in holes which are not oversized or slotted may have
the washer omitted. Hardened washers shall be used under both
the head and nut regardless of the element turned in the case of
AASHTO M 253 bolts if the material against which it bears has a
specified yield strength less than 275.76 MPa.
Table 403.2 – Bolt Tension
Minimum Bolt Tension1, kg.

AASHTO M AASHTO M
Bolt Size, 164 253
mm (ASTM A (ASTM A
325) 420)
Bolts Bolts
12.7 5 466 6 758
15.9 8 709 10 569
19.0 12 882 15 821
22.2 13 268 21 999
25.4 23 360 24 312
28.6 25 605 36 786
31.7 32 522 45 858
34.9 38 760 55 111
38.1 47 174 66 905
1
Equals to 70 percent of specified minimum tensile strength bolts. Where
an outer face of the bolted parts has a slope of more than 1:20 with respect
to a Plane normal to the bolt axis, a smooth bevelled washer shall be used
to compensate for the lack of parallel line.
c. Calibrated Wrench Tightening. When Calibrated wrenches are

used to provide the bolt tension as specified above, their setting
shall be such as to induce a bolt tension 5 to 10 percent in excess
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of this value. These wrenches shall be calibrated at least once
each working day by tightening, in a device capable of indicating
actual bolt tension, not less than three typical bolts of each
diameter from the bolts to be installed. Power wrenches shall be
adjusted to installed or cut-out at the selected tension. If manual
torque wrenches are used, the torque indication corresponding to
the calibrating tension shall be noted and used in the installation
of all the tested lot. Nuts shall be turned in the tightening direction
when torque is measured. When using calibrated wrenches to
install several bolts in a single joint, the wrench shall be returned
to “touch-up” bolts previously tightened which may have been
loosened by the tightening of adjacent bolts, until all are tightened
to the prescribed amount.
d. Turn-of-Nut Tightening. When the turn-of-nut method is used to

provide the bolt tension specified in (a) above, there shall first be
enough bolts brought to a “snug tight” condition to insure that the
parts of the joint are brought into full contact with each other.
Snug tight is defined as the tightness attained by a few impacts of
an impact wrench or the full effort of a man using an ordinary spud
wrench. Following this initial operation, bolts shall be placed in
any remaining holes in the connection and brought to snug
tightness.
All bolts in the joints shall then be tightened additionally, by the

applicable amount of nut rotation specified in Table 403.3 with
tightening progressing systematically from the most rigid part of
the joint to its free edges. During this operation, there shall be no
rotation of the part not turned by the wrench.
e. Lock Pin and Collar Fasteners. The installation of lock pin and
collar fasteners shall be by methods approved by the Engineer.
Table 403.3 – Nut Rotation From Snug Tight Condition1
Disposition of Outer Faces of

Bolted Parts
Bolt Length Both faces One face Both faces
measured from normal to normal to bolt sloped not
underside of faces normal axis and other more than 1:20
head to to bolt axis face sloped from normal to
extreme end of not more 1:20 bolt axis (bevel
point (bevel washer washers not
not used) used)
Up to and
including 4 0.33 turn 0.5 turn 0.66 turn
diameters
Over 4
diameters but 0.5 turn 0.66 turn 0.625 turn
185
not exceeding
8 diameters
Over 8
diameters but 0.66 turn 0.83 turn 1 turn
not exceeding
12 diameters2
1 Nut rotation is relative to bolt, regardless of the element (nut or bolt) being
turned. For bolts installed by ½ turn and less the tolerance should be plus or
minus 300, for bolts installed by 2/3 turn and more, the tolerance should be
plus or minus 450.
2
No research work has been performed by the Research Council on Riveted
and Bolted Structural joints to establish the turn-of-nut procedure when bolt
lengths exceed 12 diameters. Therefore, the required rotation must be
determined by actual tests in a suitable tension device simulating the actual
conditions.
4. Inspection
The Engineer will determine that the requirements of these

Specifications are not in the work. When the calibrated wrench
method of tightening is used, the Engineer shall have full opportunity
to witness the calibration tests.
The Engineer will observe the installation and tightening of the

bolts to determine that the selected tightening procedure is properly
used and will determine that all bolts are tightened.
The following inspection shall be used unless a more extensive or

different procedure is specified:
a. The Contractor shall use an inspecting wrench which may either

be a torque wrench or a power wrench that can be accurately
adjusted in accordance with the requirements of Subsection
403.3.10(3) (c) above, in the presence of the Engineer.
b. Three bolts of the same grade, size and condition as those under
inspection shall be placed individually in a calibration device
capable of indicating bolt tension. Length may be any length
representative of bolts used in the structure. There shall be a
washer under the part turned in tightening each bolt.
c. When the inspecting wrench is a torque wrench, each of the three

bolts specified above shall be tightened in the calibration device
by any convenient means to the minimum tension specified for its
size in Table 403.2. The inspecting wrench shall then be applied
to the tightened bolt and the torque necessary to run the nut or
head 5 degrees (approximately 25.4 mm at 304.8 mm radius) in
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the tightening direction shall be determined. The average torque
measured in the tests of three bolts shall be taken as the job
inspection torque to be used in the manner specified below.
d. When the inspecting wrench is a power wrench, it shall be

adjusted so that it will tighten each of the three bolts specified to a
tension at least 5 but not more than 10 percent greater than the
minimum tension specified for its size in Table 403.2. This setting
of wrench shall be taken as the job inspecting torque to be used
in the manner specified below.
e. Bolts, represented by the three samples bolts prescribed above,

which have been tightening in the structure shall be inspected by
applying, in the tightening direction, the inspecting wrench and its
job inspecting torque to 10 percent of the bolts, but not less than
two bolts selected at random in each connection. If no nut or bolt
head is turned by this application of the job inspecting torque, the
connection shall be accepted as properly tightened. If any nut or
bolt head is turned by the application of the job inspecting torque,
this torque shall be applied to all bolts in the connection, and all
bolts whose nut or head is turned by the job inspecting torque shall
be tightened and re-inspected, or alternatively, the fabricator or
erector, at his option may re-tighten all the bolts in the connection
and then resubmit the connection for the specified inspection.
403.3.11 Welding
Welding shall be done in accordance with the best modern practice and the
applicable requirements at AWS D1.1 except as modified by AASHTO “Standard
Specifications for Welding of Structural Steel Highway Bridges”.
403.3.12 Erection
1. General
The Contractor shall provide the falsework and all tools, machinery and
appliances, including driftpins and fitting-up bolts, necessary for the expeditious
handling of the work and shall erect the metal work, remove the temporary
construction, and do all work necessary to complete the structure as required by
the Contract and in accordance with the Plans and these Specifications.
If shown on the Plans or in the Special Provisions, the Contractor shall

dismantle the old structure on the bridge site in accordance with Item 101, Removal
of Structures and Obstructions.
403.3.13 Handling and Storing Materials
Materials to be stored shall be placed on skids above the ground. It shall

be kept clean and properly drained. Girders and beams shall be placed upright
and shored. Long members, such as columns and chords, shall be supported on
187
skids placed near enough together to prevent injury from deflection. If the Contract
is for erection only, the Contractor shall check the material turned over to him
against the shipping lists and report promptly in writing any shortage or damage
discovered. He shall be responsible for the loss of any material while in his care,
or for any damage caused to it after being received by him.
403.3.14 Falsework
The false work shall be properly designed and substantially constructed and
maintained for the loads which will come upon it. The Contractor shall prepare and
submit to the Engineer working drawings for falsework and working drawings for
changes in any existing structure for maintaining traffic, in accordance with Clause
45 of Part G, Div. II, Vol. I.
403.3.15 Method and Equipment
Before starting the work of erection, the Contractor shall inform the Engineer
fully as to the method of erection he proposes to follow, and the amount and
character of equipment he proposes to use, which shall be subject to the approval
of the Engineer. The approval of the Engineer shall not be considered as relieving
the Contractor of the responsibility for the safety of his method or equipment or from
carrying out the work in full accordance with the Plans and Specifications. No work
shall be done until such approval by the Engineer has been obtained.
403.3.16 Straightening Bent Materials
The strengthening of plates, angles, other shapes and built-up members,

when permitted by the Engineer, shall be done by methods that will not produce
fracture or other injury. Distorted members shall be straightened by mechanical
means or, if approved by the Engineer, by the carefully planned and supervised
application of a limited amount of localized heat, except that heat straightening of
AASHTO M 244 (ASTM A 514) or ASTM A 517 steel members shall be done only
under rigidly controlled procedures, each application subject to the approval of the
Engineer. In no case shall the maximum temperature of the AASHTO M 244
(ASTM A 514) or ASTM A 517 steels exceed 607.2 0C, nor shall the temperature
exceed 5100C at the weld metal or within 152.4 mm of weld metal. Heat shall not
be applied directly on weld metal. In all other steels, the temperature of the heated
area shall not exceed 648.90C (a dull red) as controlled by temperature indicating
crayons, liquids or bimetal thermometers.
Parts to be heat-straightened shall be substantially free of stress and from

external forces, except stresses resulting from mechanical means used in
conjunction with the application of heat.
Following the straightening of a bend or buckle, the surface of the metal shall
be carefully inspected for evidence of fracture.
188
403.3.17 Assembling Steel
The parts shall be accurately assembled as shown on the working drawings

and any matchmarks shall be followed. The material shall be carefully handled so
that no parts will be bent, broken or otherwise damaged. Hammering which will
injure or distort the members shall not be done. Bearing surfaces and surfaces to
be in permanent contact shall be cleaned before the members are assembled.
Unless erected by the cantilever methods, truss spans shall be erected on blocking
so placed as to give the trusses proper camber. The blocking shall be left in place
until the tension chord splices are fully connected with permanent fasteners and all
other truss connections pinned and erection bolted. Splices of butt joints of
compression members, that are milled to bear and of railing shall not be
permanently fastened until the spans have been swung, except that such
permanent fastening may be accomplished for the truss members at any time that
joint holes are fair. Splices and field connections shall
have one-half of the holes filled with erection bolts and cylindrical erection pins (half
bolts and half pins) before placing permanent fasteners. Splices and connections
carrying traffic during erection shall have three-fourths of the holes so filled, unless
otherwise permitted by the Engineer.
Fitting-up bolts shall be of the same nominal diameter as the permanent

fasteners and cylindrical erection pins will be 1.6 mm larger.
403.3.18 Riveting
Pneumatic hammers shall be used for field riveting except when the use of
hand tools is permitted by the Engineer. Rivets larger than 15.9 mm in diameter
shall not be driven by hand. Cup-faced dollies, fitting the head closely to insure
good bearing, shall be used. Connections shall be accurately and securely fitted
up before the rivets are driven.
Drifting shall be only such as to draw the parts into position and not sufficient
to enlarge the holes or distort the metal. Unfair holes shall be reamed or drilled.
Rivets shall be heated uniformly to a “light cherry red” color and shall be driven
while hot. They shall not be overheated or burned. Rivet heads shall be full and
symmetrical, concentric with the shank, and shall have full bearing all around. They
shall not be smaller than the heads of the shop rivets. Rivets shall be tight and
shall grip the connected parts securely together. Caulking or recupping will not be
permitted. In removing rivets, the surrounding metal shall not be injured. If
necessary, they shall be drilled out.
403.3.19 Pin Connections
Pilot and driving nuts shall be used in driving pins. They shall be furnished
by the Contractor without charge. Pins shall be so driven that the members will
take full bearing on them. Pin nuts shall be screwed up tight and the threads burred
at the face of the nut with a pointed tool.
403.3.20 Setting Shoes and Bearings
189
Shoes and bearing shall not be placed on bridge seat bearing areas that are
improperly finished, deformed, or irregular. They shall be set level in exact position
and shall have full and even bearing. The shoes and bearing plates may be set by
either of the following methods:
1. Method 1
The bridge seat bearing area shall be heavily coated with red lead
paint and then covered with three layers of 405 to 472 g/m 2 duck, each
layer being coated thoroughly on its top surface with red lead paint.
The shoes and bearing plates shall be placed in position while the
paint is plastic.
As alternatives to canvas and red lead, and when so noted on the

Plans or upon written permission by the Engineer, the following may
be used:
a. Sheet lead of the designated thickness
b. Preformed fabric pad composed of multiple layers of 270 g/m 2

duck impregnated and bound with high quality natural rubber or of
equivalent and equally suitable materials compressed into resilient
pads of uniform thickness. The number of plies shall be such as
to produce the specified thickness, after compression and
vulcanizing. The finished pads shall withstand compression loads
perpendicular to the plane of the laminations of not less than 7
kg/mm2 without detrimental reduction in thickness or extension.
c. Elastomeric bearing pads
2. Method 2
The shoes and bearing plates shall be properly supported and

fixed with grout. No load shall be placed on them until the grout has
set for at least 96 hours, adequate provision being made to keep the
grout well moistened during this period. The grout shall consist of
one part Portland Cement to one part of fine-grained sand.
The location of the anchor bolts in relation to the slotted holes in

expansion shoes shall correspond with the temperature at the time of
erection. The nuts on anchor bolts at the expansion ends shall be
adjusted to permit the free movement of the span.
403.3.21 Preparing Metal Surfaces for Painting
All surfaces of new structural steel which are to be painted shall be blast
cleaned unless otherwise specified in the Special Provisions or approved in writing
by the Engineer.
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In repainting existing structures where partial cleaning is required, the
method of cleaning will be specified in the Special Provision.
The steel surfaces to be painted shall be prepared as outlined in the “Steel

Structures Painting Council Specifications” (SSPC) meeting one of the following
classes of surface preparation.
a. SSPC – SP – 5 White Metal Blast Cleaning

b. SSPC – SP – 6 Commercial Blast Cleaning
c. SSPC – SP – 8 Pickling
d. SSPC – SP – 10 Near White Blast Cleaning
Blast cleaning shall leave all surfaces with a dense and uniform anchor
pattern of not less than one and one-half mills as measured with an approved
surface profile comparator.
Blast cleaned surfaces shall be primed or treated the same day blast
cleaning is done. If cleaned surface rust or are contaminated with foreign material
before painting is accomplished, they shall be recleaned by the Contractor at his
expense.
When paint systems No. 1 or 3 are specified, the steel surfaces shall be blast
cleaned in accordance with SSPC – SP – 10. When paint systems No. 2, 4 or 5
are specified, the steel surface shall be blast cleaned in accordance with SSPC –
SP – 6.
403.3.22 System of Paint
The paint system to be applied shall consist of one as set forth in Table 403.4
and as modified in the Special Provisions.
403.3.23 Painting Metal Surfaces
1. Time of Application
The prime coat of paint or pretreatment when specified, shall be

applied as soon as possible after the surface has been cleaned and
before deterioration of the surface occurs. Any oil, grease, soil, dust
or foreign matter deposited on the surface after the surface
preparation is completed shall be removed prior to painting. In the
event the rusting occurs after completion of the surface preparation,
the surfaces shall be again cleaned.
Particular care shall be taken to prevent the contamination of

cleaned surfaces with salts, acids, alkali, or other corrosive chemicals
before the prime coat is applied and between applications of the
remaining coats of paint. Such contaminants shall be removed from
the surface. Under these circumstances, the pretreatments or, in the
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absence of a pretreatment, the prime coat of paint shall be applied
immediately after the surface has been cleaned.
2. Storage of Paint and Thinner
All paint and thinner should preferably be stored in a separate

building or room that is well ventilated and free from excessive heat,
sparks, flame or the direct ray of the sun.
All containers of paint should remain unopened until required for

use. Containers which have been opened shall be used first.
Paint which has livered, gelled, or otherwise deteriorated during

storage shall not be used. Thixotropic materials which may be stirred
to attain normal consistency are satisfactory.
3. Mixing and Thinning
All ingredients in any container of paint shall be thoroughly mixed

before use and shall be agitated often enough during application to
keep the pigment in suspension.
Paint mixed in the original container shall not be transferred until

all settled pigment is incorporated into the vehicle. This does not
imply that part of the vehicle cannot be poured off temporarily to
simplify the mixing.
Mixing shall be by mechanical methods, except that hard mixing

will be permitted for container up to 19 litres in size.
Mixing in open containers shall be done in a well ventilated area

away from sparks or flames.
Paint shall not be mixed or kept in suspension by means of an air

stream bubbling under the paint surface.
When a skin has formed in the container, the skin shall be cut loose
from the sides of the container, removed, and discarded. If such
skins are thick enough to have a practical effect on the composition
and quality of the paint, the paint shall not be used.
The paint shall be mixed in manner which will insure breaking up

of all lumps, complete dispersion of settled pigment, and a uniform
composition. If mixing is done by hand, most of the vehicle shall be
poured off into a clean container. The pigment in the paint shall be
lifted from the bottom of the container with a broad, flat paddle, lumps
shall be broken up, and the pigment thoroughly mixed with the
vehicle. The poured off vehicle shall be returned to the paint with
simultaneous stirring, or pouring repeatedly from one container to
another until the composition is uniform. The bottom of the container
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shall be inspected for unmixed pigment. Tinting pastes or colors shall
be wetted with a small amount of thinner, vehicle, or paint and
thoroughly mixed. The thinned mixture shall be added to the large
container of paint and mixed until the color is uniform.
Paint which does not have a limited pot life, or does not deteriorate
on standing, may be mixed at any time before using, but if settling has
occurred, it must be remixed immediately before using. Paint shall
not remain in spray pots, painter’s buckets, etc., overnight, but shall
be gathered into a container and remixed before use.
No thinner shall be added to the paint unless necessary for proper

application. In no case shall more than 0.5 litres of thinner be added
per 3.8 litres unless the paint is intentionally formulated for greater
thinning.
The type of thinner shall comply with the paint specification.
When the use of thinner is permissible, thinner shall be added to

paint during the mixing process. Painters shall not add thinner to
paint after it has been thinned to the correct consistency.
All thinning shall be done under supervision of one acquainted with

the correct amount and type of thinner to be added to the paint.
Table 403.4 – Paint System

Paint System
1 2 3 4 5
High Pollution or Coastal x x x
Mild Climate x X
Note:
1. Paint system shown for severe areas are satisfactorily in less
severe areas.
2. Coastal - within 304.8 m of ocean or tidal water.
High pollution-air pollution environment such as industrial areas.
Mild-other than coastal areas not in air pollution environment.
All structural steel shall be painted by one of the following systems.

The required system or choice of systems will be shown in the
Contract.
System 4 is intended for use in mild climates or to repaint existing

structures where the other systems are not compatible.
Coating Thickness Specifications Min. Dry Film

System 1 – Vinyl Paint System
Wash Prime 708.03 (b) 12.7
Intermediate Coat 708.03 (b) 38.10 – 50.80
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3rd Coat 708.03 (b) 38.10 – 50.80
4th Coat 708.03 (b) 38.10 – 50.80
Finish Coat 708.03 (b) 38.10 – 50.80
Total thickness 165.10 – 203.20
System 2 – Epoxy-Polymide System
Prime Coat 708.03 (c) 50.80 – 76.20
Intermediate Coat 708.03 (c) 50.80 – 76.20
3rd Coat 708.03 (c) 50.80 – 76.20
Finish Coat 708.03 (c) 38.10 – 50.80
* The third coat may be eliminated in mild climates
Coating Thickness Specifications Min. Dry Film

System 3 – Inorganic Zinc-Rich Coating
System
Prime Coat 708.03(d) 88.90 – 127
Epoxy Intermediate Coat 708.03 (d) 40.80 – 76.20
Finish Coat 708.03 (d) 38.10 – 50.80
Total thickness 177.80 – 254
Alternate System
Prime Coat 708.03 (d) 88.90 – 127
Wash Primer Tie Coat 708.03 (d) 12.70
Finish Coat 708.03 (d) 38.10 – 50.80
System 4 – Alkyd-Oil-Basic Lead-Chromate System
Prime Coat 708.03 (e) 38.10 – 50.80
Intermediate Coat 708.03 (e) 38.10 – 50.80
Finish Coat 708.03 (e) 38.10 – 50.80
* The paint system may be specified as four coats for new
structure steel in mild climate, with a minimum thickness of
152.40 mm.
System 5 – Organic Zinc-Rich Paint System
Prime Coat 708.03 (f) 38.10 – 50.80
Intermediate Coat 708.03 (f) 50.80 – 63.50
Wash Primer Tie Coat 708.03 (f) 12.70
Finish Coat 708.03 (f) 38.10 – 50.80
4. Application of Paint
a. General
The oldest of each kind of paint shall be used first. Paint shall be
applied by brushing or spraying or a combination of these methods.
Daubers or sheepskins may be used when no other method is
practicable for proper application in places of difficult access.
Dipping, roller coating, or flow coating shall be used only when
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specifically authorized. All paints shall be applied in accordance with
the manufacturer’s instructions.
Open seams at contact surfaces of built up members which would

retain moisture shall be caulked with red lead paste, or other approved
material, before the second undercoat of paint is applied.
Paint shall not be applied when the surrounding air temperature is

below 4.40C. Paint shall not be applied when the temperature is
expected to drop to 00C before the paint has dried. Paint shall not be
applied to steel at a temperature over 51.7 0C unless the paint is
specifically formulated for application at the proposed temperature,
nor shall paint be applied to steel which is at a temperature that will
cause blistering or porosity or otherwise will be detrimental to the life
of the paint.
Paint shall not be applied in fog or mist, or when it is raining or

when the relative humidity exceeds 85 percent. Paint shall not be
applied to wet or damp surfaces.
When paint must be applied in damp or cold weather, the steel

shall be painted under cover, or protected, or sheltered or the
surrounding air and the steel heated to a satisfactory temperature. In
such cases, the above temperature and humidity conditions shall be
met. Such steel shall remain under cover or be protected until dry or
until weather conditions permit its exposure.
Any applied paint exposed to excess humidity, rain or

condensation shall first be permitted to dry. Then damaged areas of
paint shall be removed, the surface again prepared and then
repainted with the same number of coats of paint of the same kind as
the undamaged areas.
If stripe painting is stipulated in the Special Provisions or if the

