Field Perspective 2.ppt - virginiadot.org

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Field Perspective

2018 Bridge Construction Inspection School

Steve Wright

VDOT Senior Construction Inspector

OBJECTIVES

• A Visual Perspective of Bridge Construction

• Identify Key Inspection Points

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DEMOLITION/IN-STREAM WORK2016 VDOT Road & Bridge Spec 413

• In many cases an old structure has to be removed prior to new construction.

• Often, construction occurs

over waterways.

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• Permits included in the Contract give allowances for work done in and around waterways.


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• Phase 1


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• Phase 2


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• Phase 3


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• Phase 4


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• Removing structures with hazardous materials, i.e. lead paint, requires an approved removal and disposal plan.


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Key Inspection Points

• SAFETY!!• Is the contractor using proper fall protection when

required?

• Environmental• Is the contractor adhering to Permits included in the

Contract Documents?

• Is there an approved Hazardous Material plan on site?


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STRUCTURE EXCAVATION2016 VDOT Road & Bridge Spec 401

• Once the old structure has been removed, new construction can begin.

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• As is the case with Demolition, all excavation in and around waterways must take place within the permitted cofferdam.

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• Beginning Pier excavation


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• Pier excavation


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• Pier excavation continued…


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• Pier excavation complete.


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• Abutment excavation.


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• Bedrock foundation


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Inspector's Checklist -- Section 4011. Is an area staked off 18 inches around the neatlines of the footing and record original

ground elevations, including irregularities, prior to excavation operations?

2. Does the Inspector verify the Contractor's layout of excavation area?

3. Does the Contractor install the required erosion and siltation control devices?

4. Does the Contractor verify the need for cofferdams or shoring to retain the

embankment in compliance with applicable safety codes during excavation?

5. Does the Inspector check the plans for the bottom elevation of the footing and notify

the Contractor not to exceed this elevation?

6. Does the Contractor examine the foundation for proper location, dimensions, grade

and stability? The Contractor is to explore at least five feet below the contemplated

foundation elevation. Usually, three to five drilled holes or rod soundings are

sufficient to determine the adequacy of the sub-foundation. Note location of

exploration in project records.

7. Does the Inspector notify the Area Construction Engineer and/or District Bridge

Engineer for inspection and approval of foundation?

8. Does the Inspector record foundation irregularities and computed excavation

quantities?

9. Is the foundation cleaned of loose materials prior to placement of concrete?

10. Are the concrete strength requirements met prior to form removal and subsequent

backfill?

11. Is the backfill placed in uniform lifts and compacted properly?

12. Has the material used for backfill been approved by the Engineer?

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• Piling is used to transfer the load of the structure to soil or bedrock

PILING2016 VDOT Road & Bridge Spec 403

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• Piles seen here are Friction Piles, which uses resistance against the soil to create bearing.


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• Example of an approved hammer


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• Data was collected using Dynamic Testing to determine the resistance (friction) needed for the piles.


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• Data was collected using Dynamic Testing to determine the resistance (friction) needed for the piles. As well as if additional piles were needed.


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• Pile documentation is critical for recording data for each pile


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Inspector’s Checklist – Section 403

1. Has the Contractor submitted the Pile and Driving Equipment Data Form for each

hammer and pile type?

2. Were driving tests completed prior to the Contractor submitting his/her pile order list?

3. Do the lengths of piles match the order list?

4. Are the piles being handled and stored on-site properly?

5. Is the location of each pile verified prior to and after driving?

6. Is Form C-1 being completed for each pile driven?

7. Has the center of gravity (C.G.) for each pile group been checked?

8. Are all piles driven to the required capacity?

9. Are all splices performed in accordance with the Specifications?

10. Has the Contractor performed loading tests as required?

11. Has Form C-4 Pile Loading Test Data been completed and submitted to the Area

Construction Engineer and District Bridge Engineer?

12. Are steel pile shells checked after driving to determine if distortion or collapsing of

the piles has occurred?

13. Is the correct reinforcing steel properly installed in the pile shells?


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• Proper formwork and steel placement is critical for construction.

REINFORCING STEEL & SUBSTRUCTURE CONCRETE

2016 VDOT Road & Bridge Spec 406 & 404

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• Form dimensions and steel placement should be verified as they are being installed and prior to concrete placement.



