Douglas F. Rose, P.E. NYSDOT, Region 1 Bridge Maintenance

328 State Street Schenectady, NY 12305 Phone: (518) 388-0397

DROSE@dot.state.ny.us Synopsis:

Last year the NYS Department of Transportation started two maintenance initiatives called ‘Vertical Down” and “Joint”. Both target deficient elements on “good” bridges. The Vertical Down initiative focuses on improving the substructure condition of bridges that are otherwise in good condition. The Joint initiative aims at preventing contamination of the substructure elements by ensuring a watertight seal at the joint. Both initiatives are performance based and can be tracked using biennial inspection data. This presentation will cover the details of these two initiatives as well as Region One’s Bridge Maintenance’s efforts on a structure which met the criteria for both of them. Repairs were made to the concrete substructures using a “Dry-Pak-It” concrete repair system. This was the first repair done using this system in Region One. It is a pneumatic system that employs a unique concept of applying material and water to the repair simultaneously but separately through fixed nozzles. The joints were replaced with XJS armorless joints.

About the Presenter:

Doug Rose has been with DOT since 1985 and is currently the Regional Bridge Maintenance Engineer for Region One in Schenectady. He is responsible for the Bridge Maintenance Program for the 835 DOT maintained bridges in Region One. DOT bridge maintenance work is performed by 6 crews located in 5 facilities across the Region. Prior to coming to Maintenance, Doug was a Regional Structures Engineer and Bridge Management Engineer in two DOT Regions. He has a Bachelor’s Degree in Civil Engineering from Worcester Polytechnic Institute.

SESSION 5.3

DOT Corrective Maintenance Initiatives

Maintenance First Initiatives Maintenance First Initiatives at Region Oneat Region One

Douglas F. Rose, P.E.Douglas F. Rose, P.E.Regional Bridge Maintenance EngineerRegional Bridge Maintenance EngineerNYSDOT NYSDOT -- Region OneRegion OneEE--mail: mail: drose@dot.state.ny.usdrose@dot.state.ny.us

Maintenance and Operations FirstMaintenance and Operations First

“…“…provides a focus on maintenance and provides a focus on maintenance and operations with an emphasis on systems operations with an emphasis on systems management, operations management, management, operations management, response management, preventive response management, preventive maintenance and design modification maintenance and design modification (corrective) maintenance.(corrective) maintenance.””

Which means?Which means?

““Try to keep our good stuff goodTry to keep our good stuff good””

Bridge Corrective Maintenance Bridge Corrective Maintenance ActivitiesActivities

5 to 7 Repairs5 to 7 RepairsVertical DownVertical DownJointsJoints

““55--77”” RepairsRepairs

Objective: Repair the deficient element Objective: Repair the deficient element and thus extend the nonand thus extend the non--deficient life of deficient life of the bridgethe bridge

Criteria: Condition Rating > 4.8 with Criteria: Condition Rating > 4.8 with individual elements < 5.individual elements < 5.

Vertical DownVertical Down

Objective: Repair deficiencies in Objective: Repair deficiencies in substructures (i.e. bearings, pedestals, substructures (i.e. bearings, pedestals, bridge seat/cap beam, columns/stems) bridge seat/cap beam, columns/stems) where needed.where needed.

CriteriaCriteria–– Condition Rating > 4.8 and < 6.0Condition Rating > 4.8 and < 6.0–– Substructure Condition Index < 5.0Substructure Condition Index < 5.0

JointsJoints

Objective: Repair deficient joints to Objective: Repair deficient joints to prevent water and chlorides from falling prevent water and chlorides from falling onto substructure elements.onto substructure elements.