Contractor chooses to do so at his option, all edges, corners, crevices,
rivets, bolts, weld and sharp edges shall be painted with the priming
paint by brush before the steel receives first full prime coat of paint.
Such striping shall extend for at least 25.4 mm from the edge. When
practicable, this stripe coat shall be permitted to dry before the prime
coat is applied, otherwise the stripe coat shall set to touch before the
full prime coat is applied. However, the stripe coat shall not be
permitted to dry for a period of long enough to allow rusting of the
unprimed steel. When desired, the stripe coat may be applied after
a complete prime coat.
To the maximum extent practicable, each coat of paint shall be

applied as continuous film of uniform thickness free of pores. Any
thin spots or areas missed in the application shall be repainted and
permitted to dry before the next coat of paint is applied. Film
thickness is included in the description of paint systems. Each coat
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of paint shall be in a proper state of cure or dryness before application
of the succeeding coat.
b. Brush Application
Paint shall be worked into all crevices and corners where possible
and surfaces not accessible to brushes shall be painted by spray,
doubers, or sheepskins. All runs or rags shall be brushed out. There
shall be a minimum of brush marks left in the paint.
c. Spray Application of Paint
The equipment used for spray application of paint shall be suitable

for the intended purpose, shall be capable of properly atomizing the
paint to be applied and shall be equipped with suitable pressure
regulators and gages. The air caps, nozzles, and needles shall be
those recommended by the manufacturer of the equipment for the
material being sprayed. The equipment shall be kept in satisfactory
condition to permit proper paint application. In closed or recirculating
paint spray system, where gas under pressure is used over the liquid,
the gas shall be an inert, one such as nitrogen. Traps or separators
shall be provided to remove oil and water from the compressed air.
These traps or separators shall be adequate size and shall be drained
periodically during operations. The air from the spray gun impinging
against the surface shall show no water or oil.
Paint ingredients shall be kept properly mixed in the spray pots or

containers during paint applications either by continuous mechanical
agitation or by intermittent agitation as frequently as necessary.
The pressure on the material in the pot and of the air at the guns
shall be adjusted for optimum spraying effectiveness. The pressure
on the material in the pot shall be adjusted when necessary for
changes in elevation of the gun above the pot. The atomizing air
pressure at the gun shall be high enough to atomize the paint properly
but not so high as to cause excessive fogging of paint, excessive
evaporation of solvent or loss by overspray.
Spray equipment shall be kept sufficiently clean so that dirt, dried

paint and other foreign material are not deposited in the paint film.
Any solvents left in the equipment shall be completely removed before
applying paint to the surface being painted.
Paint shall be applied in uniform layer, with overlapping at the edge

of the spray pattern. The spray shall be adjusted so that the paint is
deposited uniformly. During application, the gun shall be held
perpendicular to the surface and at a distance which will insure that a
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wet layer of paint is deposited on the surface. The trigger of the gun
should be released at the end of each stroke.
All rums and sags shall be brushed out immediately or the paint
shall be removed and the surface repainted. Spray application of
prime coats shall in all cases be immediately followed by brushing
Areas inaccessible to the spray gun shall be painted by brush, if

not accessible by brush, daubers or sheepskins shall be used.
Brushes shall be used to work paint into cracks, crevices and blind
spots where are not adequately painted by spray.
d. Shop Painting
Shop painting shall be done after fabrication and before any

damage to the surface occurs from weather or other exposure. Shop
contact surfaces shall not be painted unless specified.
Surfaces not to be in contact but which will be inaccessible after

assembly shall receive the full paint system specified or three shop
coats of the specified before assembly.
The areas of steel surfaces to be in contact with concrete shall not

be painted, unless otherwise shown on the Plans, the areas of steel
surfaces to be in contact with wood shall receive either the full paint
coats specified or three shop coats of the specified primer.
If paint would be harmful to a welding operator or would be

detrimental to the welding operation or the finished welds, the steel
shall not be painted within a suitable distance from the edges to be
welded. Welding through inorganic zinc paint systems will not be
permitted unless approved by the Engineer.
Antiweld spatter coatings shall be removed before painting. Weld

slag and flux shall be removed by methods at least as effective as
those specified for the cleaning.
Machine-finished or similar surfaces that are not to be painted, but

do not require protections, shall be protected with a coating of rust
inhibitive petroleum, other coating which may be more suitable, for
special conditions.
Erection marks and weight marks shall be copied on area that have
been previously painted with the shop coat.
e. Field Painting
Steel structures shall be painted as soon as practicable after

erection.
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Metal which has been shop coated shall be touched up with the
same type of paints as the shop coat. This touch-up shall include
cleaning and painting of field connections, welds, rivets and all
damaged or defective paint and rusted areas. The Contractor may,
at his option, apply an overall coat of primer in place of touch-up spot
painting.
Surfaces (other than contact surfaces) which are accessible before

erection but which will not be accessible after erection shall receive
all field coats of paint before erection.
If possible the final coat of paint shall not be applied until all
concrete work is finished. If concreting or other operations damage
any paint, the surfaces shall be cleaned and repainted. All cement
or concrete spatter and dripping shall be removed before any paint is
applied.
Wet paint shall be protected against damage from dust or other

detrimental foreign matter to the extent practicable.
f. Drying of Painted Metal
The maximum practicable time shall be allowed for paint to dry

before recoating or exposure. No drier shall be added to paint on the
job unless specifically called for in the Specifications for the paint. No
painted metal shall be subjected to immersion before the paint is dried
through. Paint shall be protected from rain, condensation,
contamination, and freezing until dry, to the fullest extent practicable.
g. Handling of Painted Steel
Painted steel shall not be handled until the paint has dried, except
for necessary handling in turning for painting or stacking for drying.
Paint which is damaged in handling shall be scraped off and

touched-up with the same number of the coats and kinds of paint as
were previously applied to the steel.
Painted steel shall not be loaded for shipment or shipped until it is

dry.
Precautions shall be taken to minimize damage to paint films

resulting from stocking members.
5. Measurement of Dry Film Thickness of Paints
a. Instrumentation
Dry paint film thickness shall be measured using Pull-Off (Type 1)

or Fixed Probe (Type 2) Magnetic Gages. Type 1 gages include
Tinsley, Elcometer, Microtest and Inspector models. Type 2 gage
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include Elcometric, Minitector, General Electric, Verimeter and
Accuderm models.
b. Calibration
1. Type 1 (Pull-Off) Magnetic Gages
Measure the coating thickness on a series of reliable

standards covering the expected range of paint thickness.
Record the calibration correction either plus (+) or minus (-)
required at each standard thickness. To guard against gage
drift during use, re-check occasionally with one or more of the
standards.
When the gage adjustment has drifted so far that large

corrections are needed, it is advisable to re-adjust closer to the
standard values and re-calibrate.
For Type 1 gages, the preferred basic standards are small,

chromeplated steel panels that may be available from the
National Bureau of Standards in coating thickness from 12.70
mm to 203.20 mm.
Plastic shims of certified thickness in the appropriate ranges

may also be used to calibrate the gages. The gage is held firmly
enough to press the shim tightly against the steel surface.
Record the calibration correction as above.
2. Type 2 (Fixed Probe) Magnetic Gages
Shims of plastic or non-magnetic metals laid on the

appropriate steel base (at least 76.2 x 76.2 x 3.2 mm) are
suitable working standards. These gages are held firmly
enough to press the shim tightly against the steel surface. One
should avoid excessive pressure that might indent the plastic or,
on a blast cleaned surface, might impress the steel peaks into
the undersurface of the plastic.
The National Bureau of Standards – standards panels shall

not be used to calibrate Type 2 gages.
c. Measurement Procedures
To determine the effect of the substrate surface condition on the

gage readings, access is required to some unpainted areas.
Repeated gage readings, even at points close together, may differ

considerably due to small surface irregularities. Three gage readings
should therefore be made for each spot measurement of either the
substrate or the paint. Move the probe a short distance for each new
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gage reading. Discard any unusually high of flow gage reading that
cannot be repeated consistently. Take the average of the three gage
readings as the spot measurement.
1. Measurement with Type 1 (Pull-Off) Gage
Measure (A), the bare substrate, at a number of spots to

obtain a representative average value. Measure (B), the dry
paint film, at the specified number of spots.
Correct the (A) and (B) gage readings or averages as

determined by calibration of the gage. Subtract the corrected
readings (A) from (B) to obtain the thickness of the paint above
the peaks of the surface.
2. Measurement with Type 2 (Fixed Probe) Gage
Place a standard shim of the expected paint thickness on the

bare substrate that is to be painted. Adjust the gage in place on
the shim so that it indicates the known thickness of the shim.
Conform the gage setting by measuring the shim at several

other area of the bare substrate. Re-adjust the gage as needed
to obtain an average setting representative of the substrate.
With the gage adjustment as above, measure the dry paint

film at three points. The gage readings indicate the paint film
thickness at the three points. The gage readings indicate the
paint thickness above the peaks of the surface profile.
Re-check the gage setting at frequent intervals during a long

series of measurements. Make five separate spot
measurements spaced evenly over each section of the structure
9.29 square metres in area, or of other area as may be specified.
The average of five spot measurements for each such section
shall not be less than the specified thickness. No single spot
measurement (average of three readings) in any section shall be
less than 80% of the specified thickness.
Since paint thickness is usually specified (or implied) as a

minimum, greater thickness that does not cause defects of
appearance or functions such as mud cracking, wrinkling, etc.,
is permitted unless otherwise specified.
d. Special Notes
All of the above magnetic, if properly adjusted and in good

condition, are inherently accurate to within +15% of the true thickness
of the coating.
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Much larger, external errors may be caused by variations in
method of use of the gages or by unevenness of the surface of the
substrate or of the coating. Also, any other film present on the steel
(rust or mill scale or even a blast cleaned profile zone) will add to the
apparent thickness of the applied paint film.
The surface of the paint and the probe of the gage must be free
from dust, grease and other foreign matter in order to obtain close
contact of the probe with the paint and also to avoid adhesion of the
magnet. The accuracy of the measurement will be affected if the
coating is tacky or excessively soft.
The magnetic gages are sensitive to geometrical discontinuities of

the steel, as at holes, corners or edges. The sensitivity to edge
effects and discontinuities varies from gage to gage. Measurements
closer than 25.4 mm from the discontinuity may not be valid unless
the gage is calibrated specifically for that location.
Magnetic gage readings also may be affected by proximity to

another mass of steel close to the body of the gage, by surface
curvature and presence of other magnetic fields.
All of the magnets or probe must be held perpendicular to the

painted surface to produce valid measurements.
403.3.24 Clean-up
Upon completion and before final acceptance, the Contractor shall remove
all falsework, falsework piling down to at least 609.6 mm below the finished ground
line, excavated or unused materials, rubbish and temporary buildings. He shall
replace or renew any fences damaged and restored in an acceptable manner all
property, both public and private, which may have been damaged during the
prosecution of the work and shall leave the work site and adjacent highway in a
neat and presentable condition, satisfactory to the Engineer. All excavated material
or falsework placed in the stream channel during construction shall be removed by
the Contractor before final acceptance.
403.4.1 Unit Basis
The quantity of structural steel to be paid for shall be the number of kilos
complete in place and accepted. For the purpose of measurement for payment
components fabricated from metals listed in (1) below, such as casting, alloy steels,
steel plates, anchor bolts and nuts, shoes, rockers, rollers, pins and nuts, expansion
dams, roadway drains and souppers, welds metal, bolts embedded in concrete,
cradles and brackets, posts, conduits and ducts, and structural shapes for
expansion joints and pier protection will be considered as structural steel.
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Unless otherwise provided, the mass of metal paid for shall be computed
and based upon the following mass:
1. Unit Density kg/m3
Aluminum, cast or rolled 2771.2

Bronze or copper alloy 8585.9
Copper sheet 8938.3
Iron, cast 7128.2
Iron, malleable 7528.7
Lead, sheet 11229
Steel, cast or rolled, including alloy
copper bearing and stainless 7849
Zinc 7208.3
2. Shapes, Plates Railing and Flooring
The mass of steel shapes and plates shall be computed on the basis of
their nominal mass and dimensions as shown on the approved shop
drawings, deducting for copes, cuts and open holes, exclusive of rivets
holes. The mass of all plates shall be computed on the basis of nominal
dimensions with no additional for overrun.
The mass of railing shall be included as structural steel unless the Bill of
Quantities contains as pay item for bridge railing under Item 401, Railings.
The mass of steel grid flooring shall be computed separately.
3. Casting
The mass of casting shall be computed from the dimensions shown on

the approved drawings, deducting for open holes. To this mass will be
added 5 percent allowable for fillets and overruns. Scale mass may be
substituted for computed mass in the case of castings of small complex parts
for which accurate computations of mass would be difficult.
4. Miscellaneous
The mass of erection bolts, shop and field paint, galvanizing the boxes,
crates and other containers used for shipping, together with sills, struts, and
rods used for supporting members during the transportation, bridge
hardware as defined in Subsection 402.2.2 excluding steel plates and
bearings, connectors used for joining timber members, nails, spikes and
bolts, except anchor bolts will be excluded.
5. Rivets Heads
The mass of all rivet heads, both files and shop, will be assumed as
follows:
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Diameter of rivet kg per 100 heads
(mm)
12.7 1.80
15.9 3.20
19.0 5.44
22.2 8.16
25.4 11.80
28.6 16.33
31.7 21.8
6. High-Strength Bolts
High-strength steel bolts shall be considered for purpose of payment, the

same as rivets of the same diameter, with the mass of the bolt heads and
nuts the same as the corresponding rivet heads.
7. Welds
The mass of shop and field fillet welds shall be assumed as follows:
Size of Weld kg per linear metre

(mm)
6.3 0.984
7.9 1.213
9.5 1.771
12.7 2.690
5.9 3.936
19.0 5.379
22.2 7.314
25.4 9.774
The mass of other welds will be computed on the basis of the theoretical
volume from dimensions of the welds, with an addition of 50 mass percent
as an allowance for overrun.
8. Other Items
The quantities of other Contract Items which enter into the completed and
accepted structure shall be measured for payment in the manner prescribed
for the Items involved.
403.4.2 Lump Sum Basis
Lump sum will be the basis of payment unless noted otherwise in the bidding
documents. No measurements of quantities will be made except as provided in
Subsection 403.5.1 (4).
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403.5.1 Structural Steel
1. Furnished, Fabricated and Erected
The quantity, determined as provided above, shall be paid for at the

contract unit price per kilogram for “Structural Steel, furnished, fabricated
and erected”, which price and payment shall constitute full compensation
for furnishing, galvanizing, fabricating, radiographing, magnetic particle
inspection, delivering, erecting ready for use, and painting all steel and
other metal including all labor, equipment, tools and incidentals
necessary to complete the work, except as provided in Subsections
403.5.2, 403.5.3 and 403.5.4.
2. Furnished and Fabricated
When a quantity and unit price for “Structural Steel, furnished and
fabricated” are shown in the Bill of Quantities, the quantity, determined
as provided above, will be paid for at the contract unit price per kilogram
which price and payment shall be full compensation for furnishing,
galvanizing, fabricating, radiographing, magnet particle inspection, shop
painting and delivering the structural steel and other metal free of charges
at the place designated in the Special Provisions and for all labor,
equipment, tools and incidentals necessary to complete the work, save
erection and except as provided in Subsection 403.5.2, 403.5.3 and
403.5.4.
3. Erected
When a quantity and unit price for “Structural Steel Erected” are
shown in the Bill of Quantities, the quantity, determined as provided
above, will be paid for at the said contract unit price per kilogram which
price and payment shall be full compensation for unloading all the
structural steel and other metal, payment of any demurrage charges,
transporting to the bridge site, erecting, magnetic particle inspection and
radiographing, complete ready for use including furnishing and applying
the field paint including all labor, equipment, tools and incidentals
necessary to complete the work, save furnishing and fabrication, and
except as provided in Subsections 403.5.2, 403.5.3 and 403.5.4.
4. Lump Sum
When the Bill of Quantities calls for lump sum price for “Structural
Steel, furnished, fabricated and erected”, the Item will be paid for at the
contract lump sum price and payment shall be full compensation for
furnishing, fabricating and erecting material and for all work herein before
prescribed in connection therewith, including all labor, equipment, tools
and incidentals necessary to complete the work, except as provided in
Subsections 403.5.2, 403.5.3 and 403.5.4.
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The estimate of the mass of structural steel shown on the Plans is
approximate only and no guarantee is made that it is the correct mass to
be furnished. No adjustment in the contract price will be made if the
mass furnished is more or less than estimated mass.
If changes in the work are ordered by the Engineer, which vary the
mass of steel to be furnished, the lump sum payment shall be adjusted
as follows:
a. The value per kilogram of the increase or decrease in mass of

structural steel involved in the change shall be determined by dividing
the contract lump sum amount by the estimate of mass shown on the
Plans. The adjusted contract lump sum payment shall be the contract
lump sum plus or minus the value of the steel involved in the change,
and no additional compensation shall be made on account of said
change.
b. Full-size members which are tested in accordance with the

Specifications when such tests are required by the Contract, shall be
paid for at the same rate as for comparable members in the structure.
Members which fail to meet the Contract requirements, and members
rejected as a result of test shall not be paid for.
403.5.2 Material Considered as Structural Steel
For the purpose of Subsection 403.5.1 and unless otherwise shown on the
Plans, castings, forgings, special alloy steels and steel plates, wrought iron, and
structural shapes of expansion joints and pier protection shall be considered as
structural steel except that when quantities and unit price for certain alloy steels,
forgings, castings or other specific categories of metal are called for in the Bill of
Quantities, the mass of such selected material, determined as provided above, shall
be paid for at the respective contract unit price per kilogram for “Structural Steel
(Alloy steel, forgings, castings, and/or other category), furnished and fabricated,
and erected” or “Structural Steel (Subsection 403.4.1), furnished and fabricated” as
named in the Bill of Quantities.
403.5.3 Other Items
The quantities of all other Contract Items which enter into the completed and
accepted structure shall be paid for at the contract unit prices for the several Pay
Items as prescribed for the Items involved.
403.5.4 Payment as Reinforcing Steel
When the Bill of Quantities does not contain a pay item for structural steel,
the quantities of metal drains, scuppers, conduits, ducts and structural shapes for
expansion joints and pier protection, measured as provided above will be paid for
as Reinforcing Steel under Item 404.
205

403 (1) Structural Steel,
furnished, fabricated kilogram
and erected
and erected
403 (5) Structural Steel erected kilogram
403 (6) Structural Steel erected kilogram
and erected
Where separate payment is to be made for certain metals or for certain

particular components, other than under the general provision for structural steel,
designation of those particular cases shall be inserted in the spaces provided in the
pay names for Item 403 (2), 403 (4) or 403 (6), as the case may be.
ITEM 404 – REINFORCING STEEL
404.1 Description
This Item shall consist of furnishing, bending, fabricating and placing of steel
reinforcement of the type, size, shape and grade required in accordance with this
Specification and in conformity with the requirements shown on the Plans or as
directed by the Engineer.
Reinforcing steel shall meet the requirements of item 710, Reinforcing Steel
and Wire Rope.
4.4.3 Construction Requirements
404.3.1 Order Lists
Before materials are ordered, all order lists and bending diagrams shall be
furnished by the Contractor, for approval of the Engineer. The approval of order
lists and bending diagrams by the Engineer shall in no way relieve the Contractor
of responsibility for the correctness of such lists and diagrams. Any expense
206
incident to the revisions of materials furnished in accordance with such lists and
diagrams to make them comply with the Plans shall be borne by the Contractor.
404.3.2 Protection of Material
Steel reinforcement shall be stored above the surface of the ground upon
platforms, skids, or other supports and shall be protected as far as practicable from
mechanical injury and surface deterioration caused by exposure to conditions
producing rust. When placed in the work, reinforcement shall be free from dirt,
detrimental rust, loose scale, paint, grease, oil, or other foreign materials.
Reinforcement shall be free from injurious defects such as cracks and laminations.
Rust, surface seams, surface irregularities or mill scale will not be cause for
rejection, provided the minimum dimensions, cross sectional area and tensile
properties of a hand wire brushed specimen meets the physical requirements for
the size and grade of steel specified.
404.3.3 Bending
All reinforcing bars requiring bending shall be cold-bent to the shapes shown
on the Plans or required by the Engineer. Bars shall be bent around a circular pin
having the following diameters (D) in relation to the diameter of the bar (d):
Nominal diameter, d, mm Pin diameter (D)

10 to 20 6d
25 to 28 8d
32 and greater 10d
Bends and hooks in stirrups or ties may be bent to the diameter of the
principal bar enclosed therein.
404.3.4 Placing and Fastening
All steel reinforcement shall be accurately placed in the position shown on

the Plans or required by the Engineer and firmly held there during the placing and
setting of the concrete. Bars shall be tied at all intersections except where spacing
is less than 300mm in each directions, in which case, alternate intersections shall
be tied. Ties shall be fastened on the inside.
Distance from the forms shall be maintained by means of stays, blocks, ties,
hangers, or other approved supports, so that it does not vary from the position
indicated on the Plans by more than 6mm. Blocks for holding reinforcement from
contact with the forms shall be precast mortar blocks of approved shapes and
dimensions. Layers of bars shall be separated by precast mortar blocks or by other
equally suitable devices. The use of pebbles, pieces of broken stone or brick, metal
pipe and wooden blocks shall not be permitted. Unless otherwise shown on the
Plans or required by the Engineer, the minimum distance between bars shall be
40mm. Reinforcement in any member shall be placed and then inspected and
approved by the Engineer before the placing of concrete begins. Concrete placed
in violation of this provision may be rejected and removal may be required. If fabric
207
reinforcement is shipped in rolls, it shall be straightened before being placed.
Bundled bars shall be tied together at not more than 1.8m intervals.
404.3.5 Splicing
All reinforcement shall be furnished in the full lengths indicated on the Plans.
Splicing of bars, except where shown on the Plans, will not be permitted without the
written approval of the Engineer. Splices shall be staggered as far as possible and
with a minimum separation of not less than 40 bar diameters. Not more than one-
third of the bars may be spliced in the same cross-section, except where shown on
the Plans.
Unless otherwise shown on the Plans, bars shall be lapped a minimum

distance of:
Splice Type Grade 40 Grade 60 But not less

min. lap min. lap than
Tension 24 bar dia 36 bar dia 300 mm
Compression 20 bar dia 24 bar dia 300 mm
In lapped splices, the bars shall be placed in contact and wired together.
Lapped splices will not be permitted at locations where the concrete section is
insufficient to provide minimum clear distance of one and one-third the maximum
size of coarse aggregate between the splice and the nearest adjacent bar. Welding
of reinforcing steel shall be done only if detailed on the Plans or if authorized by the
Engineer in writing. Spiral reinforcement shall be spliced by lapping at least one
and a half turns or by butt welding unless otherwise shown on the Plans.
404.3.6 Lapping of Bar Mat
Sheets of mesh or bar mat reinforcement shall overlap each other sufficiently
to maintain a uniform strength and shall be securely fastened at the ends and
edges. The overlap shall not be less than one mesh in width.
The quantity of reinforcing steel to be paid for will be the final quantity placed
and accepted in the completed structure.
No allowance will be made for tie-wires, separators, wire chairs and other
material used in fastening the reinforcing steel in place. If bars are substituted upon
the Contractor’s request and approved by the Engineer and as a result thereof more
steel is used than specified, only the mass specified shall be measured for payment.
No measurement or payment will be made for splices added by the

Contractor unless directed or approved by the Engineer.
When there is no item for reinforcing steel in the Bill of Quantities, costs will
be considered as incidental to the other items in the Bill of Quantities.
208
The accepted quantity, measured as prescribed in Section 404.4, shall be

paid for at the contract unit price for Reinforcing Steel which price and payment
shall be full compensation for furnishing and placing all materials, including all labor,
equipment, tools and incidentals necessary to complete the work prescribed in this
Item.