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• Form dimensions and steel placement should be verified as they are being installed and prior to concrete placement.



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• Verify necessary elevations and anchor bolt locations. (i.e. Top of Footer, Seats, Stem, Wings)

Anchor Bolts

Top of Seat



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• Verify necessary elevations and anchor bolt locations. (i.e. Top of Footer, Seats, Stem, Wings)

Anchor Bolts

Top of Footer



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• Proper storage of Reinforcing Steel prior to installation.



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• Steel shipment should match that of the rebar schedule in the plans



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• Steel shipment should match that of the rebar schedule in the plans



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• Forms should be smooth, rigid, and mortar tight.



• Once forms and reinforcing steel has been approved, concrete can be placed.



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• Bridge seat bearing areas shall be finished plane and level (within 1/16” from plane and 1/32” from level).



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• Tested in accordance with VDOT Specifications.



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• Curing and protection of concrete immediately after placement.



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• Architectural Treatment makes structures aesthetically pleasing.



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Inspector's Checklist – Section 406

1. Are samples sent to Materials Division and test reports on file?

2. Is material stored as specified?

3. Do the size dimensions, bends, and hooks of all reinforcing bars conform to the

reinforcing bar schedules shown on the plans?

4. Is the surface condition free of loose mill scale, flaky rust, dirt, oil or other coatings

that would inhibit concrete bond.

5. Was reinforcing steel tied as specified?

6. Was reinforcing steel supported as specified?

7. Was reinforcing steel placed as specified?

8. Were splices and laps made as specified?

9. Did spacing, location and edge clearances of all reinforcing bar mats conform to the

plans and Specifications?



Inspector's Checklist – Section 4041. Does the Inspector check the concrete temperature, air content, slump, batch

time/placement time prior to placement of the concrete?

2. Is the concrete placed in such a manner that segregation was minimized?

3. Do all chutes and troughs conform to the Specifications?

4. Does the distance that concrete was dropped conform to the Specifications?

5. Is the concrete deposited as near as possible to its final position?

6. Do the Contractor's vibratory procedures conform to the Specifications?

7. Is the concrete placed in continuous horizontal layers?

8. Are the Specifications adhered to when the operation was temporarily discontinued?

9. Do the reinforcing steel and the anchor bolts maintain their position during placement

of the concrete?

10. Are the curing materials approved prior to use?

11. If used, is curing compound applied at the specified rate?

12. Where liquid membrane seal was selected, are the contents of the container

thoroughly agitated before any portion is drawn off for use?

13. In cold weather, does the Contractor make provisions to maintain the temperature of

the curing concrete within the specified limits?

14. Are the correct number of probes taken and recorded in the project diary for

computing overdepths within the ½” construction tolerance?

15. Are approved plans for in place deck forms used and followed?

16. Has a dry run of the screed and form elevations of the deck been checked?



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• Protects the slope around the structure from erosion and scouring during high water events.

RIP RAP & SLOPE PROTECTION2016 VDOT Road & Bridge Spec 414 & 415

Typical Edge of River

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• Mats of 16”x16” concrete blocks cabled together were placed in front and around Abutments. Slope was graded and #26 stone was used as a base.


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• Edges of mats were embedded in the slope and locked in with A-4 Concrete. Class I Rip Rap was placed on top.


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Inspector's Checklist – Section 4141. Is all vegetation removed from the slope prior to placement of the riprap?

2. Is the slope graded as required?

3. Is geotextile fabric installed properly if required?

4. Is riprap of the gradation specified?

5. Is riprap keyed into existing toe of fill or stream bed as shown on plans or as directed

by the Engineer?

Inspector’s Checklist – Section 4151. Is the subgrade constructed properly?

2. Is the 2 inch bedding material placed properly?

3. Are blocks laid with continuous horizontal joints and staggered joints extending up

and down the slope?

4. Are all joints filled with mortar?

5. Is cast in place edging placed as specified?

6. Is the toe of slope protection in alignment with proposed and/or existing ditch?


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STRUCTURAL STEEL2016 VDOT Road & Bridge Spec 407

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• Bearings are set properly


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• Bolts are tested for tensioning.

KIPS

Torque


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• Bolts are tested for tensioning.