CriteriaCriteria–– Condition Rating > 4.8 and < 6.0Condition Rating > 4.8 and < 6.0–– Joint Rating < 5.0Joint Rating < 5.0

Some numbersSome numbers

Vertical Down CandidatesVertical Down Candidates–– State Bridges State Bridges –– 329 329 –– NonNon--State State –– 808808

Joint CandidatesJoint Candidates–– State Bridges State Bridges –– 10711071–– NonNon--State State -- 336336

Route 23 over Route 9WRoute 23 over Route 9WBIN 1007501BIN 1007501

Town of Catskill, Greene CountyTown of Catskill, Greene County

Built 1968Built 1968

3 Span Steel Multi3 Span Steel Multi--girdergirder–– 244244'' span (64span (64--9494--78)78)–– 3030'' Curb to curbCurb to curb

Route 23 over Route 9WRoute 23 over Route 9W

Route 23 over Route 9WRoute 23 over Route 9W

Route 23 over Route 9WRoute 23 over Route 9W

Condition Rating = 5.904Condition Rating = 5.904Substructure Condition IndexSubstructure Condition Index–– 6.0 6.0 –– 4.44.4 –– 4.9 4.9 –– 5.95.9Joint RatingsJoint Ratings–– 44 –– 4 4 –– 44 –– 44Meets Criteria for Vertical Down at Piers Meets Criteria for Vertical Down at Piers and all Jointsand all Joints

Joint at Pier 2Joint at Pier 2

Joint at Beginning AbutmentJoint at Beginning Abutment

Joint Header Failure at PierJoint Header Failure at Pier

Pier 2 Cap BeamPier 2 Cap Beam

Typical Pedestal ConditionTypical Pedestal Condition

Bearings and Pedestal on Pier 2Bearings and Pedestal on Pier 2

Joint RepairJoint Repair

Remove existing armored jointsRemove existing armored joints

Replace with Replace with ““Maintenance FriendlyMaintenance Friendly”” armorlessarmorlessjointsjoints

Used SSI XJS Joint System from C. S. Used SSI XJS Joint System from C. S. BehlerBehler–– SilSil--spec spec ElastomericElastomeric ConcreteConcrete–– DOW 902 Silicone SealDOW 902 Silicone Seal

Removal of old jointRemoval of old joint

SilSil--Spec InstallationSpec Installation

Finished JointsFinished Joints

Substructure RepairSubstructure Repair

Remove deteriorated concreteRemove deteriorated concrete

Replace using DryReplace using Dry--PakPak--It systemIt system

ReRe--habhab bearingsbearings–– Jack, disassemble, sandblast, paint and Jack, disassemble, sandblast, paint and

grease grease

You said, You said, ““Fix the substructures Fix the substructures with what?with what?””

DryDry--PakPak--It It SystemSystem

DryDry--PakPak--It at nozzleIt at nozzle

DryDry--PakPak--It featuresIt features

Non Shrink results are achieved by Zero Non Shrink results are achieved by Zero Slump and applying water for hydration in Slump and applying water for hydration in a unique manner that combines water and a unique manner that combines water and the cement mixture by capillary action. the cement mixture by capillary action.

Zero Slump allows continual application Zero Slump allows continual application regardless of repair depth. regardless of repair depth.

DryDry--PakPak--It featuresIt features

No sloughing or sagging. No sloughing or sagging.

Apply cement mixture, immediately trim to Apply cement mixture, immediately trim to original contour, float, and finish as original contour, float, and finish as required, all in one continuous operation. required, all in one continuous operation.

Zero SlumpZero Slump

Materials for DryMaterials for Dry--PakPak--ItIt

Portland Type I or II low alkali cementPortland Type I or II low alkali cement

Cement plaster or masonCement plaster or mason’’s sands sand

Fresh waterFresh water

Sand and Cement MixtureSand and Cement Mixture

Water tank with Ali/Cite additiveWater tank with Ali/Cite additive

Surface ConditionerSurface Conditioner

Surface ConditioningSurface Conditioning

Concrete RemovedConcrete Removed

Surface PreparationSurface Preparation

Gun in useGun in use

Applying to a ColumnApplying to a Column

Strike off excessStrike off excess

Hand float surfaceHand float surface

Finished ColumnFinished Column

Overhead ApplicationOverhead Application

SummarySummary

Maintenance isnMaintenance isn’’t just washing and paintingt just washing and painting

Try to get the most bang for the buck out of Try to get the most bang for the buck out of your maintenance dollarsyour maintenance dollars

DonDon’’t get caught in the trap of delaying t get caught in the trap of delaying corrective maintenancecorrective maintenance