404 Reinforcing Steel Kilogram
ITEM 405 – STRUCTURAL CONCRETE
405.1 Description
405.1.1 Scope
This Item shall consist of furnishing, bending, placing and finishing concrete
in all structures except pavements in accordance with this Specification and
conforming to the lines, grades, and dimensions shown on the Plans. Concrete
shall consist of a mixture of Portland Cement, fine aggregate, coarse aggregate,
admixture when specified, and water mixed in the proportions specified or approved
by the Engineer.
405.1.2 Classes and Uses of Concrete
Five classes of concrete are provided for in this Item, namely: A, B, C, P and
Seal. Each class shall be used in that part of the structure as called for on the
Plans.
The classes of concrete will generally be used as follows:
Class A – All superstructures and heavily reinforced substructures. The

important parts of the structure included are slabs, beams, girders, columns, arch
ribs, box culverts, reinforced abutments, retaining walls, and reinforced footings.
Class B – Footings, pedestals, massive pier shafts, pipe bedding, and gravity
walls, unreinforced or with only a small amount of reinforcement.
Class C – Thin reinforced sections, railings, precast R.C. piles and cribbing
and for filler in steel grid floors.
Class P – Prestressed concrete structures and members.
Seal – Concrete deposited in water.
209
405.2.1 Portland Cement
It shall conform to all the requirements of Subsection 311.2.1.
405.2.2 Fine Aggregate
It shall conform to all the requirements of Subsection 311.2.2.
405.2.3 Coarse Aggregate
It shall conform all the requirements of Subsection 311.2.3 except that

gradation shall conform to Table 405.1.
Table 405.1 – Grading Requirements for Coarse Aggregate

Sieve Designation Mass Percent Passing
Standard Alternate Class Class Class Class Class
Mm US A B C P Seal
Standard
63 2-1/2” 100
50 2” 100 95 – 100
37.5 1-1/2” 95 – 100 - 100
25 1” - 35 – 70 100 95 – 100
19.0 ¾” 35 – 70 - 100 95 – 100 -
12.5 ½” - 10 – 30 90 – 100 - 25 – 60
9.5 3/8” 10 – 30 - 40 – 70 20 – 55 -
4.75 No.4 0-5 0-5 0 – 15* 0 – 10* 0 – 10*
* The measured cement content shall be within plus (+) or minus (-) 2 mass
percent of the design cement content.
405.2.4 Water
It shall conform to the requirements of Subsection 311.2.4
405.2.5 Reinforcing Steel
Rope.
405.2.6 Admixtures
Admixtures shall conform to the requirements of Subsection 311.2.7
405.2.7 Curing Materials
Curing materials shall conform to the requirements of Subsection 311.2.8.
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405.2.8 Expansion Joint Materials
Expansion joint materials shall be:
1. Preformed Sponge Rubber and Cork, conforming to AASHTO M 153.
2. Hot-Poured Elastic Type, conforming to AASHTO M 173.
3. Preformed Fillers, conforming to AASHTO M 213.
405.2.9 Elastomeric Compression Joint Seals
These shall conform to AASHTO M 220.
405.2.10 Elastomeric Bearing Pads
These shall conform to AASHTO M 251 or Item 412 – Elastomeric Bearing

Pads.
405.2.11 Storage of Cement and Aggregates
Storage of cement and aggregates shall conform to all the requirements of

Subsection 311.2.10.
405.3 Sampling and Testing of Structural Concrete
As work progresses, at least one (1) sample consisting of three (3) concrete
cylinder test specimens, 150 x 300mm (6 x 12 inches), shall be taken from each
seventy five (75) cubic meters of each class of concrete or fraction thereof placed
each day.
Compliance with the requirements of this Section shall be determined in

accordance with the following standard methods of AASHTO:
Sampling of fresh concrete T 141

Weight per cubic metre and air content (gravi-
Metric) of concrete T 121
Sieve analysis of fine and coarse aggregates T 27
Slump of Portland Cement Concrete T 119
Specific gravity and absorption of fine aggregate T 84
Tests for strength shall be made in accordance with the following:
Making and curing concrete compressive and

flexural tests specimens in the field T 23
Compressive strength of molded concrete
Cylinders T 22
405.4 Production Requirements
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405.4.1 Proportioning and Strength of Structural Concrete
The concrete materials shall be proportioned in accordance with the

requirements for each class of concrete as specified in Table 405.2, using the
absolute volume method as outlined in the American Concrete Institute (ACI)
Standard 211.1. “Recommended Practice for Selecting Proportions for Normal and
Heavyweight Concrete”. Other methods of proportioning may be employed in the
mix design with prior approval of the Engineer. The mix shall either be designed or
approved by the Engineer. A change in the source of materials during the progress
of work may necessitate a new mix design.
The strength requirements for each class of concrete shall be as specified in

Table 405.2.
Table 405.2 - Composition and Strength of Concrete for Use in Structures
Minimum Maximum Consistency Designated Minimum

Class Cement Water/ Range in Size of Coarse Compressive
Of Content Cement Slump Aggregate Strength of
Concre Per m3 Ratio 150x300mm
te Square Opening Concrete
kg kg/kg mm (inch) Std. mm Cylinder
(bag**) Specimen at
28 days,
MN/m2 (psi)
A 360 0.53 50 – 100 37.5 – 4.75 20.7

(9 bags) (2 – 4) (1-1/2” – No. 4) (3000)
B 320 0.58 50 – 100 50 – 4.75 16.5

(8 bags) (2 – 4) (2” – No. 4) (2400)
C 380 0.55 50 – 100 12.5 – 4.75 20.7

(9.5 bags) (2 – 4) (1/2” – No. 4) (3000)
P 440 0.49 100 max. 19.0 – 4.75 37.7

(11 bags) (4 max.) (3/4” – No. 4) (5000)
Seal 380 0.58 100 – 200 25 – 4.75 20.7

(9.5 bags) (4 - 8) (1” – No. 4) (3000)
* The measured cement content shall be within plus or minus 2 mass

percent of the design cement content.
** Based on 40 kg/bag
405.4.2 Consistency
Concrete shall have a consistency such that it will be workable in the required
position. It shall be of such a consistency that it will flow around reinforcing steel
but individual particles of the coarse aggregate when isolated shall show a coating
of mortar containing its proportionate amount of sand. The consistency of concrete
shall be gauged by the ability of the equipment to properly place it and not by the
212
difficulty in mixing and transporting. The quantity of mixing water shall be
determined by the Engineer and shall not be varied without his consent. Concrete
as dry as it is practical to place with the equipment specified shall be used.
405.4.3 Batching
Measuring and batching of materials shall be done at a batching plant.
1. Portland Cement
Either sacked or bulk cement may be used. No fraction of a sack of

cement shall be used in a batch of concrete unless the cement is
weighed. All bulk cement shall be weighed on an approved weighing
device. The bulk cement weighing hopper shall be properly sealed and
vented to preclude dusting operation. The discharge chute shall not be
suspended from the weighing hopper and shall be so arranged that
cement will neither be lodged in it nor leak from it.
Accuracy of batching shall be within plus (+) or minus (-) 1 mass

percent.
2. Water
Water may be measured either by volume or by weight. The accuracy

of measuring the water shall be within a range of error of not more than
1 percent.
3. Aggregates
Stockpiling of aggregates shall be in accordance with Subsection

311.2.10. All aggregates whether produced or handled by hydraulic
methods or washed, shall be stockpiled or binned for draining for at least
12 hours prior to batching. Rail shipment requiring more than12 hours
will be accepted as adequate binning only if the car bodies permit free
drainage. If the aggregates contain high or non-uniform moisture
content, storage or stockpile period in excess of 12 hours may be
required by the Engineer.
Batching shall be conducted as to result in a 2 mass percent

maximum tolerance for the required materials.
4. Bins and Scales
The batching plant shall include separate bins for bulk cement, fine
aggregate and for each size of coarse aggregate, a weighing hopper, and
scales capable of determining accurately the mass of each component of
the batch.
Scales shall be accurate to one-half (0.5) percent throughout the

range used.
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5. Batching
When batches are hauled to the mixer, bulk cement shall be

transported either in waterproof compartments or between the fine and
coarse aggregate. When cement is placed in contact with moist
aggregates, batches will be rejected unless mixed within 1-1/2 hours of
such contact. Sacked cement may be transported on top of the
aggregates.
Batches shall be delivered to the mixer separate and intact. Each

batch shall be dumped cleanly into the mixer without loss, and, when
more than one batch is carried on the truck, without spilling of material
from one batch compartment into another.
6. Admixtures
The Contractor shall follow an approved procedure for adding the

specified amount of admixture to each batch and will be responsible for
its uniform operation during the progress of the work. He shall provide
separate scales for the admixtures which are to be proportioned by
weight, and accurate measures for those to be proportioned by volume.
Admixtures shall be measured into the mixer with an accuracy of plus or
minus three (3) percent.
The use of Calcium Chloride as an admixture will not be permitted.
405.4.4 Mixing and Delivery
Concrete may be mixed at the site of construction, at a central point or by a

combination of central point and truck mixing or by a combination of central point
mixing and truck agitating. Mixing and delivery of concrete shall be in accordance
with the appropriate requirements of AASHTO M 157 except as modified in the
following paragraphs of this section, for truck mixing or a combination of central
point and truck mixing or truck agitating. Delivery of concrete shall be regulated so
that placing is at a continuous rate unless delayed by the placing operations. The
intervals between delivery of batches shall not be so great as to allow the concrete
inplace to harden partially, and in no case shall such an interval exceed 30 minutes.
In exceptional cases and when volumetric measurements are authorized, for

small project requiring less than 75 cu.m. per day of pouring, the weight proportions
shall be converted to equivalent volumetric proportions. In such cases, suitable
allowance shall be made for variations in the moisture condition of the aggregates,
including the bulking effect in the fine aggregate. Batching and mixing shall be in
accordance with ASTM C 685, Section 6 through 9.
Concrete mixing, by chute is allowed provided that a weighing scales for

determining the batch weight will be used.
214
For batch mixing at the site of construction or at a central point, a batch mixer
of an approved type shall be used. Mixer having a rated capacity of less than a
one-bag batch shall not be used. The volume of concrete mixed per batch shall not
exceed the mixer’s nominal capacity as shown on the manufacturer’s standard
rating plate on the mixer except that an overload up to 10 percent above the mixer’s
nominal capacity may be permitted, provided concrete test data for strength,
segregation, and uniform consistency are satisfactory and provided no spillage of
concrete takes place. The batch shall be so charge into the drum that a portion of
the water shall enter in advance of the cement and aggregates. The flow of water
shall be uniform and all water shall be in the drum by the end of the first 15 seconds
of the mixing period. Mixing time shall be measured from the time all materials,
except water, are in the drum. Mixing time shall not be less than 60 seconds for
mixers having a capacity of 1.5m3 or less. For mixers having a capacity greater
than 1.5m3, the mixing time shall not be less than 90 seconds. If timing starts, the
instant the skip reaches its maximum raised position, 4 seconds shall be added to
the specified mixing time. Mixing time ends when the discharge chute opens.
The mixer shall be operated at the drum speed as shown on the

manufacturer’s name plate on the mixer. Any concrete mixed less than the
specified time shall be discarded and disposed off by the Contractor at his own
expenses.
The timing device on stationary mixers shall be equipped with a bell or other
suitable warning device adjusted to give a clearly audible signal each time the lock
is released. In case of failure of the timing device, the Contractor will be permitted
to continue operations while it is being repaired, provided he furnishes an approved
timepiece equipped with minute and second hands. If the timing device is not
placed in good working order within 24 hours, further use of the mixer will be
prohibited until repairs are made.
Retempering concrete will not be permitted. Admixtures for increasing the

workability, for retarding the set, or for accelerating the set or improving the pumping
characteristics of the concrete will be permitted only when specifically provided for
in the Contract, or authorized in writing by the Engineer.
1. Mixing Concrete: General
Concrete shall be thoroughly mixed in a mixer of an approved size

and type that will insure a uniform distribution of the materials throughout
the mass.
All concrete shall be mixed in mechanically operated mixers. Mixing

plant and equipment for transporting and placing concrete shall be
arranged with an ample auxiliary installation to provide a minimum supply
of concrete in case of breakdown of machinery or in case the normal
supply of concrete is disrupted. The auxiliary supply of concrete shall be
sufficient to complete the casting of a section up to a construction joint
that will meet the approval of the Engineer.
215
Equipment having components made of aluminum or magnesium
alloys, which would have contact with plastic concrete during mixing,
transporting or pumping of Portland Cement concrete, shall not be used.
Concrete mixers shall be equipped with adequate water storage and

a device of accurately measuring and automatically controlling the
amount of water used.
Materials shall be measured by weighing. The apparatus provided for

weighing the aggregates and cement shall be suitably designed and
constructed for this purpose. The accuracy of all weighing devices except
that for water shall be such that successive quantities can be measured
to within one percent of the desired amounts. The water measuring
device shall be accurate to plus or minus 0.5 mass percent. All
measuring devices shall be subject to the approval of the Engineer.
Scales and measuring devices shall be tested at the expense of the
Contractor as frequently as the Engineer may deem necessary to insure
their accuracy.
Weighing equipment shall be insulated against vibration or movement

of other operating equipment in the plant. When the entire plant is
running, the scale reading at cut-off shall not vary from the weight
designated by the Engineer more than one mass percent for cement, 1-
1/2 mass percent for any size of aggregate, or one (1) mass percent for
the total aggregate in any batch.
2. Mixing Concrete at Site
Concrete mixers may be of the revolving drum or the revolving blade

type and the mixing drum or blades shall be operated uniformly at the
mixing speed recommended by the manufacturer. The pick-up and
throw-over blades of mixers shall be restored or replaced when any part
or section is worn 20mm or more below the original height of the
manufacturer’s design. Mixers and agitators which have an accumulation
of hard concrete or mortar shall not be used.
When bulk cement is used and volume of the batch is 0.5m3 or more,
the scale and weigh hopper for Portland Cement shall be separate and
distinct from the aggregate hopper or hoppers. The discharge
mechanism of the bulk cement weigh hopper shall be interlocked against
opening before the full amount of cement is in the hopper. The
discharging mechanism shall also be interlocked against opening when
the amount of cement in the hopper is underweight by more than one (1)
mass percent or overweight by more than 3 mass percent of the amount
specified.
When the aggregate contains more water than the quantity necessary
to produce a saturated surface dry condition, representative samples
shall be taken and the moisture content determined for each kind of
aggregate.
216
The batch shall be so charged into the mixer that some water will enter
in advance of cement and aggregate. All water shall be in the drum by
the end of the first quarter of the specified mixing time.
Cement shall be batched and charged into the mixer so that it will not
result in loss of cement due to the effect of wind, or in accumulation of
cement on surface of conveyors or hoppers, or in other conditions which
reduce or vary the required quantity of cement in the concrete mixture.
The entire content of a batch mixer shall be removed from the drum
before materials for a succeeding batch are placed therein. The materials
composing a batch except water shall be deposited simultaneously into
the mixer.
All concrete shall be mixed for a period of not less than 1-1/2 minutes
after all materials, including water, are in the mixer. During the period of
mixing, the mixer shall operate at the speed for which it has been
designed.
Mixers shall be operated with an automatic timing device that can be

locked by the Engineer. The time device and discharge mechanics shall
be so interlocked that during normal operation no part of the batch will be
charged until the specified mixing time has elapsed.
The first batch of concrete materials placed in the mixer shall contain
a sufficient excess of cement, sand, and water to coat inside of the drum
without reducing the required mortar content of the mix. When mixing is
to cease for a period of one hour or more, the mixer shall be thoroughly
cleaned.
3. Mixing Concrete at Central Plant
Mixing at central plant shall conform to the requirements for mixing at

the site.
4. Mixing Concrete in Truck
Truck mixers, unless otherwise authorized by the Engineer, shall be

of the revolving drum type, water-tight, and so constructed that the
concrete can be mixed to insure a uniform distribution of materials
throughout the mass. All solid materials for the concrete shall be
accurately measured and charged into the drum at the proportioning
plant. Except as subsequently provided, the truck mixer shall be
equipped with a device by which the quantity of water added can be
readily verified. The mixing water may be added directly to the batch, in
which case a tank is not required. Truck mixers may be required to be
provided with a means of which the mixing time can be readily verified by
the Engineer.
217
The maximum size of batch in truck mixers shall not exceed the
minimum rated capacity of the mixer as stated by the manufacturer and
stamped in metal on the mixer. Truck mixing, shall, unless other-wise
directed be continued for not less than 100 revolutions after all
ingredients, including water, are in the drum. The mixing speed shall not
be less than 4 rpm, nor more than 6 rpm.
Mixing shall begin within 30 minutes after the cement has been added
either to the water or aggregate, but when cement is charged into a mixer
drum containing water or surface wet aggregate and when the
temperature is above 32oC, this limit shall be reduced to 15 minutes. The
limitation in time between the introduction of the cement to the aggregate
and the beginning of the mixing may be waived when, in the judgement
of the Engineer, the aggregate is sufficiently free from moisture, so that
there will be no harmful effects on the cement.
When a truck mixer is used for transportation, the mixing time

specified in Subsection 405.4.4 (3) at a stationary mixer may be reduced
to 30 seconds and the mixing completed in a truck mixer. The mixing
time in the truck mixer shall be as specified for truck mixing.
5. Transporting Mixed Concrete
Mixed concrete may only be transported to the delivery point in truck

agitators or truck mixers operating at the speed designated by the
manufacturers of the equipment as agitating speed, or in non-agitating
hauling equipment, provided the consistency and workability of the mixed
concrete upon discharge at the delivery point is suitable point for
adequate placement and consolidation in place.
Truck agitators shall be loaded not to exceed the manufacturer’s

guaranteed capacity. They shall maintain the mixed concrete in a
thoroughly mixed and uniform mass during hauling.
No additional mixing water shall be incorporated into the concrete

during hauling or after arrival at the delivery point.
The rate of discharge of mixed concrete from truck mixers or agitators

shall be controlled by the speed of rotation of the drum in the discharge
direction with the discharge gate fully open.
When a truck mixer or agitator is used for transporting concrete to the

delivery point, discharge shall be completed within one hour, or before
250 revolutions of the drum or blades, whichever comes first, after the
introduction of the cement to the aggregates. Under conditions
contributing to quick stiffening of the concrete or when the temperature
of the concrete is 30oC, or above, a time less than one hour will be
required.
6. Delivery of Mixed Concrete
218
The Contractor shall have sufficient plant capacity and transportation
apparatus to insure continuous delivery at the rate required. The rate of
delivery of concrete during concreting operations shall be such as to
provide for the proper handling, placing and finishing of the concrete. The
rate shall be such that the interval between batches shall not exceed 20
minutes. The methods of delivering and handling the concrete shall be
such as will facilitate placing of the minimum handling.
The quantity of structural concrete to be paid for will be the final quantity
placed and accepted in the completed structure. No deduction will be made for the
volume occupied by pipe less than 100mm (4 inches) in diameter or by reinforcing
steel, anchors, conduits, weep holes or expansion joint materials.
The accepted quantities, measured as prescribed in Section 405.5, shall be

paid for at the contract unit price for each of the Pay Item listed below that is
included in the Bill of Quantities.
Payment shall constitute full compensation for furnishing, placing and

finishing concrete including all labor, equipment, tools and incidentals necessary to
complete the work prescribed in the item.

Number
405 (1) Structural Concrete, Class A Cubic Meter
405 (2) Structural Concrete, Class B Cubic Meter
405 (3) Structural Concrete, Class C Cubic Meter
405 (4) Structural Concrete, Class P Cubic Meter
405 (5) Seal Concrete Cubic Meter
ITEM 406 – PRESTRESSED CONCRETE STRUCTURES
406.1 Description
This Item shall consist of prestressed concrete structures and the

prestressed concrete portions of composite structures, constructed in reasonably
close conformity with the lines, grades and dimensions shown on the Plans or
established by the Engineer and in accordance with this Specification. It shall also
include the furnishing and installing of any appurtenant items necessary for the
219
particular prestressing system to be used, including but not limited to ducts,
anchorage assemblies and grouts used for pressure grouting ducts.
406.2.1 Concrete and Grout
The materials for concrete and grout shall conform to Item 405, Structural
Concrete. The concrete shall be Class P as shown in Table 405.2, unless otherwise
shown on the Plans or specified in the Special Provisions. The proportions of the
grout will be as set out in Subsection 406.3.11, Bonding Steel.
406.2.2 Prestressing Reinforcing Steel
It shall conform to Item 710, Reinforcing Steel and Wire Rope.
406.2.3 Prestressing Steel
Rope.
All prestressing steel shall be protected against physical damage and rust or
other results of corrosion at all times from manufacture to grouting. Prestressing
steel that has sustained physical damage at any time shall be rejected.
406.2.4 Packaging, Storing and Shipping
Prestressing steel shall be packaged in containers or other shipping forms

for the protection of the steel against physical damage and corrosion during
shipping and storage. A corrosion inhibitor which prevents rust or other results of
corrosion shall be placed in the package or form, or when permitted by the
Engineer, may be applied directly to the steel. The corrosion inhibitor shall have no
deleterious effect on the steel or concrete or bond strength of concrete to steel.
Packaging or forms damaged from any cause shall be immediately replaced or
restored to original condition.
This shipping package or form shall be clearly marked with a statement that
the package contains high-strength prestressing steel and the care to be used in
handling, and the type, kind and amount of corrosion inhibitor used, including the
date when placed, safety orders and instructions for use.
406.2.5 Elastomeric Bearing Pads
This shall conform to Item 412, Elastomeric Bearing Pads.
406.2.6 Water
It shall conform to the requirements of Subsection 311.2.4, Water.
220
406.2.7 Enclosures
Duct enclosures for prestressing steel shall be galvanized ferrous metal or

of a type approved by the Engineer, mortartight and accurately placed at the
locations shown on the Plans or approved by the Engineer. Transition couplings
connecting said ducts to anchoring devices need not be galvanized.
406.2.8 Sampling and Testing
All wire, strand, anchorage assemblies or bars to be shipped to the site shall
be assigned a lot number and tagged for identification purposes.
All samples submitted shall be representative of the lot to be furnished and

in the case of wire or strand, shall be taken from the same master roll.
All of the materials specified for testing shall be furnished free of cost and
shall be delivered in time for tests to be made well in advance of anticipated time of
use.
The Contractor shall furnish for testing the following samples selected from
each lot, if ordered by the Engineer. The selection of samples will be made at the
manufacturer’s plant by the Engineer or his representative.
1. For pretensioning work-samples at least 2 m long shall be furnished of

each size of wire or strand proposed.
2. For post-tensioning work-samples of the following lengths shall be

furnished of each size of wire proposed.
a. For wire requiring heading, 2 m.

b. For wires not requiring heading, sufficient length to make up one
parallel-lay cable of 1.50 m long consisting of the same number of
wires as the cable to be furnished.
c. For strand to be furnished with fittings, 1.50 m between near ends
of fittings.
d. For bars to be furnished with thread ends and nuts, 1.5 m between
threads at ends.
3. Anchorage assemblies – If anchorage assemblies are not attached to

reinforcement samples, two (2) anchorage assemblies shall be furnished,
completed with distribution plates of each size and type to be used.
When prestressing system has been previously tested and approved for
similar projects by an agency acceptable to the Engineer, complete tendon samples
need not be furnished, provided there is no change whatsoever in the materials,
design or details previously approved.
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406.3.1 General
Prestressed concrete structural members shall be constructed in accordance

with the requirements of Item 405, Structural Concrete and Reinforcing Steel shall
be placed in accordance with the requirements of Item 404, Reinforcing Steel,
subject to the modifications and amendments contained herein.
406.3.2 Prestressing Method
The method of prestressing to be used shall be optional with the Contractor

subject to all requirements hereinafter specified.
The Contractor, prior to casting any members to be prestressed, shall submit

to the Engineer for approval complete details of the methods, materials and
equipment he proposes to use in the prestressing operations. Such details shall
outline the method and sequence of stressing, complete specifications and details
of the prestressing, steel and anchoring devices proposed for use, anchoring
stresses, type of enclosures and all other data pertaining to the prestressing
operations, including the proposed arrangement of the prestressing units in the
members, pressure grouting materials and equipment.
406.3.3 Prestressing Equipment
Hydraulic jacks used to stress tendons shall be equipped with either a

pressure gauge or a load cell for determining the jacking stress. The pressure
gauge, if used, shall have an accurate reading dial at least 154 mm (6 inches) in
diameter and each jack and its gauge shall be calibrated as a unit with the cylinder
extension in the approximate position that it will be at final jacking force, and shall
be accompanied by a certified calibration chart. The load cell, if used, shall be
calibrated and shall be provided with an indicator by means of which the
prestressing force in the tendon may be determined. The range of the load cell
shall be such that the lower ten (10) percent of the manufacturer’s rated capacity
will not be used in determining the jacking stress.
Safety measures shall be taken by the Contractor to prevent accidents due

to possible breaking of the prestressing steel or the slipping of the grips during the
prestressing process.
406.3.4 Casting Yard
The precasting of prestressed concrete structural members may be done at

a location selected by the Contractor, subject to the approval of the Engineer.
406.3.5 Placing Enclosures
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Enclosures for prestressed reinforcement shall be accurately placed at
locations shown on the Plans or approved by the Engineer.
406.3.6 Placing Steel
Steel units shall be accurately placed at the position shown on the Plans and
firmly held during the placing and setting of the concrete.
Ducts may be fabricated with either welded or interlocked seams.