Average Daily Torque Values @ 30 Kips4-1/2" 3-1/2" 3" 2-3/4" 2-1/4"420 400 460 390 440320 430 420 300 390440 420 450 350 430

393.333 416.667 443.333 346.667 420.000

Average Daily Torque Values Required Rotation4-1/2" 3-1/2" 3" 2-3/4" 2-1/4"

2/3 Turn Kips 1/2 Turn Kips 1/2 Turn Kips 1/2 Turn Kips 1/2 Turn Kips560 41 550 40 590 41 500 48 440 34440 39 470 42 550 42 440 47 480 35580 42 490 42 550 43 500 42 450 34

526.667 40.667 503.333 41.333 563.333 42.000 480.000 45.667 456.667 34.333

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• Turn of the Nut method for tensioning.

Match Markings used


Inspection wrench set at daily torque value

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1. Has the Contractor submitted working drawings for review by the Engineer of allstructural steel, bearing assemblies, and anchorage devices?

2. Do the working drawings specifically identify each piece other than ASTM A36steel?

3. Do welders have current certifications for the types of welds being made?4. Do bolts, nuts, and washers meet Specifications?5. Are bolts identified as required?6. Are bolts tensioned as required?7. Is tightness of bolt checked?8. Does the welding show quality workmanship?9. Does the Contractor keep welding rods in a hot box?10. Do the welding electrodes used in structural welding conform to the approved list?11. Is the surface of the welds relatively even, smooth, and of the required size?12. Is the welding being performed to avoid undercut?13. Has welding only been performed in locations as noted on the plans or as approved

by the Engineer?14. Have welds that do not conform to the specifications been repaired or removed and

replaced or the entire piece rejected?15. Are the bolt holes no more than 1/16 inch larger than the nominal bolt size?16. Have the burrs on the outside of the bolt holes been removed?17. Is field flame cutting of structural steel units not done?18. Are the structural steel stud shear connectors the size and spacing as shown on the

plans?19. Do the shear connectors project 2 inches above the bottom of the deck slab and 3

inches below the plane of the top of the deck slab?


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Inspector's Checklist – Section 407 (cont.)

20. Has each unit been identified with an erection mark?21. Has the Contractor furnished the materials order shipping statement and erection

diagrams?22. Were bolt tensioning devices and complete bolt assemblies tested with an approved

tension indicating device at the start of construction and on a periodic basis asdetermined by the Engineer?

23. Does the Contractor test calibrated wrenches daily or as directed by the Engineer?


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• Superstructure encompasses the components of the bridge from the bearing seats and above.

SUPERSTRUCTURE62

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• Integral Back wall is formed and poured allowing the entire superstructure to move and flex with force and temperature change. Formwork must be attached to the girders to allow movement in relation to the Abutment.

SUPERSTRUCTURE63

SUPERSTRUCTURE• An 8” Water Main runs across the bridge under the deck. An expansion

sleeve installed inside of the Abutment allows pipe to expand and contract with the bridge.

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BRIDGE DECKS65

• Stay-In-Place (SIP) deck forms are installed between the Girders.

BRIDGE DECKS66

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• Prior to SIP forms, Bolster grades are checked to verify the height of the girders in relation to bottom of the deck.

BolstersBolsters

BRIDGE DECKS67

• Straps and angles should be welded away from the girder. Ground for welder should not connect to the girder.

Bolsters

BRIDGE DECKS

Work TableGround for Work Table

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• Reinforcing Steel should be checked for proper clearance values. A dry run with the screed machine should be performed to verify the clearance with the top of deck and top mat of steel. Bar supports are used to maintain clearance between the steel mats and bottom of deck.

Screed Machine

BRIDGE DECKS69

• Concrete placed using a pump truck and finished to grade with a screed machine. Depth checks should be taken periodically to verify required thickness.

BRIDGE DECKS70

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• The final step in bridge deck construction Bridge Deck Grooving which is done prior to the bridge being opened to traffic.

BRIDGE DECKS71

Grooved shall be sawed approx. 3/16” +/- 1/16” x 1/8” wide. 3/4” on centers.

Inspector's Checklist – Section 4041. Does the Inspector check the concrete temperature, air content,

slump, batch time/placement time prior to placement of the concrete?