Galvanizing of the welded steel will not be required. Ducts shall have sufficient
strength to maintain their correct alignment and shape during placing of concrete.
Joints between sections of ducts shall be positive metallic connections which do not
result in angle changes at the joints. Waterproof tape shall be used at the
connections.
All ducts or anchorage assemblies shall be provided with pipes or other

suitable connections for the injection of grout after prestressing.
Ducts for prestressing steel shall be securely fastened in place to prevent

movement.
After installation in the forms, the end of ducts shall at all times be covered
as necessary to prevent the entry of water of debris.
All ducts for continuous structures shall be vented over each intermediate
support, and at additional locations as shown on the Plans. Vents shall be 12.7 mm
(1/2 inch) minimum diameter standard pipe. Connections to ducts shall be made
with metallic structural fasteners. The vents shall be mortar tight, taped as
necessary, and shall provide means for injection of grout through the vents and for
sealing the vents. Ends of vents shall be removed 25.4 mm (1 inch) below the
roadway surface after grouting has been completed.
Distances from the forms shall be maintained by stays, blocks, ties, hangers
or other approved supports. Blocks for holding units from contact with the forms
shall be precast mortar blocks of approved shape and dimensions. Layers of units
shall be separated by mortar blocks or other equally suitable devices. Wooden
blocks shall not be left in the concrete.
When acceptable prestressing steel for post-tensioning is installed in ducts

after completion of concrete curing, and if stressing and grouting are completed
within ten (10) calendar days after the installation of the prestressing steel, rust
which may form during said ten (10) days will not be caused for rejection of the
steel. Prestressing steel, installed, tensioned and grouted in this manner, all within
ten (10) calendar days, shall be subject to all the requirements in this Item pertaining
to corrosion protection and rejection because of rust.
No welds or grounds for welding equipment shall be made on the forms or

on the steel in the manner after the prestressing steel has been installed.
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Wires, wire groups, parallel-lay cables and any other prestressing elements
shall be straightened to insure proper positioning in the enclosures.
Suitable horizontal and vertical spacers shall be provided, if required, to hold

the wires in place in true position in the enclosures.
406.3.7 Pretensioning
The prestressing elements shall be accurately held in position and stressed

by jacks. A record shall be kept of the jacking force and the elongations produced
thereby. Several units may be cast in one continuous line and stressed at one time.
Sufficient space shall be left between ends of units to permit access for cutting after
the concrete has attained the required strength. No bond stress shall be transferred
to the concrete, nor end anchorages released until the concrete has attained a
compressive strength, as shown by cylinder tests, of at least 28 MPa unless
otherwise specified. The elements shall be cut or released in such an order that
lateral eccentricity or prestress will be a minimum.
406.3.8 Placing Concrete
Concrete shall not be deposited in the forms until the Engineer has inspected
the placing of the reinforcement, enclosures, anchorages and prestressing steel
and given his approval thereof. The concrete shall be vibrated with care and in
such a manner as to avoid displacement of reinforcement, conduits, or wires.
Prior to placing concrete, the Contractor shall demonstrate to the Engineer

that all ducts are unobstructed.
406.3.9 Curing
Steam curing process may be used as an alternative to water curing. The

casting bed for any unit cured with steam shall be completely enclosed by a suitable
type of housing, tightly constructed so as to prevent the escape of steam and
simultaneously exclude outside atmosphere. Two to four hours after placing
concrete and after the concrete has undergone initial set, the first application of
steam or radiant heat shall be made unless retarders are used, in which case the
waiting period before application of the steam or radiant heat shall be increased to
from four to six hours.
During the waiting period, the temperature within the curing chamber shall
not be less than 10.0oC (50oF) and live steam or radiant heat may be used to
maintain the curing chamber at the proper minimum temperature. The steam shall
be at 100 percent relative humidity to prevent loss of moisture and to provide
moisture for proper hydration of the cement. Application of the steam shall not be
directly on the concrete. During application of the steam, or of radiant heat, the
ambient air temperature shall increase at a rate not to exceed 4.41 oC per hour until
the curing temperature is reached. The maximum curing temperature within the
enclosure shall not exceed 71.1oC. The maximum temperature shall be held until
the concrete has reached the desired strength. Detensioning shall be
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accomplished immediately after the steam curing or the heat curing has been
discontinued and additional curing is not required after detensioning.
1. Curing with Low Pressure Steam
Application of live steam shall not be directed on the concrete forms

as to cause localized high temperatures.
2. Curing with Radiant Heat
Radiant heat may be applied by means of pipes circulating steam, hot oil or
hot water, or by electric heating elements. Radiant heat curing shall be done under
a suitable enclosure to contain the heat and moisture loss shall be minimized by
covering all exposed concrete surfaces with plastic sheeting or by applying an
approved liquid membrane curing compound to all exposed concrete surfaces. Top
surface of concrete members to be used in composite construction shall be clear of
residue of the membrane curing compound so as not to reduce bond below design
limits.
If the Contractor proposes to cure by any other special method, the method
and its details shall be subject to the approval of the Engineer.
406.3.10 Post-tensioning
Tensioning of the prestressing reinforcement shall not be commenced until

tests on concrete cylinders, manufactured of the same concrete and cured under
the same conditions, indicate that the concrete of the particular member to be
prestressed has attained compressive strength of at least 28 MPa unless otherwise
specified.
After all concrete has attained the required strength, the prestressing
reinforcement shall be stressed by means of jacks to the desired tension and the
stress transferred to the end anchorage.
Cast-in-place concrete shall not be post-tensioned until at least ten (10) days
after the last concrete has been placed in the member to be the post-tensioned and
until the compressive strength of said placed concrete has reached the strength
specified for the concrete at the time of stressing.
All side forms for girders shall be removed before post-tensioning. The
falsework under the bottom slab supporting the superstructure shall not be released
until a minimum of 48 hours have elapsed after grouting of the post-tension tendons
nor until all other conditions of the Specifications have been met. The supporting
falsework shall be constructed in such a manner that the superrestructure will be
free to lift off the falsework and shorten during post-tensioning. Formwork left inside
box girders to support the roadway slab shall be detailed in such a manner so as to
offer minimum resistance to girder shortening due to shrinkage and post-tensioning.
The tensioning process shall be so conducted that the tension being applied
and the elongation of the prestressing elements may be measured at all times. The
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friction loss in the element, i.e., the difference between the tension of the jack and
the minimum tension, shall be determined in accordance with Article 1.6.7 of
AASHTO Standard Specifications for Highway Bridges.
Suitable shims or other approved devices shall be used to insure that the
specified anchor set loss is attained.
Prestressing tendons in continuous post-tensioned members shall be

tensioned by jacking at each end of the tendon. Such jacking of both ends need
not be done simultaneously.
A record shall be kept of gage pressure and elongation at all times and
submitted to the Engineer for his approval.
406.3.11 Bonding Steel
Prestressing steel shall be bonded to the concrete by filling the void space
between the duct and the tendon with grout
.
Grout shall consist of Portland Cement, water and an expansive admixture
Water shall be potable.
No admixture containing chlorides or nitrates shall be used.
Water shall first be added to the mixer followed by cement and admixture.
The grout shall be mixed in mechanical mixing equipment of a type that will
produce uniform and thoroughly mixed grout. The water content shall be not more
than 19 litres (5 gallons) per sack of cement. Retempering of grout will not be
permitted. Grout shall be continuously agitated until it is pumped.
Grouting equipment shall be capable of grouting at a pressure of at least

0.6894 MPa (100 psi).
Grouting equipment shall be furnished with a pressure gauge having a full-

scale reading of not more than 2.07 MPa (300 psi).
Standby flushing equipment capable of developing a pumping pressure of

1.72 MPa (250 psi) and of sufficient capacity to flush out any partially grouted ducts
shall be provided.
All ducts shall be clean and free of deleterious materials that would impair
bonding of the grout or interfere with grouting procedures. All grout shall pass
through a screen with a 2 mm (0.0787 inch) maximum clear openings prior to being
introduced into the grout pump.
Grout injection pipes shall be fitted with positive mechanical shutoff valves.
Vents and ejection pipes shall be fitted with valves, caps or other devices capable
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of withstanding the pumping pressures. Valves and caps shall not be removed or
opened until the grout has set.
Post-tensioned steel shall be bonded to the concrete. All prestressing steel

to be bonded to the concrete shall be free of dirt, loose rust, grease or other
deleterious substances.
Immediately after completion of the concrete pour, the metal conduit shall be
blown out with compressed oil free air to the extent necessary to break up and
remove any mortar in the conduit before it hardens. Approximately 24 hours after
the concrete pour, the metal conduits shall be flushed out with water and then blown
out with compressed oil free air.
Prior to placing forms for roadway slabs of box girder structures, the
Contractor shall demonstrate to the satisfaction of the Engineer that all ducts are
unobstructed and if the prestressing reinforcement has been placed, that the steel
is free and unbonded in the duct.
After the tendons have been stressed to the required tension, each conduit
encasing the prestressing steel shall be blown out with compressed oil free air. The
conduit shall then be completely filled from the low end with grout under pressure.
Grout shall be pumped through the duct and continuously wasted at the outlet until
no visible slugs of water or air are ejected and the efflux time of ejected grout is not
less than 11 seconds. All vents and openings shall then be closed and the grouting
pressure at the injection end shall be raised to a minimum of 0.6894 MPa (100 psi)
and held for a minimum of 10 seconds.
If aluminum powder is used to expand the grout, it shall be added as follows:
From 2 to 4 grams of the unpolished variety (about 1 to 2 teaspoons) shall

be added for each sack of cement used in the grout. The exact amount of aluminum
powder will be designated by the Engineer. The dosage per batch of grout shall be
carefully weighed. A number of weighings may be made in the laboratory and
doses placed in glass vials for convenient use in the mix. The aluminum powder
shall be blended with pumicite or other inert powder in the proportion of one (1)
part powder to fifty (50) parts pumicite (or other inert powder) by weight. The blend
shall be thoroughly mixed with the cement. The amount of the blend used should
vary from 120 g (4-1/2 ounces) per sack of cement for concrete having a
temperature of 21.1oC to 190 g (7 ounces) for a temperature of 4.44oC after all
ingredients are added, the batch shall be mixed for 3 minutes. Batches of grout
shall be placed within 45 minutes after mixing.
406.3.12 Unbonded Steel
Where the steel is not to be bonded to the concrete, it shall be carefully

protected against corrosion by a coating of tar of other waterproofing material, in
addition to any galvanizing which may be specified in addition to the requirements
of ASTM A 416 (AASHTO M 203) and ASTM A 421 (AASHTO M 204.)
406.3.13 Handling
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Extreme care shall be exercised in handling and moving precast prestressed
concrete mortar members. Precast girders and slabs shall be transported in an
upright position and the points of support and directions of the reactions with respect
to the member shall be approximately the same during transportation and storage
as when the members are in their final position. If the Contractor deems it expedient
to transport or store precast units in other than this position, it shall be done at his
own risk after notifying the Engineer of his intention to do so.
Prestressed concrete girders shall not be shipped until tests on concrete

cylinders, manufactured of the same concrete and cured under the same conditions
as the girders, indicate that the concrete of the particular girder has attained a
compressive strength equal to the specified design compressive strength of the
concrete in the girder and has attained a minimum age of 14 days.
406.3.14 Composite Slab Construction
The manufacturing tolerances for pre-cast members shall not exceed those
given for length, cross-section and straightness on the Plans, as specified in the
Contract or as approved by the Engineer. In addition, where beams are laid side
by side in a deck:
1. The difference on soffit level between adjacent units before the in-situ
concrete is placed shall not exceed 5 mm for units up to 10 mm for longer
units.
2. The width of the deck soffit shall be within ±25 mm.
3. In adjacent span, the continuity of the outside beams shall be maintained.
4. The width of gap between individual beams shall not exceed twice the
nominal gap.
5. The alignment of transverse holes shall permit the reinforcement or
prestressing cables to be placed without distortion.
406.4.1 Structural Members
The quantity to be measured for payment will be the actual number of precast
prestressed concrete structural members, except piling, of the several types and
sizes, installed in place, completed and accepted. Each member will include the
concrete, reinforcement and prestressing steel, anchorages, plates, nuts,
elastomeric bearing pads, and other such material contained within or attached to
the unit.
Piling will be measured as provided in Item 400.
406.4.2 Other Items
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The quantities of other Contract items which enter into the completed and
accepted structure will be measured for payment in the manner prescribed for the
several items involved.
The accepted quantities, measured as prescribed in Section 406.4 shall be

paid for at the contract unit price for each of the particular item listed below that is
included in the Bill of Quantities, which price and payment shall be full
compensation for furnishing and placing all materials, including all labor, equipment,
tools and incidentals necessary to complete the work prescribed in this Item.

Number
406 (1) Prestressed Structural Concrete

Members (Identification) Each
406 (2) Prestressed Concrete Lump Sum
ITEM 407– CONCRETE STRUCTURES
407.1 Description
This Item shall consist of the general description of the materials, equipment,
workmanship and construction requirements of concrete structures and the
concrete portions of composite structures conforming to the alignment, grades,
design, dimensions and details shown on the Plans and in accordance with the
Specifications for piles, reinforcing steel, structural steel, structural concrete and
other items which constitute the completed structure. The class of concrete to be
used in the structure or part of the structure shall be as specified in Item 405,
Structural Concrete.
1. Concrete and Concrete Ingredients
Concrete and concrete materials shall conform to the requirements in Item

405, Structural Concrete. Unless otherwise shown on the Plans or specified in
Special Provisions, concrete shall be of Class A.
2. Reinforcing Steel
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Reinforcing steel shall conform to the requirements in Item 404, Reinforcing
Steel.
3. Structural Steel
Structural steel shall conform to the requirements of corresponding materials

in Item 403, Metal Structures.
4. Bridge Bearing (Elastomeric Bearing Pad)
Elastomeric bearing pads shall conform to Item 412, Elastomeric Bearing

Pads.
5. Paints
Paints shall conform to the requirements in Item 411, Paint.
6. Waterproofing and Dampproofing
Unless otherwise shown on the Plans or indicated in Special Provisions,

materials for waterproofing and dampproofing shall conform to the requirements of
the following specifications:
a. AASHTO M 115 Asphalt for dampproofing and waterproofing.
b. AASHTO M 116 Primer for the use with Asphalt in dampproofing and
waterproofing.
c. AASHTO M 117 Woven cotton fabrics saturated with bituminous
substances for use in waterproofing.
d. AASHTO M 118 Coal-Tar pitch for roofing, dampproofing and water-
proofing.
e. AASHTO M 121 Creosote for priming coat with coal-tar pitch damp-
proofing and waterproofing.
f. AASHTO M 159 Woven burlap fabric saturated with bituminous
substances for use in waterproofing.
g. AASHTO M 166 Numbered cotton duck and array duck.
h. AASHTO M 239 Asphalt for use in waterproofing membrane construction.
7. Concrete Curing Compound
Curing compound shall conform to the requirements of AASHTO M 148

Liquid membrane-forming compounds for curing concrete.
8. Joint Filler
Unless otherwise shown on the Plans or in Special Provisions, materials for

expansion joint filler shall conform to the requirements of the following
specifications:
230
a. AASHTO M 33 Preformed expansion joint filler for concrete.
b. AASHTO M 153 Preformed sponge rubber and cork expansion joint fillers
for concrete paving and structural construction.
c. AASHTO M 173 Concrete joint sealer hot poured elastic type.
d. AASHTO M 213 Preformed expansion joint filler for concrete paving and
structural construction-non-extruding and resilient bituminous types.
e. AASHTO M 220 Preformed elastomeric compression joint seals for

concrete.
407.2.1 Proportioning and Strength of Structural Concrete
This shall be in accordance with Item 405, Structural Concrete.
This shall be in accordance with Item 405, Structural Concrete.
407.3 Construction and Requirements
407.3.1 Handling and Placing Concrete: General
Concrete shall not be placed until forms and reinforcing steel have been
checked and approved by the Engineer.
If lean concrete is required in the Plan or as directed by the Engineer prior to

placing of reinforcing steel bar, the lean concrete should have a minimum
compressive strength of 13.8 MPa (2,000 psi)..
In preparation for the placing of concrete all sawdust, chips and other
construction debris and extraneous matter shall be removed from inside the
formwork, struts, stays and braces, serving temporarily to hold the forms in correct
shape and alignment, pending the placing of concrete at their locations, shall be
removed when the concrete placing has reached an elevation rendering their
service unnecessary. These temporary members shall be entirely removed from
the forms and not buried in the concrete.
No concrete shall be used which does not reach its final position in the forms
within the time stipulated under “Time of Hauling and Placing Mixed Concrete”.
Concrete shall be placed so as to avoid segregation of the materials and the

displacement of the reinforcement. The use of long troughs, chutes, and pipes for
conveying concrete to the forms shall be permitted only on written authorization of
the Engineer. The Engineer shall reject the use of the equipment for concrete
transportation that will allow segregation, loss of fine materials, or in any other way
will have a deteriorating effect on the concrete quality.
231
Open troughs and chutes shall be of metal lined; where steep slopes are
required, the chutes shall be equipped with baffles or be in short lengths that
reverse the direction of movement to avoid segregation.
All chutes, troughs and pipes shall be kept clean and free from coatings of
hardened concrete by thoroughly flushing with water after each run. Water used
for flushing shall be discharged clear of the structure.
When placing operations would involve dropping the concrete more than 1.5
m, concrete shall be conveyed through sheet metal or approved pipes. As far as
practicable, the pipes shall be kept full of concrete during placing and their lower
end shall be kept buried in the newly placed concrete. After initial set of the
concrete, the forms shall not be jarred and no strain shall be placed on the ends of
projecting reinforcement bars.
The concrete shall be placed as nearly as possible to its final position and
the use of vibrators for moving of the mass of fresh concrete shall not be permitted.
407.3.1.1 Placing Concrete by Pneumatic Means
Pneumatic placing of concrete will be permitted only if specified in the

Special Provisions or authorized by the Engineer. The equipment shall be so
arranged that vibration will not damage freshly placed concrete.
Where concrete is conveyed and placed by pneumatic means, the

equipment shall be suitable in kind and adequate in capacity for the work. The
machine shall be located as close as practicable to the work. The discharge lines
shall be horizontal or inclined upwards from the machine. The discharge end of the
line shall not be more than 3 m from the point of deposit.
At the conclusion of placing the concrete, the entire equipment shall be

thoroughly cleaned.
407.3.1.2 Placing of Concrete by Pumping
The placing of concrete by pumping will be permitted only if specified or if

authorized by the Engineer. The equipment shall be so arranged that vibration will
not damage freshly placed concrete.
Where concrete is conveyed and placed by mechanically applied pressure

the equipment shall be suitable in kind and adequate in capacity for the work. The
operation of the pump shall be such that a continuous stream of concrete without
air pockets is produced. When pumping is completed, the concrete remaining in
the pipeline, if it is to be used, shall be ejected in such a manner that there will be
no contamination of the concrete or separation of the ingredients. After this
operation, the entire equipments shall be thoroughly cleaned.
407.3.1.3 Placing Concrete in Water
232
Concrete shall not be placed in water except with approval of the Engineer
and under his immediate supervision. In this case the method of placing shall be
hereinafter specified.
Concrete deposited in water shall be Class A concrete with a minimum

cement content of 400 kg/m3 of concrete. The slump of the concrete shall be
maintained between 10 and 20 cm. To prevent segregation, concrete shall be
carefully placed in a compact mass, in its final position, by means of a tremie, a
bottom-dump bucket, or other approved means, and shall not be disturbed after
being placed.
A tremie shall consist of a tube having a diameter of not less than 250 mm
constructed in sections having flanged couplings fitted with gaskets with a hopper
at the top. The tremie shall be supported so as to permit free movement of the
discharge and over the entire top surface of the work and so as to permit rapid
lowering when necessary to retard or stop the flow of concrete. The discharge end
shall be closed at the start of work so as to prevent water entering the tube and
shall be completely submerged in concrete at all times; the tremie tube shall be kept
full to the bottom of the hopper. When a batch is dumped into the hopper, the flow
of concrete shall be induced by lightly raising the discharge end, but always keeping
it in the placed concrete. The flow shall be continuous until the work is completed.
When the concrete is placed with a bottom-dump bucket, the top of the
bucket shall be open. The bottom doors shall open freely downward and outward
when tripped. The buckets shall be completely filled and slowly lowered to avoid
backwash. It shall not be dumped until it rests on the surface upon which the
concrete is to be deposited and when discharged shall be withdrawn slowly until
well above the concrete.
407.3.2 Compaction of Concrete
Concrete during and immediately after placing shall be thoroughly

compacted. The concrete in walls, beams, columns and the like shall be placed in
horizontal layers not more than 30 cm thick except as hereinafter provided. When
less than a complete layer is placed in one operation, it shall be terminated in a
vertical bulkhead. Each layer shall be placed and compacted before the preceding
layer has taken initial set to prevent injury to the green concrete and avoid surfaces
of separation between the layers. Each layer shall be compacted so as to avoid
the formation of a construction joint with a preceding layer.
The compaction shall be done by mechanical vibration. The concrete shall

be vibrated internally unless special authorization of other methods is given by the
Engineer or is provided herein. Vibrators shall be of a type, design, and frequency
approved by the Engineer. The intensity of vibration shall be such as to visibly
affect a mass of concrete with a 3 cm slump over a radius of at least 50 cm. A
sufficient number of vibrator shall be provided to properly compact each batch
immediately after it is placed in the forms. Vibrators shall be manipulated so as to
thoroughly work the concrete around the reinforcement and embedded fixtures and
into the corners and angles of the forms and shall be applied at the point of placing
and in the area of freably placed concrete. The vibrators shall be inserted into and
233
withdrawn from the concrete slowly. The vibration shall be of sufficient duration and
intensity to compact the concrete thoroughly but shall not be continued so as to
cause segregation and at any one point to the extent that localized areas of grout
are formed. Application of vibrators shall be at points uniformly spaced, and not
farther apart than twice the radius over which the vibration is visibly effective.
Vibration shall not be applied directly or thru the reinforcement to sections or layers
of concrete that have hardened to the degree that the concrete ceases to be plastic
under vibration. It shall not be used to make concrete flow in the forms over
distances so great as to cause segregation, and vibrators shall not be used to
transport concrete in the forms of troughs or chutes.
407.3.3 Casting Sections and Construction Joints
The concrete in each form shall be placed continuously. Placing of concrete

in any such form shall not be allowed to commence unless sufficiently inspected
and approved materials for the concrete is at hand, and labor and equipment are
sufficient to complete the pour without interruption.
Joints in the concrete due to stopping work shall be avoided as much as

possible. Such joints, when necessary, shall be constructed to meet the approval
of the Engineer.
When the placing of concrete is temporarily discontinued, the concrete, after

becoming firm enough to retain its shape, shall be cleaned of laitance and other
objectionable material to a sufficient depth to expose sound concrete. Where a
“faster edge” might be produced at a construction joint, as in the sloped top surface
of a wingwall, an inset formwork shall be used to produce an edge thickness of not
less than 15 cm in the succeeding layer. Work shall not be discontinued within 50
cm of the top of any face, unless provision has been made for a coping less than
50 cm thick, in which case if permitted by the Engineer, the construction joint may
be made at the underside of coping.
Immediately following the discontinuance of placing concrete, all

accumulations of mortar splashed upon the reinforcing steel and the surfaces of
forms shall be removed. Dried mortar chips and dust shall not be puddled into the
unset concrete. Care shall be exercised, during the cleaning of the reinforcing steel,
not to injure or break the concrete-steel bond at and near the surface of the
concrete.
407.3.4 Casting Box Culverts
In general, the base slab of box culverts shall be placed and allowed to set
before the remainder of the culvert is constructed. In the construction of box
culverts the side walls and top slab may be constructed as a monolith.
234
If the concrete in the walls and top slab is placed in two separate operations,
special care shall be exercised in order to secure bonding in the construction joint
and appropriate keys shall be left in the sidewalls for anchoring the top slab. Each
wingwall shall be constructed, if possible, as a monolith. Construction joints where
unavoidable, shall be horizontal and so located that no joints will be visible in the
exposed face of the wingwall above the ground line.
Vertical construction joints shall be at right angles to the axis of the culverts.
407.3.5 Casting Columns, Slabs and Girders
Concrete in columns shall be placed in one continuous operation, unless

otherwise directed. The concrete shall be allowed to set for at least 20 hours before
the caps are placed.
Unless otherwise permitted by the Engineer, no concrete shall be placed in

the superstructure until the column forms have been stripped sufficiently to
determine the condition of the concrete in the column. The load of the super-
structure shall not be allowed to come upon the bents until they have been in place
at least 14 days, unless otherwise permitted by the Engineer.
Concrete in slab spans shall be placed in one continuous operation for each
span unless otherwise provided.
Concrete in T-Beam or deck girder spans shall be placed in one continuous

operation unless otherwise directed. If it is permitted to place the concrete in two
separate operations, each of the operations, shall be continuous: first, to the top of
the girder stems, and second, to completion. In the latter case, the bond between
stem and slab shall be secured by means of suitable shear keys which may be
formed by the use of timber blocks approximately 50 mm x 100 mm in cross-section
having a length of 100 mm less than the width of the girder stem. These key blocks
shall be placed along the girder stems as required, but the spacing shall not be
greater than 300 mm center to center. The blocks shall be beveled and oiled in
such a manner as to insure their ready removal, and they shall be removed as soon
as the concrete has set sufficiently to retain its shape. If the contractor wishes to
place the concrete in two separate operations, he shall, with his request for
permission to do so, submit plans and proposals of the required changes to the
reinforcement, which plans and proposals shall be subject to the approval of the
Engineer.
In box girders, the concrete in the bottom slab be poured first, as a separate
operation.
The concrete in the webs and the top slab shall be placed in one continuous
operation unless otherwise specified. If it is permitted to place the concrete in more
than one operation, the requirements for T-beam shall apply.
407.3.6 Construction Joints
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Construction joints shall be made only where shown on the Plans or called
for in the pouring schedule, unless otherwise approved by the Engineer. Shear
keys or reinforcement shall be used, unless otherwise specified, to transmit shear
or to bond the two sections together.
Before depositing new concrete on or against concrete which has hardened,

the forms shall be retightened. The surface of the hardened concrete shall be
roughened as required by the Engineer, in a manner that will not leave loose
particles of aggregate or damage concrete at the surface. It shall be thoroughly
cleaned of foreign matter and laitance. When directed by the Engineer, the surface
of the hardened concrete which will be in contact with new concrete shall be washed
with water to this satisfaction, and to insure an excess of mortar at the juncture of
the hardened and the newly deposited concrete, the cleaned and saturated
surfaces, including vertical and inclined surfaces shall first be thoroughly covered
with a coating of mortar of the same proportion of sand and cement as the class of
concrete used against which the new concrete shall be placed before the grout or
mortar has attained its initial set.
The placing of concrete shall be carried continuously from joint to joint. The
face edges of all joints which are exposed to view shall be carefully finished true to
line and elevation.
407.3.7 Concrete Surface Finishing
Surface finishing shall be classified as follows:
Class 1, Ordinary Finish

Class 2, Rubbed Finish
Class 3, Floated Finish
All concrete shall be given Class 1, Ordinary Finish and additionally any
further finish as specified.
Unless otherwise specified, the following surfaces shall be given a Class 2,

Rubbed Finish.
1. The exposed faces of piers, abutments, wingwalls, and retaining walls.

2. The outside faces of girders, T-beams, slabs, columns, brackets, curbs,
headwalls, railings, arch rings, spandrel walls and parapets.
Excluded, however, are the tops and bottoms of floor slabs and sidewalks,
bottoms of beams and girders, sides of interior beams and girders, backwalls above
bridge seats or the underside of copings. The surface finish on piers and abutments
shall include all exposed surfaces below the bridge seats to 20 cm below low water
elevation or 50 cm below finished ground level when such ground level is above the
water surface. Wingwalls shall be finished from the top to 50 cm below the finished
slope lines on the outside face and shall be finished on top and for a depth of 20
cm below the top on the back sides.
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Unless otherwise specified, the surface of the traveled way shall be Class 3,
Floated Finish.
Class 1, Concrete Ordinary Finish
Immediately following the removal of forms, all fins and irregular protection
shall be removed from all surface except from those which are not to be exposed
or are not to be waterproofed. On all surfaces the cavities produced by form ties
and all other holes, honeycomb spots, broken corners or edges and other defects
shall be thoroughly cleaned, and after having been kept saturated with water for a
period of not less than three hours shall be carefully pointed and made true with a
mortar of cement and fine aggregate mixed in the proportions used in the grade of
the concrete being finished. Mortar used in pointing shall not be more than one
hour old. The mortar patches shall be cured as specified under Subsection 407.3.8.
All construction and expansion joints in the completed work shall be left carefully
tooled and free of all mortar and concrete. The joint filler shall be left exposed for
its full length with a clean and true edges.
The resulting surface shall be true and uniform. All repaired surfaces, the
appearance of which is not satisfactory to the Engineer, shall be “rubbed” as
specified below.
Class 2, Concrete Rubbed Finish
After removal of forms, the rubbing of concrete shall be started as soon as

its condition will permit. Immediately before starting this work, the concrete shall be
kept thoroughly saturated with water for a minimum period of three hours. Sufficient
time shall have elapsed before the wetting down to allow the mortar used in the
pointing of road holes and defects to thoroughly set. Surfaces to be finished shall
be rubbed with a minimum coarse carborundum stone using a small amount of
mortar on each face. The mortar shall be composed of cement and fine sand mixed
in the proportions used in the concrete being finished. Rubbing shall be continued
until all form marks, protections and irregularities have been removed, all voids have
been filled, and a uniform surface has been obtained. The face produced by this
rubbing shall be left in place at this time.
After all concrete above the surface being created has been cast, the final
finish shall be obtained by rubbing with a fine carborundum stone and water. This
rubbing shall be continued until the entire surface is of smooth texture and uniform
color.
After the final rubbing is completed and the surface has dried, it should be
rubbed with burlap to remove loose powder and shall be left free from all unsound
patches, paste, powder and objectionable marks.
Class 3, Concrete Floated Finish
After the concrete is compacted as specified in Subsection 407.3.2,

Compaction of Concrete, the surface shall be carefully struck off with a strike board
to conform to the cross-section and grade shown on the Plans. Proper allowance
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shall be made for camber if required. The strike board may be operated
longitudinally or transversely and shall be moved forward with a combined
longitudinal and transverse motion, the manipulation being such that neither is
raised from the side forms during the process. A slight excess of concrete shall be
kept in front of the cutting edge at all times.
After striking off and consolidating as specified above, the surface shall be
made uniform by longitudinal or transverse floating or both. Longitudinal floating
will be required except in places where this method is not feasible.
The longitudinal float, operated from foot bridges, shall be worked with a
sawing motion while held in a floating position parallel to the road centerline and
passing gradually from one side of the pavement to the other. The float shall then
be moved forward one-half of each length and the above operation repeated.
Machine floating which produces an equivalent result may be substituted for the
above manual method.
The transverse float shall be operated across the pavement by starting at

the edge and slowly moving to the center and back again to the edge. The float
shall then be moved forward one-half of each length and the above operation
repeated. Care shall be taken to preserve the crown and cross-section of the
pavement.
After the longitudinal floating has been completed and the excess water
removed, but while the concrete is still plastic, the slab surface shall be tested for
trueness with a straight-edge. For the purpose, the Contractor shall furnish and use
an accurate 3 m straight-edge swing handless 1 m longer than one half the width
of the slab.
The straight-edge shall be held in successive positions parallel to the road

centerline and in contact with the surface and the whole area gone over from one
side of the slab to the other as necessary advancement along the deck shall be in
successive stages of not more than one-half the length of the straight-edge. Any
depression found shall be immediately filled with freshly mixed concrete, struck off,
consolidated and refinished. The straight-edge testing and refloating shall continue
until the entire surface is found to be free from observable departure from the
straight-edge and the slabs has the required grade and contour, until there are no
deviations of more than 3 mm under the 3 m straight-edge.
When the concrete has hardened sufficiently, the surface shall be given a
broom finish. The broom shall be an approved type. The strokes shall be square
across the slabs from edge to edge, with adjacent strokes slightly overlapped, and
shall be made by drawing the broom without tearing the concrete, but so as to
produce regular corrugations not over 3 mm in depth. The surface as thus finished
shall be free from porous spots, irregularities, depressions and small pockets or
rough spots such as may be caused by accidental disturbing, during the final
brooming of particles of coarse aggregate embedded near the surface.
Concrete Surface Finish for Sidewalk.
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After the concrete has been deposited in place, it shall be compacted and
the surface shall be struck off by means of strike board and floated with a wooden
or cork float. An edging tool shall be used on all edges and at all expansion joints.
The surface shall not vary more than 3 mm under a 3 m straight-edge. The surface
shall have a granular or matted texture which will not slick when wet.
407.3.8 Curing Concrete
All newly placed concrete shall be cured in accordance with this

Specification, unless otherwise directed by the Engineer. The curing method shall
be one or more of the following:
1. Water Method
The concrete shall be kept continuously wet by the application of

water for a minimum period of 7 days after the concrete has been placed.
The entire surface of the concrete shall be kept dump by applying

water with an atomizing nozzle. Cotton mats, rugs, carpets, or earth or
sand blankets may be used to retain the moisture. At the expiration of
the curing period the concrete surface shall be cleared of the curing
medium.
2. Curing Compound
Surfaces exposed to the air may be cured by the application of an

impervious membrane if approved by the Engineer.
The membrane forming compound used shall be practically colorless

liquid. The use of any membrane-forming compound that will alter the
natural color of the concrete or impart a slippery surface to any wearing
surface shall be prohibited. The compound shall be applied with a
pressure spray in such a manner as to cover the entire concrete surface
with a uniform film and shall be of such character that it will harden within
30 minutes after application. The amount of compound applied shall be
ample to seal the surface of the concrete thoroughly. Power-operated
spraying equipment shall be equipped with an operational pressure
gauge and means of controlling the pressure.
The curing compound shall be applied to the concrete following the

surface finishing operation immediately after the moisture sheen begins
to disappear from the surface, but before any drying shrinkage or craze
cracks begin to appear. In the event of any delay, in the application of
the curing compound, which results in any drying or cracking of the
surface, application of water with an atomizing nozzle as specified under
“Water Method”, shall be started immediately and shall be continued until
the application of the compound is resumed or started, however, the
compound shall not be applied over any resulting free standing water.
Should the film of compound be damaged from any cause before the
expiration of 7 days after the concrete is placed in the case of structures,
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the damaged portion shall be repaired immediately with additional
compound.
Curing compound shall not be diluted or altered in any manner after

manufacture. At the time of use, the compound shall be in a thoroughly
mixed condition. If the compound has not been used within 120 days
after the date of manufacture, the Engineer may require additional testing
before the use to determine compliance to requirements.
An anti-setting agent or a combination of anti-setting agents shall be

incorporated in the curing compound to prevent caking.
The curing compound shall be packaged in clean barrels or steel

containers or shall be supplied from a suitable storage tank located on
the Site. Storage tank shall have a permanent system designed to
completely redisperse any settled material without introducing air or any
other foreign substance. Containers shall be well-sealed with ring seals
and lug type crimp lids. The linings of the containers shall be of a
character that will resist the solvent of the curing compound. Each
container shall be labeled with a manufacturer’s name, specification
number, batch number, capacity and date of manufacture, and shall have
label warning concerning flammability. The label shall also warn that the
curing compound shall be well-stirred before use. When the curing
compound is shipped in tanks or tank trunks, a shipping invoice shall
accompany each load. The invoice shall contain the same information
as that required herein for container labels.
Curing compound may be sampled by the Engineer at the source of

supply and on the Site.
3. Waterproof Membrane Method
The exposed finished surfaces of concrete shall be sprayed with

water, using a nozzle that so atomizes the flow that a mist and not a spray
is formed until the concrete has set, after which a curing membrane of
waterproof paper or plastic sheeting shall be placed. The curing
membrane shall remain in place for a period of not less than 72 hours.
Waterproof paper and plastic sheeting shall conform to the

specification of AASHTO M 171.
The waterproof paper or plastic sheeting shall be formed into sheets

of such width as to cover completely the entire concrete surface.
All joints in the sheets shall be securely cemented together in such a

manner as to provide a waterproof joint. The joint seams shall have a
minimum lap of 100 mm.
The sheets shall be securely weighed down by placing a bank of earth

on the edges of the sheets or by other means satisfactory to the Engineer.
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Should any portion of the sheets be broken or damaged within 72
hours after being placed, the broken or damaged portions shall be
immediately repaired with new sheets properly cemented into place.
Sections of membrane which have lost their waterproof qualities or

have been damaged to such an extent as to render them unfit for curing,
the concrete shall not be used.
4. Forms-in-Place Method
Formed surfaces of concrete may be cured by retaining the form-in-

place. The forms shall remain in place for a minimum period of 7 days
after the concrete has been placed, except that for members over 50 cm
in least dimensions, the forms shall remain in place for a minimum period
of 5 days. Wooden forms shall be kept wet by watering during the curing
period.
5. Curing Cast-In-Situ Concrete
All newly placed concrete for cast-in-situ structures, other than

highway bridge deck, shall be cured by the water method, the forms-in-
place method, or as permitted herein, by the curing compound method,
all in accordance with the requirements of Subsection, 407.3.8 Curing
Concrete.
The curing compound method may be used on concrete surfaces

which are to be buried under ground and surfaces where only Ordinary
Surface Finish is to be applied and on which a uniform color is not
required and which will not be visible from public view.
The top surface of highway bridge decks shall be cured by either the
curing compound method or the water method. The curing compound
shall be applied progressively during the deck finishing operations. The
water cure shall be applied not later than 4 hours after completion of the
deck finishing.
When deemed necessary by the Engineer during periods of hot

weather, water shall be applied to concrete surface being cured by the
curing compound method or by the forms-in-place method until the
Engineer determine that a cooling effect is no longer required.
6. Curing Pre-Cast Concrete (except piles)
Pre-cast concrete members shall be cured for not less than 7 days by
the water method or by steam curing. Steam curing for pre-cast members
shall conform to the following provisions:
a. After placement of the concrete, members shall be held for a minimum

4-hour pre-steaming period.
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b. To prevent moisture loss on exposed surfaces during the pre-
steaming period, members shall be covered immediately after casting
or the exposed surface shall be kept wet by fog spray or wet blankets.
c. Enclosures for steam curing shall allow free circulation of steam about
the member and shall be constructed to contain the live steam with a
minimum moisture loss. The use of tarpaulins or similar flexible
covers will be permitted, provided they are kept in good condition and
secured in such a manner to prevent the loss of steam and moisture.
d. Steam at jets shall be low pressure and in a saturated condition.

Steam jets shall not impinge directly on the concrete, test cylinders,
or forms. During application of the steam, the temperature rise within
the enclosure shall not exceed 20oC per hour. The curing
temperature throughout the enclosure shall not exceed 65oC and shall
be maintained at a constant level for a sufficient time necessary to
develop the required compressive strength. Control cylinders shall be
covered to prevent moisture loss and shall be placed in a location
where temperature of the enclosure will be the same as that of the
concrete.
e. Temperature recording devices that will provide an accurate

continuous permanent record of the curing temperature shall be
provided. A minimum of one temperature recording device per 50 m
of continuous bed length will be required for checking temperature.
f. Curing of pre-cast concrete will be considered completed after the

termination of the steam curing cycle.
7. Curing Pre-cast Concrete Piles
All newly placed concrete for pre-cast concrete piles, conventionally

reinforced or prestressed shall be cured by the “Water Method” as
described in Subsection 407.3.8, Curing Concrete, except that the
concrete shall be kept under moisture for at least 14 days. At the option
of the Contractor, stream curing may be used in which case the steam
curing provisions of Subsection 407.3.8 (6), Curing Pre-Cast Concrete
(except piles) shall apply except that the concrete shall be kept wet for at
least 7 days including the holding and steaming period.
407.3.9 Falsework Design and Drawings
Detailed working drawings and supporting calculations of the false work shall
be furnished by the Contractor to the Engineer. No falsework construction shall
start until the Engineer has reviewed and approved the design. The Contractor
shall provide sufficient time for the Engineer to complete this review. Such time
shall be proportionate to the complexity of the falsework design and in no case be
less than two weeks.
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The Contractor may review the falsework drawings at any time provided
sufficient time is allowed for the Engineer’s review before construction is started on
the revised portion.
Assumptions used in design of the falsework shall include but not be limited
to the following:
1. The entire superstructure cross-section, except for the railing, shall be

considered to be placed at one time, except when in the opinion of
the Engineer, a portion of the load is carried by members previously
cast and having attained a specified strength.
2. The loading used on timber piles shall not exceed the bearing value
for the pile and shall in no case exceed 20 tonne per pile.
3. Soil bearing values and soil condition (wet and dry) shall be
designated by the Contractor on the falsework drawings. Falsework
footings shall be designed to carry the loads imposed upon them
without exceeding estimated soil bearing values or allowable
settlements.
4. The maximum loadings and deflections used on jacks, brackets,
columns and other manufactured devices shall not exceed the
manufacture’s recommendations. If requested by the Engineer, the
Contractor shall furnish catalogue or other data verifying these
recommendations.
5. If the concrete is to be prestressed, the falsework shall be designed
to support any increased or readjusted loads caused by the
prestressing forces.
6. Joints supporting slabs and overhangs shall be considered as
falsework and designed as such.
For the construction of falsework over and adjacent to roadways where

falsework openings are required for maintaining traffic, the Contractor shall provide
any additional features for the work needed to insure that the falsework will be
stable if subjected to impact by vehicles.
The falsework design at the locations where said openings are required shall
include but not be limited to the following minimum provisions:
a. Each exterior stringer in a span shall be securely anchored to the

following cap or framing.
b. Adequate bracing shall be used during all stages of falsework

construction and removal over or adjacent to public traffic.
c. Falsework members shall be at least 300 mm clear of temporary

protective railing members.
The falsework drawings shall include a superstructure placing diagram

showing proposed concrete placing sequence and construction joint locations,
except that where a schedule for placing concrete is shown on the Contract Plans,
no deviation will be permitted there from unless approved in writing by the Engineer.
243
The falsework drawings shall show pedestrian openings which are required
through the falsework.
Anticipated total settlements of falsework and forms shall be indicated by the

Contractor on the falsework drawings. These should include falsework footing
settlements over 20 mm will not be allowed unless otherwise permitted by the
Engineer. Deck slab forms between girders shall be constructed with no allowance
for settlement relative to the girders.
Detailed calculations by the Contractor showing the stresses deflections, and

camber necessary to compensate for said deflections in all load supporting
members shall be supplied.
After approving the Contractor’s falsework deflection camber, the Engineer

will furnish to the Contractor the amounts of camber necessary to compensate for
vertical alignment or anticipated structure deflection, if these are not shown on the
drawings. The total camber used in constructing falsework shall be the sum of the
aforementioned cambers.
407.3.10 Falsework Construction
The falsework shall be constructed to conform to the falsework drawings.

The materials used in the falsework construction shall be of the quantity and quality
necessary to withstand the stresses imposed. The workmanship used in falsework
shall be of such quality that the falsework will support the loads imposed on it
without excessive settlement or take-up beyond that shown on the falsework
drawings.
When falsework is supported on piles, the piles shall be driven to a bearing

value equal to the total calculated pile loading as shown on the falsework drawings.
Suitable jacks or wedges shall be used in connection with falsework to set

the forms to their required grade and to take up any excessive settlement in the
falsework either before or during the placing of concrete.
The Contractor shall provide tell-tales attached to the soffit forms easily
readable and in enough systematically-placed locations to determine the total
settlement of the entire portion of the structure where concrete is being placed.
Should unanticipated events occur, including settlements that deviate more

than ±20 mm from those indicated on the falsework drawings, which in the opinion
of the Engineer would prevent obtaining a structure conforming to the requirement
of the Specification, the placing of concrete shall be discontinued until corrective
measures satisfactory to the Engineer are provided. In the event satisfactory
measures are not provided prior to initial set of the concrete in the affected area,
the placing of concrete shall be discontinued at a location determined by the
Engineer. All unacceptable concrete shall be removed.
407.3.11 Removing Falsework
244
Unless otherwise shown on the drawings, or permitted by the Engineer,
falsework supporting any span of a supported bridge shall not be released before
14 days after the last concrete, excluding concrete above the bridge deck, has been
placed. Falsework supporting any span of a continuous or rigid frame bridge shall
not be released before 14 days after the last concrete excluding concrete above the
bridge deck, has been placed in that span and in the adjacent portions of each
adjoining span for a length equal to at least half the length of the span where
falsework is to be released.
Falsework supporting deck overhangs and deck slabs between girders shall
not be released until 7 days after the deck concrete has been placed.
In addition to the above requirements, no falsework for bridges shall be

released until the supported concrete has attained a compressive strength of at
least 80% of the required 28-day strength. Falsework for cast-in place prestressed
portion of structure shall not be released until after the prestressing steel has been
tensioned.
All falsework materials shall be completely removed. Falsework piling shall

be removed at least 50 cm below the surface of the original ground or stream bed.
When falsework piling is driven within the limits of ditch or channel excavation
areas, the falsework piling within such areas shall be removed to at least 50 cm
below the bottom and side slopes of said excavated areas.
All debris and refuse resulting from work shall be removed and the site left
in a neat and presentable condition.
407.3.12 Formwork Design and Drawings
The Contractor shall prepare drawings and materials data for the
formwork and shutters to be submitted to the Engineer for approval
unless otherwise directed.
The requirements for design of formwork are the same as described under
Section 407.3.9.
407.3.13 Formwork Construction
Concrete forms shall be mortar-tight, true to the dimensions, lines and

grades of the structure and with the sufficient strength, rigidity, shape and surface
smoothness as to leave the finished works true to the dimensions shown on the
Plans or required by the Engineer and with the surface finish as specified.
Formwork and shutters are to be constructed in accordance with the

approved Plans.
The inside surfaces of forms shall be cleaned of all dirt, mortar and foreign
material. Forms which will later be removed shall be thoroughly coated with form
oil prior to use. The form oil shall be of commercial quality form oil or other approved
245
coating which will permit the ready release of the forms and will not discolor the
concrete.
Concrete shall not be deposited in the forms until all work in connection with
constructing the forms has been completed, all materials required for the unit to be
poured, and the Engineer has inspected and approved said forms and materials.
Such work shall include the removal of all dirt, chips, sawdust and other foreign
material from the forms.
The rate of depositing concrete in forms shall be such to prevent bulging of

the forms or form panels in excess of the deflections permitted by the Specification.
Forms for all concrete surfaces which will not be completely enclosed or
hidden below the permanent ground surface shall conform to the requirements
herein for forms for exposed surfaces. Interior surfaces of underground drainage
structures shall be completely enclosed surfaces.
Formwork for concrete place under water shall be watertight. When lumber
is used, this shall be planed, tongued and grooved.
Forms for exposed concrete surface shall be designed and constructed so

that the formed surface of the concrete does not undulate excessively in any
direction between studs, joists, form stiffeners, form fasteners, or wales.
Undulations exceeding either 2 mm or 1/270 of the center to center distance
between studs, joists, form stiffeners, form fasteners, or wales will be considered to
be excessive. Should any form of forming system, even though previously
approved for use, produce a concrete surface with excessive undulations, its use
shall be discontinued until modifications satisfactory to the Engineer have been
made. Portions of concrete structures with surface undulations in excess of the
limits herein specified may be rejected by the Engineer.
All exposed surfaces of similar portions of a concrete structure shall be

formed with the same forming material or with materials which produce similar
concrete surface textures, color and appearance.
Forms for exposed surfaces shall be made of form materials of even

thickness and width and with uniform texture. The materials shall have sharp edges
and be mortar-tight.
Forms for exposed surfaces shall be constructed with triangular fillets at least
20 mm wide attached so as to prevent mortar runs and to produce smooth straight
chamfers at all sharp edges of the concrete.
Form fasteners consisting of form bolts, clamps or other devices shall be

used as necessary to prevent spreading of the forms during concrete placement.
The use of ties consisting of twisted wire loops to hold forms in position will not be
permitted.
246
Anchor devices may be cast into the concrete for later use in supporting
forms or for lifting precast members. The use of driven types of anchorage for
fastening forms of form supports to concrete will not be permitted.
407.3.14 Removal of Forms and Falsework
Forms and falsework shall not be removed without the consent of the
Engineer. The Engineer’s consent shall not relieve the Contractor of responsibility
for the safety of the work. Blocks and bracing shall be removed at the time the
forms are removed and in no case shall any portion of the wood forms be left in the
concrete.
Falsework removal for continuous or cantilevered structures shall be as

directed by the Engineer or shall be such that the structure is gradually subjected
to its working stress.
When concrete strength tests are used for removal of forms and supports,
such removal should not begin until the concrete has attained the percentage of the
specified design strength shown in the table below.
Minimum Time Minimum Percentage

Design Strength
Centering under girders,
beams frames or arches 14 days 80%
Floor slabs 14 days 70%
Walls 1 day 70%
Columns 2 days 70%
Sides of beams and all
other vertical surfaces 1 day 70%
In continuous structures, falsework shall not be released in any span until

the first and second adjoining spans on each side have reached the strength
specified herein, or in the Special Specifications. When cast-in-place post
tensioned bridges are constructed, falsework shall remain in place until all post
tensioning has been accomplished.
Falsework under all spans of continuous structures shall be completely

released before concrete is placed in railings and parapets. In order to determine
the condition of column concrete, forms shall be removed from columns before
releasing supports from beneath beams and girders.
Forms and falsework shall not be released from under concrete without first
determining if the concrete has gained adequate strength without regard to the time
element. In the absence of strength determination, the forms and falsework are to
remain in place until removal is permitted by the Engineer.
The forms for footings constructed within cofferdams or cribs may be left in
place when, in the opinion of the Engineer, their removal would endanger the safety
of the cofferdam or crib, and when the forms so left intact will not be exposed to
247
view in the finished structure. All other forms shall be removed whether above or
below the ground line or water level.
All forms shall be removed from the cells of concrete box girders in which
utilities are present and all formwork except that necessary to support the deck slab
shall be removed from the remaining cells of the box girder.
To facilitate finishing, forms used on ornamental work, railing, parapets and

exposed vertical surfaces shall be removed in not less than 12 nor more than 48
hours, depending upon weather conditions. In order to determine the condition of
concrete in columns, forms shall always be removed from them before the removal
of shoring from beneath beams and girders.
Falsework and centering for spandrel-filled arches not be struck until filling
at the back of abutments has been placed up to the spring line. Falsework
supporting the deck of rigid frame structure shall not be removed until fills have
been placed back to the vertical legs.
The quantity of structural steel, structural concrete, reinforcing steel or other

Contract Pay Items shall constitute the completed and accepted structure which
shall be measured for payment in the manner prescribed in the several items
involved.
The quantities measured as provided in Section 407.4, Method of

Measurement shall be paid for at the contract price for the several pay items which
price and payment shall be full compensation for furnishing, preparing, fabricating,
placing, curing and for all labor, equipment, tools and incidentals necessary to
complete the Item. Such payment shall constitute full payment for the completed
structure ready for use.
Pay Item Number Description Unit

of Measurement
405 (1) Concrete Class A, C & P Cubic Meter
405 (2) Concrete Post/Baluster Each
Railings Linear Meter
405 (3) Parapet Walls Cubic Meter
400 Piling Linear Meter
103 Structure Excavation Cubic Meter
601 Sidewalk Concrete Square Meter or
Cubic Meter
404 Reinforcing Steel Bars Kilogram
248
407 (1) Lean Concrete Cubic Meter
When more than one item is specified, means of identification shall be

inserted in parenthesis immediately after the Pay Item and letter suffixes shall be
included within the parenthesis of the Pay Item Number.
ITEM 408– STEEL BRIDGES
408.1 Description
This Item shall consist of the construction of steel structure conforming to the
lines, grades, dimensions and designs shown on the Plans and in accordance with
the Specifications for piling, concrete metal reinforcement, structural steel and other
items which constitute the completed structure.
408.2 Materials
All materials shall conform to the detailed requirements specified for the
component parts of the completed structure. Where special materials are required,
they shall be shown on the Plans or in the Special Provisions.
408.3 Construction Methods
408.3.1 Organization and Equipment
During the progress of the work the Contractor shall have a competent
foreman or superintendent, experienced in steel erection, in personal charge of the
work.
Before starting work, the Contractor shall inform the Engineer as to the
method of erection he proposes to follow and the amount and character of
equipment he proposes to use, which shall be subject to the approval of the
Engineer. The approval of the Engineer shall not be considered as relieving the
Contractor of the responsibility for the safety of his method or equipment or from
carrying out the work in full accordance with the Plans and Specifications. Erection
diagrams shall be approved by the Director, Bureau of Design.
408.3.2 Handling and Storing Materials
Steel and timber shall be placed on skids above the ground and shall be kept
clean. The underlying ground shall be kept free from vegetation and properly
drained. Girders and beams shall be placed upright and shored. Long members,
such as columns and chords, shall be supported on skids placed close enough
together to prevent injury by deflection. The Contractor shall be responsible for the
loss of any material, which has been paid for by the Bureau, while it is in his care,
or for any damage, resulting from his work. The loading, transporting, unloading
and piling of structural material shall be so conducted that the metal will be kept
free from injury from rough handling.
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408.3.3 Erection
The Contractor shall furnish and place all falsework, erect all metal work,
remove the temporary construction, and do all work required to complete the
structure as covered by the Contract, including the removal of the old structure or
structures if so stipulated, all in accordance with the Plans and these Specifications.
If the substructure and superstructure are built under separate contracts, the
Department will provide the substructure, constructed to correct lines and
elevations and properly finished, and will establish the lines and elevation required
for setting the steel.
If the fabrication and erection of the superstructure are done under separate
contract, the Department will furnish detail plans for the bridge or bridges to be
erected, including shop details, camber diagrams, erection diagrams, list of field
rivets and bolts, and copy of shipping statements showing a list of parts and their
weights.
The Contractor shall provide all tools, machinery, and appliances including
drift pins and fitting up bolts, necessary for the expeditious handling of the work.
The falsework shall be properly designed, substantially built and maintained

for the loads which will come upon it. The Contractor, shall prepare and submit to
the Engineer for approval plans for falsework or for changes in existing structure
necessary for maintaining traffic. Approval of the Contractor’s plans shall not be
considered as relieving him of any responsibility.
The parts shall be accurately assembled as shown on the Plans and any
matchmarks shall be followed. The material shall be carefully handled that no parts
will be bent, broken or otherwise damaged. No hammering shall be done that will
in any way injure or damage a member. Bearing surface and surfaces to be in
permanent contact shall be cleaned before the members are assembled. Unless
erected by the cantilever method, truss spans shall be erected on blocking so
placed as to give the trusses proper camber. The blocking shall be left in place,
until the tension chord splices are fully riveted and all other truss connection pinned
and bolted. Rivets in splices of butts joints of compression members and rivets in
railings shall not be driven until the span is swung. Splices and filled connections
shall have one-half of the holes filled with bolts and cylindrical erection pin (half
bolts and half pins) before riveting. Splices and connections carrying traffic during
erection shall have three-fourths of the holes so filled. Fitting up bolts shall be of
the same nominal diameter as the rivets and cylindrical erection pins shall be 0.75
mm (1/32 inch) larger.
408.3.4 Welding
Where so indicated on the Plans, structural members shall be joined by

welding. The welds shall be of the size and type indicated and shall be made by
competent operators. Shop welding shall conform in all details to the Standard
Specifications for Welded Highway and Railway Bridges of the American Welding
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Society. Field welding shall conform to the requirement of Item 409, Welded
Structural Steel.
408.3.5 Bent Material
The straightening of plates, angles, and other shapes shall be done by

methods not likely to produce fractures or other injury. The metal shall not be
heated. Following the straightening of a bend or buckle, the surface shall be
carefully inspected for evidence of fracture. Sharpkinks and bends may be cause
for the rejection of the material.
408.3.6 Alignment
Before beginning the field riveting, the structural steel shall be adjusted to
correct grade and alignment and elevation of panel points (end of floor beams)
properly regulated. For truss spans a slight excess camber will be permitted while
the bottom chords are being riveted.
408.3.7 Field Riveting
Pneumatic hammers shall be used for field riveting. Cup-faced dollies, fitting
the head closely, shall be used to insure good bearing. Connections shall be
secured and accurately fitted up before the rivets are driven. Drifting shall be only
such as to draw the parts into position and not sufficient to enlarge the holes or
distort the metal. Unfair holes shall be reamed or drilled. Rivets shall be heated
uniformly to light cherry-red color and shall be driven while hot. They shall not be
overheated or burned. Rivet heads shall be full and symmetrical, concentric with
the shank, and shall have full bearing all around. They shall not be smaller than
the heads of the shop rivets. Rivets shall be tight and shall grip the connected parts
securely together. Caulking or recupping will not be permitted. In removing rivets,
the surrounding metal shall not be injured, and if necessary they shall be drilled out.
408.3.8 Bolted Connections
In bolted connections, the nut shall be drawn up tight and set by center
punching the threads of the bolt at the face of the nut.
408.3.9 Pin Connections
Pilot and driving nuts shall be used in driving pins. Pins shall be so driven
that the members will take full bearing on them. Pin nuts shall be screwed up tight
and threads burred at the face of the nut with a center punch.
408.3.10 Misfits and Shop Errors
The connection of minor misfits involving non-harmful amounts of reaming,

cutting and chipping will be considered a legitimate part of the erection. However,
any error in the shop fabrication or deformation resulting from handling and
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transportation which prevents the proper assembling and fitting up of parts by the
moderate use of drift pins or a moderate amount of reaming and slight chipping and
cutting shall be reported immediately to the Engineer, and his approval of the
method of correction obtained. If the Contract provides for completed fabrication
and erection, the Contractor shall be responsible for all misfits, errors and injuries
and shall make the necessary correction and replacements. If the Contract is for
erection only, the inspector, with the cooperation of the Contractor shall keep a
correct record of labor and materials and be used in correction of misfits, errors and
injuries, not due to actions of the Contractor, and the Contractor shall render within
30 days of itemized bill for the approval of the Engineer.
408.3.11 Placing Anchor Bolts
Anchor bolts shall be placed as provided under Item 407, Concrete

Structures or as shown on the Plans.
408.3.12 Setting Shoes and Bearing
Shoes and bearing plates shall not be placed on bridge seat bearing areas
that are improperly finished or that are deformed or irregular. They shall be set
level in exact position and elevation and shall have full even bearing. Unless
otherwise specified, the shoes and bearing plates shall be set by the following
methods:
a. The bridge seat bearing area shall be heavily coated with lead paint and
then covered with three layers of 340.2 to 369.8 g (12 to 14 ounces) duck,
each layer being coated thoroughly on its top surface with red-lead paint.
The shoes and bearing plates shall be placed in position while the paint
is plastic. As an alternate to canvas and red lead 3 mm (1/8 inch) sheet
lead may be used if called for on the Plans or is approved by the
Engineer.
b. The shoes and bearing plates shall be properly supported and fixed with
grout. No lead shall be placed upon them until the grout has set for at
least 96 hours, adequate provision being made to keep the grout well
moistened during this period. The grout shall consist of one part Portland
Cement to one part fine-grained sand.
The location of the anchor bolts in relation to the slotted holes in the
expansion shoes correspond to the temperature at the time of erection. The nuts
on the anchor bolts at the expansion end of spans shall be adjusted to permit the
free movement of span. Anchor bolt nuts shall be set by center punching the
threads of the bolts at the face of the nut.
408.3.13 Painting
Unless otherwise specified, metal work shall be given two shop coats of red
lead paint and two field coats of paint as specified under Item 411, Paint.
408.3.14 Placing Concrete
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On steel spans, the concrete floor shall not be placed until the span has been
swung or released from the falsework.
The concrete shall be placed symmetrically on the span beginning at the

center and working simultaneously towards each end or beginning at the ends and
working simultaneously towards the center. In either case, the concrete shall be
placed continuously between construction joints designated on the Plans or
approved in writing by the Engineer.
Concrete shall be cured specified under Item 407, Concrete Structures.
408.3.15 Timber Floors
Timber floors of the species and grade indicated on the plans shall be built
as specified under Timber Structures, Item 402.
408.3.16 Field Inspection
All materials and work of erection shall be subject to the inspection of the
Engineer, who shall be given all facilities required.
Materials and workmanship not previously inspected will not inspected after
its delivery to the site of the work. Any materials inspected and accepted prior to
delivery on the work shall be subject to rejection if found defective after delivery.
The quantity of structural steel and other Contract Pay Items which constitute
the completed and accepted structure shall be measured for payment in the manner
prescribed in the several items involved.
The quantities, measured as prescribed above, shall be paid for at the

contract until price for the several Pay Items which price and payments shall be full
compensation for furnishing, preparing, fabricating, transporting, placing and
erecting all structural steel and all other materials for the complete structure; for all
shop work, painting and field work; for all labor, equipment, tools and incidentals
necessary to complete the item. Such payment shall constitute full payment for the
completed structure ready for use, and no allowance shall be made for cofferdam
construction, falsework, or other erection expenses as provided under Subsection
408.3.10.
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ITEM 409 – WELDED STRUCTURAL STEEL
409.1 Description
This work shall consist of the joining of structural steel members with welds
of the type, dimensions, and design shown on the Plans and in accordance with the
Specifications.
It is the intent of this Specification to provide for work of a quality comparable

to that required under the Standard Specifications for Welded Highway and Railway
Bridges of the American Welding Society. In case of dispute or for situations not
adequately provided for in this Specification, those designated Standard
Specifications shall be considered as the final authority and shall govern except as
amended by the Special Provisions.
Welding of Structural Steel shall be done only when shown on the Plans or
authorized in writing by the Engineer.
409.2 Materials Requirements
Steel base metal to be welded shall be open-hearth or electric furnace steel

conforming to AASHTO M 183.
All arc-welding electrodes shall conform to the requirements of American

Welding Society Specifications. Electrodes shall be of classification numbers
E7016, E7018 or E7028 as required for the positions, type of current and polarity,
and other conditions of intended use, and to conform to any special requirements
indicated on the Plans.
Filler material to be used in the repair or strengthening of old structures or

for joining new parts to existing steel members, shall be adopted to the material to
be welded and may depart from the foregoing requirements only if agreed by the
Engineer.
409.3.1 Equipment
409.3.1.1 General
All items of equipment for welding and gas cutting shall be so designed and
manufactured and in such condition as to enable qualified welders to follow the
procedures and attain the results prescribed in this Specification.
409.3.1.2 Arc-Welding Equipment
Welding generators and transformers shall be designed expressly for

welding. They shall be capable of delivering steady currents adjustable through a
range ample for the work requirements. They shall respond automatically and
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quickly to changes in power requirements due to variations in arc length and shall
deliver full current promptly on striking an arc.
Welding cable shall have sufficient conductivity to avoid overheating and

inadequate current at the arc and shall be effectively insulated against welding
circuit voltage. Earth or ground connections and circuits shall be secured and
adequate to carry the welding currents.
Electrode holders shall grip the electrode firmly and with good electrical
contact.
Approved automatic welding heads may be used, with suitable auxiliary

handling equipment to provide automatic instead of manual control of electrode and
welding arc.
409.3.1.3 Gas-Cutting Equipment
Torches and tips shall be of proper size and type of the work at hand.
Suitable regulators shall afford the welder complete control over the pressure and
rate of flow of each gas.
409.3.1.4 Protective Equipment
All personnel protective equipment shall conform to the American Standard

Association Code for such equipment.
The Contractor shall enforce the use of approved accessories necessary for
the protection and convenience of the welders and for the proper and efficient
execution of the work.
Suitable protection against the light of the arc shall be maintained by the
Contractor when arc-welding operation might be viewed within harmful range by
persons other than the actual welders and inspectors.
409.3.2 Welding
409.3.2.1 General
Welding shall be performed by the metal-arc process, using the electrodes

specified with either direct or alternating current.
Surfaces to be welded shall be smooth, uniform and free from fins, tears,
and other defects which would adversely affect the quality of the weld. Edges of
material shall be trimmed by machining, chipping, grinding, or machine gas-cutting
to produce a satisfactory welding edge wherever such edge is thicker than: 13 mm
for sheared edge of material; 16 mm for toes of angles or rolled shapes (other than
wide flange sections); 25 mm for universal mill plate or edges of flange sections.
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The width of root face used, shall be not more than 1.5 mm for parts less
than 10 mm in thickness nor more than 3 mm for parts 10 mm or more in thickness.
Butt welds shall be proportioned so that their surface contours will lie in
gradual transition curves. For butt welded joints between base metal parts of
unequal thickness, a transition shall be provided on a slope or level not greater than
1 in 2.5 to join the offset surfaces. This transition may be provided by sloping the
surface of the weld metal or by bevelling the thicker part or by combination of these
two methods.
Surfaces to be welded shall be free from loose scale, slag, rust, grease or
other material that will prevent proper welding. Mill scale that withstands vigorous
wire brushing or a light film of drying oil or rust inhibitive coating may remain.
Surfaces within 50 mm of any weld location shall be free of any paint or other
material that would prevent proper welding or produce objectionable fumes while
welding.
No operation or actual welding or gas-cutting shall be performed on a

member while it is carrying live load stress or while subject to shock and vibration
and from moving loads. Welding and gas-cutting shall cease in advance of the
application of such loads.
409.3.2.2 Welders
All welding shall be done by approved competent and experienced and fully
qualified welders.
409.3.2.3 Preparation of Materials for Welding
Dimensional tolerance, straightness and flatness of the structural shapes

and plates shall be within the limits prescribed in this Specification.
Structural steel which is to be welded shall preferably not be painted until all
welding is completed.
Preparation of edges by gas-cutting shall, wherever practicable, be done by

machine gas-cutting. Machine gas-cutting edges shall be substantially as smooth
and regular as those produced by edge planning and shall be left free of slag.
Manual gas cutting shall be permitted only where machine gas-cutting is not
practicable and with the approval of the Engineer. The edge resulting from manual
gas-cutting shall be inspected and smoothed with special care. All re-entrant
corners shall be filleted to a radius at least 19 mm. The cut lines shall not extend
beyond the fillet and all cutting shall follow closely the line prescribed.
409.3.2.4 Assembly
The parts to be joined by fillet welds shall be brought into a close contact as
practicable, and no event shall be separated more than 5 mm. If the separation is
1.5 mm or greater, the leg of the fillet weld shall be increased by the amount of
separation. The separation between faying surfaces of lap joints and of butt joints
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landing on a backing structure shall not exceed 1.5 mm. The fit of joints which are
not sealed by welds throughout their length shall be sufficiently close to exclude
water after painting. Where irregularities in rolled shape or plates, after
straightening, do not permit contact within the above limits, the procedure
necessary to bring the material within these limits shall be subject to the approval
of the Engineer.
Cutting parts to be joined by butt welds shall be carefully aligned. Where the
parts are effectively restrained against bending due to eccentricity or alignment, a
maximum offset of 10 percent of the thickness or the thinner part joined, but in no
case more than 3 mm, may be permitted as a departure from the theoretical
alignment. In connecting alignment in such cases, the parts shall not be drawn into
a greater slope than two degrees (1 in 30). Measurement of offset shall be between
centerline of parts unless otherwise shown on the Plans.
When parts abutting edge to edge differ in thickness, the joint shall be of
such form that the slope of either surface through the transition zone does not
exceed 1 in 2.5, the thicker part being bevelled, if necessary.
Members to be welded shall be brought into correct alignment and held in

position by bolts, clamps, wedges, guy lines, struts, other suitable devices or tack
welds until welding has been completed. The use of jigs and fixtures is
recommended where practicable. Such fastening devices as may be used shall be
adequate to insure safety.
Plug and slot welds may be used to transmit shear in a lap joint or to prevent
the buckling or separation of lapped parts.
The diameter of the hole for a plug weld shall not be less than the thickness
of the part containing it plus 8 mm nor shall it be greater than 2.25 times the
thickness of the weld.
The minimum center spacing of plug welds shall be four times the diameter
of the hole.
The length of the slot for a slot weld not exceed ten times the thickness of
the weld. The width of the slot shall not be less than the thickness of the part
containing it plus 8 mm nor shall it be greater than 2.25 times the thickness of the
weld.
The ends of the slot shall be semicircular or shall have the corners rounded
to a radius not less than the thickness of the part containing it, except those ends
which extend to the edge of the part.
The minimum spacing of lines of slot welds in a direction transverse to their

length shall be 4 times the width of the slot. The minimum center to center spacing
in a longitudinal direction on any line shall be 2 times the length of the slot.
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The thickness of plug or slot welds in material 16 mm or less in thickness
shall be equal to the thickness of the material. In material over 16 mm in thickness,
it shall be at least one-half the thickness of the material but not less than 16 mm.
Tack welds, located where the final welds will later be made, shall be subject
to the same quality requirements as the final weld. Tack welds shall be as small as
practicable and where encountered in the final welding, shall be cleaned and fused
thoroughly with the final weld. Defective, cracked or broken tack welds shall be
removed before final welding.
Members or component parts of structures shall be assembled and

matchmarked prior to erection to insure accurate assembly and adjustment of
position on final erection. Painted assembly marks shall be removed from any
surface to be welded.
409.3.2.5 Control of Distortion and Shrinkage Stresses
In assembling and joining parts of a structure or a built-up member and in

welding reinforcing parts to existing members, the procedure and sequence of
welding shall be such as will avoid distortion and minimize shrinkage stresses.
As far as practicable, long parallel lines of welding on a part or member shall

be executed concurrently, and all welds shall be deposited in a sequence that will
balance the applied heat of welding on various sides as much as possible while the
welding progresses.
Before the commencement of welding on a structural member in which

severe shrinkage stresses or distortion are likely to occur, a complete program for
welding sequence and distortion control shall be submitted to the Engineer and
shall be subject to his approval.
The direction of the general progression in welding on a member shall be

from points where parts are relatively fixed in position, with respect to each other,
toward points which have a greater relative freedom of movement.
Where part or member is to be welded on both ends into a rigid structure or

assembly, the connection at which the greatest shrinkage will occur in the direction
of the length of the part or member, shall be made while the part or member is free
to move in the direction of the shrinkage; and the connection involving the least
shrinkage shall be made last.
A weld designed to sustain tensile stress shall be made in such a way that
their welding is being performed at any point, all parts that would offer restraint
against shrinkage can shrink, deform or move enough to preclude serious
shrinkage stresses.
In welding of built-up members of heavy sections, particularly those T or H-

shapes where the flanges are considerably heavier than the stems or webs, and in
any case where the component parts are 38 mm or greater in thickness, special
care shall be exercised during welding to avoid weld cracking. In the welding of
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members of such heavy section, the temperature of contiguous areas about a
welding operation shall be equal, and not less than 55 oC. If necessary, the lighter
parts shall be heated while the weld is cooling, to keep the temperature of
contiguous parts substantially equal.
In the fabrication of cover-plated beams and built-up members, all shop

splices in each component part shall be made before such component part is
welded to other parts of the member.
In making all butt-welded splices in rolled shapes and in making butt-welded

field splices in built-up sections (such as in H or I-sections) the sequence and
procedure of welding shall be such as to take into account unequal amounts of
expansion or contraction in the parts being welded. The procedure and sequence
shall be such that while the weld and the heated base metal are contracting at any
point, any part of the member that would furnish restraint against such contraction
can move or shrink enough to prevent the shrinkage of the heated metal from
producing harmful internal stresses. The procedure and sequence that is used for
making such splices shall be planned in advance in full detail and submitted to the
Engineer and shall be subject to his approval.
The ends of all butt welds in flanges of beams and girders shall be made with
extension bars regardless of the thickness of such flanges.
Welding shall not be done when surfaces are wet from condensation or rain
which is falling on the surfaces to be welded; nor during periods of high winds unless
the welding operator and the work are properly protected.
409.3.2.6 Technique of Arch-Welding
The welding current shall conform with respect to voltage and current (and
polarity, of direct current is used) to the recommendations of the manufacturer of
the electrode being used, as indicated in the instructions that are included with
each container of electrodes.
Arc lengths and electrical potential and current shall be suited to the
thickness of material, type of groove and other circumstances attendant to the work.
The maximum size of electrode permitted shall be 5 mm with the following

exceptions:
1. The maximum size for flat position welding of all passes except the root
pass shall be 8 mm.
2. The maximum size for horizontal fillet welds shall be 6 mm.
The electrode for the single pass fillet weld and for the root passes of all
multiple layer welds in all cases shall be of the proper size to insure thorough fusion
and penetration with freedom from slag inclusions.
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A single layer of the weld metal, whether deposited-in one pass or made up
of several parallel beads, shall not exceed 3 mm in thickness except that the bead
at the root may be 6 mm in thickness if the position of welding and the viscosity of
the weld metal permit control of the latter so that it does not over flow upon unfused
base metal.
The maximum size of fillet weld which may be made in one pass shall be 8
mm except that for vertical welds made upward the maximum size made in one
pass shall be 13 mm.
In vertical welding the first root pass shall be formed from the bottom upward.
Succeeding passes may be formed by any technique that will fulfill the requirements
of the Specification and Plans.
The electrode manipulation during welding shall insure that:
1. Complete fusion between the base metal and the deposited weld metal
is obtained.
2. The melted base metal is replaced by weld metal so that no undercut

remains along the edges of the finished weld.
3. The molten weld metal floats all slag, oxide and gases to the surface
behind the advancing arc.
Each time the arc is started, either to begin a weld or to continue partly
completed weld, the arch shall be manipulated to obtain complete fusion of the
deposited weld metal with the base metal and with any previously deposited weld
metal, before any progression of the arc along the joint.
At the completion of a pass or weld, the arc shall be manipulated so as to fill

the crater with sound metal.
Before welding over previously deposited metal, the slag shall be removed
and the weld and adjacent base metal shall be brushed clean. This requirement
shall apply not only to cratered areas but also when welding is resumed after any
interruption. It shall not, however, restrict the making of plug and slot welds, in
accordance with the following paragraphs.
In making plug welds the following techniques shall be used:
1. For flat welds, the arc shall be carried around the root of the joint and
then weaved along a spiral path to the center of the hole, fusing and
depositing a layer of weld metal in the root and bottom of the joint. The
arc shall then be carried to the periphery of the hole, and the procedure
repeated, fusing and depositing successive layers to fill the hole to the
depth required. The slag covering the weld metal shall be kept molten,
or nearly so, until the weld is finished. If the arc is broken, except briefly
for changing electrodes, the slag must be allowed to cool and shall be
completely removed before restarting the weld.
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2. For vertical welds, the arc shall be started at the root of the joint, at the
lower side of the hole and carried upward on the zigzag path, depositing
a layer about 5 mm thick on the exposed face at the thinner plate and
fused to it and to the side of the hole. After cleaning the slag from the
weld, other layers shall be similarly deposited to fill the hole to the
required depth.
3. For overhead welds, the procedure shall be the same as for flat welds
except that the slag shall be allowed to cool and shall be completely
removed after depositing each successive layer until the hole is filled to
the required depth.
Slot welds shall be made with a technique similar to that specified above for
plug welds, except that if the length of the slot exceeds three times the width, or if
the slot extends to the edges of the part of the technique specified above for making
plug welds shall be followed for the type of flat position welds.
409.3.2.7 Details of Welds
The following tabulation shows that the relation between weld size and the
maximum thickness of material on which various sizes of fillet welds may be used:
Size of Fillet Weld Maximum Thickness of Part

5 mm 13 mm
6 mm 19 mm
8 mm 32 mm
10 mm 51 mm
13 mm 152 mm
16 mm over 152 mm
The maximum size of fillet weld that may be used along the edge of material
6 mm or more in thickness shall be 1.5 mm less than the thickness of the material.
The minimum effective length of fillet weld shall be four times its size and in
no case less than 38 mm.
Fillet welds terminating at the corners of parts or members shall, wherever

practicable, be turned continuously full size around the corners for a distance not
less than twice the nominal size of the weld.
Intermittent fillet welds, preferably, shall not be used. They shall be permitted
only where the required weld area is less than that of a continuous fillet weld of the
minimum size. If used on main members, they shall be chain intermittent welds. In
all other cases, chain intermittent welding is preferable to staggered intermittent
welding.
Spacing of intermittent fillet welds shall be measured between the center of

the weld segments. The spacing shall conform to the following requirements unless
calculated stresses between the parts require closer spacing:
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1. At the end of members, there shall preferably be continuous longitudinal
fillet welds at least as long as the width of the element or member being
connected.
2. The clear spacing in the direction of stress of stitch welds that connect
plates to other plates or to shapes shall not exceed:
a. For compression members ….10 times the thickness of the thinner

part but not more than 300 mm.
b. For tension members ….. 14 times the thickness of the thinner part
but not more than 300 mm.
The spacing transverse to the direction of stress shall not exceed
24 times the thickness of the thinner part connected.
3. For members composed of two or more rolled shapes in contact with one
another, the longitudinal spacing of stitch welds shall not exceed 600 mm.
Fillet welds in holes or slots may be used to transmit shear in lap joints or to
prevent the buckling or separation of lapped parts. The fillet welds in a hole or slot
may overlap.
Seal welding shall preferably be accomplished by a continuous weld

combining the function of sealing and strength, changing sections only as the
required strength may necessitate.
Exposed faces of welds shall be made reasonably smooth and regular, shall
conform as closely as practicable to the design requirements and shall not at any
place be inside the intended cross-section. Weld dimension in excess of the design
requirements shall not be a cause for rejection, but in case excess weld metal
involves serious malformation, such work shall be rejected.
All fillet welds shall be of acceptable types. All fillet welds that carry reversed
stresses running in a direction perpendicular to their longitudinal axis shall be of the
concave type or the 0-gee type when the fillet weld is flushed with the edge of a
member. When one of these types is specifically indicated on the Plans for a weld,
it shall be of that type.
Butt welds shall preferably be made with a slight reinforcement, except as

may be otherwise provided, and shall have no defects. The height of reinforcement
shall be not more than 3 mm.
All butt welds, except produced with aid of backing material, shall have the
root of the initial layer chipped out or otherwise cleaned to sound metal and welded
in accordance with the requirements of the Specification. Butt welds made with the
use of a backing of the same materials as the base metal shall have the weld metal
thoroughly fused with the backing materials.
Ends of butt welds shall be extended past the edges of the parts joined by
means of extension bars providing a similar joint preparation and having a width not
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less than the thickness of the thicker part jointed; or for material 19 mm or less in
thickness, the ends of the welds shall be chipped or cut down to solid metal and
side welds applied to fill out the ends to the same reinforcement as the face of the
welds. Extension bars shall be removed upon completion and cooling of the weld
and the ends of the weld made smooth and flush with the edges of the abutting
parts.
409.3.2.8 Quality of Welds
Weld metal shall be solid throughout except that very small gas pockets and
small inclusions of oxide or slag may be accepted if well dispersed and if none
exceeds 1.5 mm in greatest dimension, and if the sum of the greatest dimensions
of all such defects of weld metal area does not exceed 15 mm in an area of 10 cm2.
There shall be complete fusion between the weld metal and the base metal
and between successive passes throughout the joint.
Welds shall be free from overlap and the base metal free from undercutting.
All craters shall be filled to the full cross-section of the welds.
409.3.2.9 Correction
In lieu of rejection of an entire piece of member containing welding which is

unsatisfactory or indicates inferior workmanship, the following corrective measures
may be permitted by the Engineer whose specific approval shall be obtained for
making each correction:
1. Removal of part or all of the welds shall be affected by chipping, grinding

or gas-gouging.
2. Defective or unsound welds shall be corrected either by removing and

replacing the welds, or as follows:
a. Excessive convexity – Reduce to size by removal of excess weld

metal.
b. Shrinkage crack in base metal, craters and excessive porosity –
Remove defective portion of base and weld metal down to sound
metal and deposit additional weld metal.
c. Undercutting, undersize and excessive concavity – Clean and deposit
additional weld metal.
d. Overlapping and lack of fusion – Remove and replace the defective
length of weld.
e. Slag inclusion – Remove those parts of the weld containing slag and
fill with weld metal.
f. Removal of adjacent base metal during welding – Clean and form full
size by depositing additional weld metal.
3. Where corrections require the depositing of additional weld metal, the

electrode used shall be smaller than the electrode used in making the
original weld.
263
4. A cracked weld shall be removed throughout its length, unless by the use
of acid etching, magnetic inspection or other equally positive means, the
extent of the crack can be ascertained to be limited, in which case sound
metal 50 mm or more beyond each end of the crack need not be
removed.
5. In removing defective parts of a weld, the gas-gouging, chipping or

grinding shall not extend into the base metal any substantial amount
beyond the depth of the web penetration unless cracks or other defects
exist in the base metal.
6. Where the work performed subsequent to the making of a deficient weld

has rendered the weld inaccessible or has caused new conditions which
would make the correction of the deficiency dangerous or ineffectual, the
original condition shall be restored by renewal of welds or members, or
both before making the necessary corrections, or else the deficiency shall
be compensated by additional work according to a revised design
7. Caulking of welds shall not be done.
8. Before adding weld metal or rewelding, the surfaces shall be cleaned

thoroughly. Where incomplete fusion is disclosed by chipping, grinding
or gas gouging, to correct defects, that part of the weld shall be removed
and rewelded.
409.3.2.10 Stress Relieving
Peening to reduce residual stress of multi-layer welds may be used only if

authorized and ordered by the Engineer. Care shall be exercised to prevent
overpeening which may cause overlapping, scaling, flecking or excessive cold
working of weld and base metal.
409.3.2.11 Cleaning and Protective Coatings
Painting shall not be done until the work has been accepted and shall be in
accordance with the Specification. The surface to be painted shall be cleaned of
spatter, rust, loose scale, oil and dirt. Slag shall be cleaned from all welds.
Welds that are to be galvanized shall be treated to remove every particle of

slag.
409.3.2.12 Identification
The operator shall place his identification mark with crayon, or paint, near
the welds made by him.
409.3.2.13 Inspection
264
On completion of the welding work, inspection shall be carried out by an
Inspector appointed by the Engineer.
The size and contour of welds shall be measured with suitable gauges. The
inspector shall identify with a distinguishing mark all welds that he has inspected
and accepted.
The Contractor shall remove and replace, or correct as instructed, all welds
found defective or deficient. He shall also replace all methods found to produce
inferior results, with methods which will produce satisfactory work.
In the event that fault welding or the removal for rewelding of faulty welding
shall damage the base metal, the Contractor shall remove and replace the damaged
material.
409.4 Measurement and Payment
Unless otherwise provided in the Special Provisions, welded structural steel

structures shall not be measured and paid for separately, but the cost thereof shall
be considered as included in the contract price for other items.
ITEM 410 – TREATED AND UNTREATED TIMBER
410.1 Description
This Item shall consist of structural timber of the specie and size called for
on the Plans, either treated or untreated as called for in the Proposal. It shall include
the furnishing of the timber, the framing, erecting, furnishing of hardware and the
furnishing of paint and paintings if paint is called for on the Plans or in the Special
Provisions.
410.2.1 Timber
Timber shall be the specie specified on the Plans. Unless otherwise noted
on the Plans or in the Special Provisions, only the best grade shall be used. It shall
be free from loose knots, splits, worm holes decay, warp, ring separation, or any
defect which will impair its strength or render it unfit for its intended use. Any specie
specified on the Plans may be used for untreated timber and if that specie is not
available, a specie of equivalent strength and durability may be used if authorized
by the Engineer. If the timber is to be treated, only those species shall be used
which are known to possess properties which make them favorable to treatment.
265
410.2.2 Paint
When painting of timber is required, the paint shall conform to the

requirements of Item 411, Paint.
410.2.3 Hardware
Hardware shall conform to the requirements of Item 402, Timber Structures.
410.2.4 Preservatives
The preservatives shall be creosote oil or creosote petroleum oil blend as

called for on the Plans or by the Special Provisions, and shall conform to the
Standard Specifications for Pressure Treatment of Timber Products, ASTM D-1760.
When timber is intended for marine use, the creosote petroleum oil blend
shall not be used.
410.3.1 Timber Treatment
Treatment shall consist of the forcing of either creosote oil or a creosote

process. The process shall be in accordance with AASHTO M 133, preservatives
and pressure treatment process for timber, but with such changes in temperatures,
pressures, duration of treatment and other factors affecting the final treatment that
experience has shown to be necessary in the treatment of structural timbers sawn
from woods native to the Philippines. The treatment shall be so regulated that the
curing process will not induce excessive checking.
The minimum penetration of the preservative into the surface of the timber
shall be 20 mm. The minimum retention of the preservative per cubic metre of
timber shall be as follows:
For general use, 192 kg by empty cell process

For marine use, 320 kg by full cell process
The Engineer shall be notified at least 10 days in advance of the date that
the treating process will be performed in order that the untreated timber, the
treatment process, and the finished treatment timber may all be inspected. The
Engineer shall inspect the timber prior to treatment to determine conformance with
those Specifications and suitability of conditions for treatment. He shall be
permitted free access to the plant in order that temperatures, pressures and
quantities and type of treatment materials used may be observed. Samples of the
creosote or creosote petroleum oil mixture shall be furnished as required for tests.
After completion of the treatment, the timber shall be checked to determine

penetration of treatment, amount of checking quantity of free preservative
remaining on the timber and will check any other visual evidence that the treatment
266
has been performed in a satisfactory manner. The penetration of treatment shall
be determined by boring a sufficient number of well-distributed holes to determine
the average penetration. All such holes shall be plugged with plugs approximately
1.6 mm larger in diameter that the bit used in boring the holes.
charge, or such parts thereof as are determined by the Inspector to be
unsatisfactory, may be retreated. If after retreatment the penetration is still
insufficient, the treated pieces shall be rejected.
Any excessive checking caused by the treating process shall be cause for
rejection of the pieces in which the excessive checking occurs.
The treating plant shall be equipped with adequate thermometers and

pressure gauges so that the process can be accurately controlled and a continuous
record made of all stages of the treating process. If required by the Engineer,
records shall be furnished showing the duration, maximum and minimum
temperatures and pressures used during all stages of the process.
The quantity to be paid for shall be the number of cubic meter of timber
complete in place and accepted. Measurement of timber shall be computed from
the nominal dimension of the timber even though the actual dimensions may be
scant. The measurement of timber shall include only such timber as a part of the
completed and accepted work and will not include any timber required for a
falsework, bracing or other timber required in the erection.
The quantities, determined as provided in Section 410.4, Method of

Measurement, shall be paid for at the contract unit price per cubic meter for Timber
or Untreated Timber as called for in the Proposal, which price and payment shall
constitute full compensate for furnishing all timber, for preservative treating when
required, and for the delivery, framing, erecting, painting if required, and for the
furnishing of all labor, hardware, tools, equipment and incidentals necessary to
complete the Item.

410 (1) Timber Cubic Meter
410 (2) Treated Timber Cubic Meter
ITEM 411 – PAINT
411.1 Description
267
This Item shall consist of furnishing and applying all paint materials including
vehicles, pigments, pastes, driers, thinners and mixed paints for steel and wooden
structures; sampling testing and packing; preparation of the surface and application
of paint to structures.
411.2 Materials Requirements
411.2.1 General
Paint, except aluminum paint, shall consist of pigments of the required

fineness and composition ground to the desired consistency in linseed oil in a
suitable grinding machine, to which shall be added additional oil, thinner and drier
as required.
Aluminum paint shall consist of aluminum powder or paste of the required

fineness and composition to which shall be added the specified amount of vehicle.
The paint shall be furnished for use in ready mixed, paste or powder form.
All paints shall meet the following general requirements:
1. The paint shall show no excessive settling and shall easily redisperse
with a paddle to a smooth, homogeneous state. The paint shall show no
curdling, livering, caking or color separation and shall be free from lumps
and skins.
2. The paint as received shall brush easily, possess good leveling

properties and shall show no running or sagging when applied to a
smooth vertical surface.
3. The paint shall dry to a smooth uniform finish, free from roughness grit,
unevenness and other imperfections.
4. The paint shall not skin within 48 hours in a ¾ filled tightly closed
container.
411.2.2 The paint shall conform to the requirements of the Specifications indicated
as follows:
Ready Mixed Red Lead AASHTO M 72 and PNS

Paint Type I, II, III & IV
Aluminum Paint AASHTO M 69 and PNS
Type I & II
White & Tinted Ready
Mixed Paint AASHTO M 70
Foliage Green Bridge
Paint AASHTO M 67
Black Paint for Bridges
And Timber Structures AASHTO M 68
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Basic Lead-Silico-Chromate
Ready Mixed Primer AASHTO M 229
Ready Mixed Aluminum Paint AASHTO M 260 and PNS
411.2.3 Drier
This Specification covers both straight oil drier (material free from resins and
gums), and Japan drier (material containing varnish gums). The drier shall be
composed of lead manganese or cobalt or a mixture of any of these elements,
combined with a suitable fatty oil, with or without resins or gums, and mineral spirits
or turpentine, or a mixture of these solvents. The drier shall conform to the following
requirements:
1. Appearance – Free from sediment and suspended matter.
2. Flash Point – (Tag Close Up) Not less than 30oC.
3. Elasticity – The drier when flowed on metal and baked for 2 hours at
100oC shall have an elastic film.
4. Drying – It shall mix with pure raw linseed oil in the proportion of 1 volume
of drier to 19 volume of oil without curdling and the resulting mixture when
flowed on glass shall dry in not more than 18 hours.
5. Color – When mixed with pure, raw linseed oil in the proportion of 1
volume of drier to 8 volume of oil, the resulting mixture shall be darker
than a solution of 6 grams of Potassium Dichromate in 13 cc of pure
Sulfuric Acid (sp.gr. 1.84).
411.3.1 Proportion of Mixing
It is the intent of this Specification to provide a paint of proper brushing

consistency, which will not run, steak or sag and which will have satisfactory drying
qualities.
411.3.2 Aluminum Paint, Field Coats On Structural Steel
The paint shall be mixed in the proportion of 240 grams of aluminum powder
or paste per liter of vehicle of long oil spar varnish. This makes a paint containing
21 percent pigment and 79 percent vehicle. The weighed amount of powder or
paste shall be placed in a suitable mixing container and the measured volume of
vehicle poured over it. The paste or powder shall be incorporated in the paint by
vigorous stirring with a paddle. The powder or paste will readily disperse in the
vehicle. Before removing any paint from the container, the paint shall be thoroughly
stirred to insure a uniform mixture, and the paint shall be suitably stirred during use.
The paint shall be mixed on the job and only enough for one day’s use shall be
mixed at one time.
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When two field coats of aluminum paint are specified, the first coat shall be
tinted with lampblack paste or Prussian blue paste in the quantity of 24 grams/liter
of paint. The exact quantity used shall be sufficient to give a contrast in color which
can be readily distinguished. When three field coats of aluminum paint are
specified, the second coat shall be tinted.
411.3.3 Aluminum Paint, Field Coats on Creosoted Timber
The paint shall be mixed as specified for Aluminum Paint for Structural Steel
except that the proportions shall be 270 grams of aluminum powder or paste to one
litre of vehicle.
Other paint composition may be used when and as stipulated in the Special
Provisions.
411.3.4 Containers and Markings
All paints shall be shipped to strong substantial containers plainly marked

with the weight, color and volume in litres of the paint content, a true statement of
the percentage composition of the pigment, the proportions of the pigment to
vehicle, the name and address of the manufacturers, and the stencil of the
authorized inspecting agency. Any package or container not so marked will not be
accepted for use.
Method of sampling shall be as follows:
1. One 20-litre can sample in original unopened container shall be obtained

for 100 cans of the delivered material or 10% fraction thereof.
2. One 4-litre can sample in original unopened container shall be obtained

for every 100 cans or fraction thereof of the delivered material.
Methods of testing will be in accordance with the applicable AASHTO or

ASTM Methods.
411.3.6 Painting
411.3.6.1
The painting of structure shall include the proper preparation of the surface;
the application, protection and drying of the paint coatings, the protection of the
pedestrians, vehicular or other traffic upon or underneath the structures, the
protection of all parts of the structure (both superstructure and substructure) against
disfigurement by spatters, splashes and smirches of paint or of paint materials; and
the supplying of all tools, tackle, scaffolding labor, paint and materials necessary
for the entire work.
270
Paint shall not be applied during rain, storms or when the air is misty, or
when, in the opinion of the Engineer, conditions are otherwise unsatisfactory for
the work. Paint shall not be applied upon damp surfaces or upon metal which has
absorbed heat sufficient to cause the paint to blister and produce a pervious paint
film.
No wide flat brush shall be used. All brushes preferably shall be either round
or oval but if flat brushes are used, they shall not exceed 100 mm in width.
The paint when applied shall be so manipulated as to produce a uniform

even coating in close contact with the surface being painted, and shall be worked
into all corners and crevices.
On surfaces inaccessible to brushes, the paint shall be applied by spray gun

or with sheepskin daubers specially constructed for the purposes.
Paint shall be thoroughly stirred, preferably by means of mechanical mixers,

before being removed from the containers, and, to keep the pigments in
suspension, shall be kept stirred while being applied.
When a paint gun is used, the equipment used shall be of an approved type
and shall have provision for agitation of paint in the spray container. In the case of
aluminum paint, the pressure used shall be only that necessary to secure adequate
atomization. If in the opinion of the Engineer unsatisfactory results are obtained
from the use of a spray gun, its use shall be discontinued and the painting
completed by the use of brushes.
411.3.6.2 Painting Structural Steel
Surfaces of metals to be painted shall be thoroughly cleaned of rust, loose

mill, scale, dirt, oil or grease, and other foreign substances. Unless cleaning is to
be done by sandblasting, all weld areas, before cleaning is begun, shall be
neutralized with a proper chemical, after which they shall be thoroughly rinsed with
water. Cleaning may be by any of the following three methods:
1. Hand Cleaning
The removal of rust, scale and dirt shall be done by the use of metal
brushes, scrapers, chisels, hammers or other effective means. Oil and
grease shall be removed by the use of gasoline or benzene. Bristle or
wood fiber brushes shall be used for removing loose dust.
2. Sandblasting
Sandblasting shall remove all scale and other substances down to the
base metal. Special attention shall be given to the cleaning of corners
and re-entrant angels. Before painting, sand adhering to the steel in
corners and elsewhere shall be removed. The cleaning shall be
approved by the Engineer prior to any painting. The material shall be
painted before the rust forms and not later than 2 hours after cleaning.
271
3. Flame Cleaning
Oil and grease shall be removed by washing with suitable solvent.

Excess solvent shall be wiped from the work before proceeding with
subsequent operation. The surface to be painted shall be cleaned and
dehydrated (freed of occluded moisture) by the passage of oxyacetylene
flames which have an oxygen to acetylene of at least one. The inner
cones of these flames shall have a ratio length to port diameter of at least
8 and shall not be more than 4 mm center to center. The oxyacetylene
flames shall be traversed over the surface of the steel in such manner
and at such speed that the surface is dehydrated, and dirt, rust, loose
scale, scale in the form of blisters or scabs, and similar foreign matter are
freed by the rapid intense heating by the flames. The flames shall not be
traversed so slowly that loose scale or other foreign matter is fused to the
surface of the steel. The number, arrangement and manipulation of the
flames shall be such that all parts of the surface are adequately cleaned
and dehydrated. Promptly after the application of the flames, the surface
of the steel shall be wire-brushed, hand scraped wherever necessary and
then swept and dusted to remove all free materials and foreign particles.
Compressed air shall not be used for this operation. Paint shall be
applied promptly after the steel has been cleaned and while the
temperature of the steel is still above that of the surrounding atmosphere,
so that there will be no recondensation of moisture on the cleaned
surfaces.
4. Shop Painting of Structural Steel
When all fabrication work is completed and has been tentatively

accepted, all surfaces not painted before assembling shall be given two
coats of Red Lead Shop Paint conforming to the requirements of this
Specification. (The inside of top chords for trusses and laced members
or inaccessible parts, except contact surfaces, may be painted before
assembling). Shipping pieces shall not be located for shipment until
thoroughly dry. No painting shall be done after loading the materials on
transport vehicles.
Erection marks for field identifications of members shall be painted

upon previously painted surfaces.
With the exception of abutting joints and base plates, machine-

finished surface shall be coated, as soon as practicable after acceptance
with a hot mixture of white lead and tallow before removal from the shop.
The composition used for coating machine-finished surface shall be
mixed in the following proportions:
Pure Tallow 1,915 grams

Pure White Lead 958 grams
Pure Linseed Oil 1.0 liter
272
5. Field Painting of Structural Steel
When the erection work is complete including riveting and

straightening of bent metal; all adhering rust, scale, dirt, grease or other
foreign material shall be removed as specified under cleaning of
surfaces.
As soon as the Engineer has examined and approved all field rivets,
the heads of such rivets and field bolts, all welds and any surfaces from
which the shop coat of paint has become worn off or has otherwise
become defective, shall be cleaned and thoroughly covered with one coat
of shop coat paint.
When the paint applied for “touching up” rivet heads and abraded
surfaces has become thoroughly dry, such field coats as called for shall
be applied. In no case shall a succeeding coat be applied until the
previous coat has dried throughout the full thickness of the film. All small
cracks and cavities which were not sealed in water-tight manner by the
first field coat shall be filled with a pasty mixture of red lead and linseed
oil before the second field coat is applied.
The following provisions shall apply to the application of all field coats.
To secure a maximum coating on edges of plates or shapes, rivet heads
and other parts subjected to special wear and attack, these parts shall
first be stripped, followed immediately by the general painting of the
whole surface, including the edges and rivet heads.
The application of the final coats shall be deferred until adjoining

concrete work has been placed and finished. If concreting operations
have damaged that paint, the surface shall be recleaned and repainted.
411.3.6.3 Painting and Timber Structures
Timber structures shown on the Plans to be painted, shall be given two coats
of the specified materials, which shall be thoroughly brushed in. Additional coats
shall be required when so specified on the Plans. All surfaces shall be thoroughly
dry before painting, and each coat shall be allowed to stand for three or four days,
or until thoroughly dry before applying the succeeding coat.
Timber which required painting must be seasoned timber surfaced on 4

sides. It shall be either untreated or salt-treated timber as specified on the Plans.
The entire surface of all untreated timber that is to be painted, shall be given
a priming coat immediately after the material is delivered to the project. All contact
surfaces shall receive the second coat paint.
Special care shall be taken during construction and handling so that the
pieces to be painted do not come in contact, except when required, with the
creosoted materials and that no oil is brushed on the same during construction
operations. The Contractor shall be required to pile such pieces separately from
273
the creosoted materials and keep them from contact with same until ready for
erection.
Creosoted materials such as guardrails and guide posts which are to be

painted, shall be painted with aluminum paint as specified above.
411.3.6.4 Painting Galvanized Surface
For the purpose of conditioning the surface of galvanized surfaces to be

painted, the painting shall be deferred as long as possible in order that the surface
may weather.
Before painting galvanized surfaces they shall be treated as follows:
1. In 4 litres of soft water, dissolve 60 ml of copper chloride, copper nitrate,

and sal ammonia, then add 60 ml of commercial muriatic acid. This
should be done in earthenware or glass vessel, never in tin or other metal
receptacle. Apply the solution with a wide flat brush to the galvanized
surface, when it will assume a dark almost black color which on drying
becomes a grayish film.
2. The surfaces, when dry, may then be painted as described.
411.3.6.5 Repainting Existing Structures
When called for on the Plans or in the Special Provisions, existing structures
shall be given the number and kind of coats of field paint as stipulated. The surface
to be repainted shall be cleaned as specified under Subsection 411.3.6.2, Painting
Structural Steel, with the added provisions that all dead or loose paint shall be
removed by scraping, chipping, or brushing as may be necessary. Timber railings,
name plates, planking and other interfering parts shall be removed before cleaning
is begun and shall be replaced after the painting has been completed and the last
coat has thoroughly dried. The application of the coat shall be as specified under
Subsection 411.3.6.2, (5), Field Painting of Structural Steel.
411.4 Measurement and Payment
Painting shall not be measured and paid for separately, but the cost thereof
shall be considered as included in the contract unit price of the items where called
for.
ITEM 412 – ELASTOMERIC BEARING PADS
412.1 Description
412.1.1 Scope
274
This Item shall consist of the requirement for elastomeric bearing pads
whose main function is to transfer loads or accommodate relative movement
between a bridge superstructure and its supporting structure, or both while avoiding
damaging strain and additional tension. Elastomeric bearings shall include
unreinforced pads (consisting of elastomer only) and reinforced bearings with steel
laminates.
412.1.2 General Requirements
All bearings shall be designed in accordance with specifications contained

in the latest edition of the AASHTO Standard Specification for Highway
Bridges, 15th Edition, 1992.
412.1.3 Classification and Use
The following are the types of elastomeric bearings:
a. Plain Elastomeric Bearing Pad

b. Plain Elastomeric Sandwich Bearing
c. Steel-Laminated Elastomeric Bearing without External Load Plates

d. Steel-Laminated Elastomeric Bearing with External Load Plate(s)
A laminated bearing pad is required when the thickness of the plain pad is
more than 31.75 mm and the compressive strain is more than 15%.
The elastomer for the manufacture of the bearing is furnished in two types
as follows:
1. Type CR-Chloroprene Rubber

2. Type NR-Natural Rubber
The elastomer compound used in the construction of a bearing shall contain

only either natural rubber or a chloroprene rubber as the raw polymer. No reclaimed
rubber shall be used.
Steel laminates used for reinforcement shall be made from rolled mild steel
conforming to ASTM A 36, A 570 or equivalent, unless otherwise specified by the
Engineer. The laminates shall have a minimum nominal thickness of 20 gage.
412.2.1 Physical Requirements
A. The elastomer compound shall meet the minimum requirement of Table

1.
B. Dimensions and Permissible Variations
275
All elastomeric layers, for example, plain bearing pads, laminates, and
covers, shall be of uniform thickness unless otherwise specified in the contract or
purchase order.
All internal steel laminates shall be of uniform thickness. When specified in

the contract or purchase order, the thickness of the outer steel laminates may differ
if not adjacent to an external load plate.
The minimum thickness of internal steel laminates shall be 1.5 mm or 0.060

in (16 gage) when the greater of the length or width of a rectangular bearing or
diameter of a circular bearing is less than 450 mm or 18 in. In all other cases, the
minimum thickness shall be 2 mm or 0.075 inch (14 gage).
Bearing dimensions and elastomer layer thicknesses shall satisfy the

tolerances in Table 2, in which D is the length, width or diameter as appropriate,
and T is the total elastomer thickness.
Variation from a plane parallel to a design surface shall not exceed an

average slope of 0.005 for the upper surface and 0.006 for a side surface.
Table 1 – Quality Control Properties of Elastomer
Natural Rubber Chloroprene

(NR) Rubber (CR)
Grade (Durometer)
Physical Properties:
A. Before Aging
Tensile Strength, MPa (D412) 15.5 15.5 15.5 15.5
(min.) (min.) (min.) (min.)
Elongation, % (D412) 400 300 350 300
Durometer Hardness, Shore Pts. 60±5 70±5 60±5 70±5
(D2240)
Tear Resistance, N/mm (D624) 31.5 31.5 31.5 31.5
Compression Set , % (D395) 25 25 35 35
(max.) (max.) (max.) (max.)
Method B, Temperature, oC 70 70 100 100
B. After Aging
Temperature of the Test, oC 70 70 100 100
Aging Time, Hours 168 168 70 70
Tensile Strength, % (D573) -25 -25 -15 -15
Elongation, % -25 -25 -40 -40
Durometer Hardness, Shore Pts. +10 +10 +15 +15
Other Properties:
276
Ozone Resistance (D1149)
Partial Pressure, MPa 25 25 100 100
Duration, Hours 48 48 100 100
Tested at 20% strain 37.7 oC ±1 oC No No
Mounting procedure D518 - - cracks cracks
Procedure A
Brittleness D2137, low temp.
Brittleness at -40 oC Pass Pass Pass Pass
Shear Modulus
Nominal Hardness Shear
Modulus at 23 oC, MPa 0.85- 1.13- 0.85- 1.13-
1.1 1.84 1.1 1.84
Plain pads and laminated bearings shall be manufactured to the design

dimensions and these specifications with the tolerances listed in Table 2, unless
other tolerances are shown on the design drawings.
Table 2 – Tolerances
Mm
Overall vertical dimensions
Design thickness 32 mm (1 ¼ in) or less -0, +3
Design thickness over 32 mm (1 ¼) -0, +6
Overall horizontal dimensions
914 mm (36 in) and less -0, +6
Over 914 mm (36 in) -0, +12
Thickness of individual layers of ±20 percent of design value but
elastomer (laminated bearing only) at no more than ±3 mm (1/8 in)
any point within the bearing
Variation from a plane parallel to the
theoretical surface: (as determined by
measurements at the edge of the
bearings)
Top Slope relative to the bottom of no
more than 0.005 radian
Sides 6
Position of exposed connection members 3
Edge cover of embedded laminated -0, +3
connection members
Size of holes, slots or inserts ±3
Position of holes, slots, or inserts ±3
277
412.3.1 Handling, Transport, Storage and Installation
During handling, transport, storage, and installation, bearings shall be kept

clean and protected from mechanical damage, heat, contaminants and other
deleterious effects.
Bearings shall be placed on surfaces that are plane to within 1.6 mm and
unless the bearings are placed in opposing pairs, horizontal to within 0.01 radians.
Any lack of parallelism between the top of bearing and the underside of the
girder that exceeds 0.01 radians shall be corrected either grinding of the surface,
grout pack bearing seats or modification of the bearing such that the intended
bearing placement is as originally designed with the least amount of bearing
modification, or as otherwise directed by the Engineer.
Exterior plates of the bearing shall not be welded unless at least 38.1 mm of
steel exists between the weld and the elastomer.
Each completed bearing shall have its components clearly identified, be

securely bolted, straffed or otherwise fastened to prevent any relative movement
and marked on its top as to location and orientation in each structure in the projects
conformity with the plans.
Dismantling at the site shall not be done unless absolutely necessary for
inspecting or installation.
412.3.2 Sampling
Sampling, testing and acceptance consideration will be made on a lot basis.

A lot shall be further defined as the smallest number of bearings as determined by
the following criteria:
a. A lot shall not exceed a single contract or project quantity.

b. A lot shall not exceed 50 bearings.
c. A lot shall consist of those bearings of the same type regardless of load
capacity.
For acceptance purposes, bearing from within the lot shall be selected at
random as samples for inspection and testing.
A minimum of three bearings shall be taken from the lot for testing. If the
number of bearings in the lot exceeds 50 then for each additional 50 or part thereof,
one additional bearing shall be taken for testing.
412.3.3 Acceptance Requirements
1. If lack of elastomer to steel bond is indicated, the bearing shall be

rejected.
2. If laminate placement faults are observed which results in elastomer layer
thickness that exceed the tolerances in Table 2, the bearing shall be rejected.
278
3. If there are at least three separate surface cracks which are each at least
2 mm wide and 2 mm deep. The bearing shall be rejected.
4. Record the median compressive stiffness (K) of the bearing of median
stiffness.The compressive stiffness of each bearing tested shall not differ form (K)
by more than 10%.
5. For each bearing that fails to meet the requirements in (1), two
additional bearings maybe sampled and shall meet the requirements in (1) or the
lot shall be rejected.
6. If the lot is not rejected, the bearing of median stiffness (K) shall be
subjected to the elastomeric material tests in (2).
The quantity of elastomeric bearing pad to be paid for will be the final quantity
placed and accepted in the completed structure. The dimensions of elastomeric
bearing pads will be the quantity placed in accordance with the Plans or as
otherwise directed by the Engineer.
The accepted quantity, measured as prescribed in Section 412.4, shall be

paid for at the contract unit price for Elastomeric Bearing Pads which price and
payment shall be full compensation for furnishing and placing all materials,
including all labor, equipment, tools and incidentals necessary to complete the work
prescribed in this Item.
412 Elastomeric Bearing Pads Each
ITEM 413 - PREFORMED SPONGE RUBBER AND CORK EXPANSION JOINT

FILLERS FOR CONCRETE PAVING AND STRUCTURAL
CONSTRUCTION
Preformed sponge rubber and cork expansion joint fillers for concrete paving
and structural construction shall conform to the applicable requirements of
AASHTO M 153.
279
280

Blue Book Item 400

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PART F – BRIDGE CONSTRUCTION

ITEM 400 – PILING

In determining lengths of piles for ordering and to be included for payment,

400.1.2 Test Piles

400.1.3.1 Static Testing

Test loading shall consist of the application of incremental static loads to a

The load shall be applied in increments of 5 or 10 tonnes as directed by the

When diesel or other types of hammers requiring calibration are to be used,

400.1.3.2 Pile Testing

Pile testing shall be done by Low-Strain Dynamic Method, High-Strain

400.1.3.2.1 Low-Strain dynamic Method

Pile integrity testing by Low-Strain Dynamic Method shall conform to ASTM

400.1.3.2.2 High-Strain Dynamic Testing

Pile Integrity testing by High-Strain Dynamic Method shall conform to ASTM

400.1.3.2.3 Cross-Hole Sonic Logging of Bored Holes

By sending ultrasonic pulses through concrete from one probe to another

400.1.4 Timber Pile Bearing Value by Formula

For single-action steam or air hammers, and for diesel hammers

For double-action steam or air hammers, and diesel hammers having

For diesel or steam hammers on very heavy piles,

P = Safe load per pile in Newton or kg

The above formula are applicable only when:

1. The hammer has a free fall.

If there is a measurable bounce, twice the height of bounce shall be

The bearing power as determined by the appropriate formula listed in

When bearing power is determined by a formula, timber piles shall be

400.1.5 Concrete and Steel Pile Bearing Values

a. Modified Hiley’s Formula or any formula from brochures of the

Ru = ultimate capacity of piles (KN)

Ru = ultimate capacity of pile (KN)

Required minimum penetration of all piles shall be six (6)

Values of C1 for Hiley Formula

Temporary Compression Allowance C1 for Pile Head and Cap

76–100mm (3-4 in.)

4.76mm (3/16 in.)

Head of steel piling

Drop Hammer released by trigger 1.00

Values of Coefficient of Restitution, n

Helmet with Timber dolly, and

Hammer direct on pile with pad - 0.50

Driving cap with Timber dolly 0.30 0.30

Hammer direct on pile - 0.50

400.1.6 Safe Loads

400.1.7 Jetted Piles

400.2 Material Requirements

400.2.1 Untreated Timber Piles

Table 400.1 – Dimension of Piles

Length of Pile Diameter (1 metre from the Butt) Minimum Tip

Square piles shall have the dimensions shown on the Plans.

400.2.2 Treated Timber Piles

400.2.3 Concrete Piles

Concrete shall conform to the requirements of Item 405, Structural Concrete.

Concrete shall be proportioned to achieve a range of 6”-8” (150 mm to 200

The use of appropriate plasticizer/additives to assure mix fluidity and

Reinforcing steel shall conform to the requirements of Item 404, Reinforcing

400.2.4 Steel Shells

1. Shells Driven Without a Mandrel

2. Shells Driven With a Mandrel

The shell shall be of sufficient strength and thickness to withstand driving