2. Is the concrete placed in such a manner that segregation was minimized?

3. Do all chutes and troughs conform to the Specifications?

4. Does the distance that concrete was dropped conform to the Specifications?

5. Is the concrete deposited as near as possible to its final position?

6. Do the Contractor's vibratory procedures conform to the Specifications?

7. Is the concrete placed in continuous horizontal layers?

8. Are the Specifications adhered to when the operation was temporarily discontinued?

9. Do the reinforcing steel and the anchor bolts maintain their position during placement of the concrete?

10. Are the curing materials approved prior to use?

11. If used, is curing compound applied at the specified rate?

12. Where liquid membrane seal was selected, are the contents of the container thoroughly agitated before any portion is drawn off for use?

13. In cold weather, does the Contractor make provisions to maintain the temperature of

the curing concrete within the specified limits?

14. Are the correct number of probes taken and recorded in the project diary for computing overdepths within the ½” construction tolerance?

15. Are approved plans for in place deck forms used and followed?

16. Has a dry run of the screed and form elevations of the deck been checked?

72 BRIDGE DECKSInspector's Checklist – Section 4061. Are samples sent to Materials Division and test reports

on file?

2. Is material stored as specified?

3. Do the size dimensions, bends, and hooks of all reinforcing bars conform to the

reinforcing bar schedules shown on the plans?

4. Is the surface condition free of loose mill scale, flaky rust, dirt, oil or other coatings

that would inhibit concrete bond.

5. Is epoxy coated reinforcing steel being used where required?

6. Is epoxy coating intact and free of defects?

7. Is epoxy coated steel left in sun light more than 30 days without covering?

8. Was reinforcing steel tied as specified?

9. Was reinforcing steel supported as specified?

10. Was reinforcing steel placed as specified?

11. Were splices and laps made as specified?

12. Did spacing, location and edge clearances of all reinforcing bar mats conform to the

plans and Specifications?

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• The last structural component of the bridge is the railing or parapet

RAILINGS & PARAPETS73

• Parapet forming can often be a complicated procedure. As in all formwork, proper clearance, dimensions, and elevations need to be verified as constructed. Maintain proper alignment of the chamfer strip to ensure an even finished appearance.


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• Installation of BR27C Railing on top of parapet wall.



1. Are railings and parapets constructed at the proper height?

2. Are metal railings constructed in accordance with the Specification?

3. Are metal railings or metal parapets grounded properly?

4. Are concrete railings, median barriers and parapets given a Class I finish?

5. Is reinforcing steel placed as specified?

6. Are chamfer strips placed as required?

7. Are construction and expansion joints constructed as required?

8. Is there sufficient clearance of reinforced steel to edge of concrete?


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COMPLETED PROJECT!77

INSPECTION & DOCUMENTATION78

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INSPECTION & DOCUMENTATION

INSPECTION & DOCUMENTATION404.08—Measurement and PaymentConcrete will be measured in cubic yards within the neat lines of the structure as shown on the plansand will be paid for at the contract unit price per cubic yard for the Class designated. Deductions willnot be made for chamfers 1 inch or less in width or for grooves less than 1 inch in depth. The volume ofreinforcing steel or any other material or internal voids within the concrete will be deducted.The volume of bridge deck slab concrete allowed for payment will be computed using the actual thicknessof the slab, not to exceed the plan thickness plus 1/2 inch, for the area between faces of sidewalks,curb lines, railings, or parapets. The area beneath sidewalks, curbs, railings, or parapets will be based onthe plan thickness.Unless designated as separate pay items, this price shall include waterstops, waterproofing, damp-proofing,anchor bolts, drain assemblies, silicone treatment, protective coating for concrete exposed to tidalwaters, and trial batches.If corrugated metal bridge deck forms are used in lieu of removable forms, the price for concrete shallinclude furnishing and placing metal forms, additional concrete required to fill corrugations, work necessaryto facilitate inspection of the underside of the deck, repairing deficiencies, and strengthening beamsor girders to maintain the design live-load rating of the bridge….

Payment will be made under:—————————————————————Pay Item Pay Unit—————————————————————Concrete (Class) item Cubic yardBridge-deck grooving Square yardCover Depth Survey Square yard

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• Sketches are important when calculating area or volume.


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• Calculations should accompany the sketch. Be sure to include any required deductions.


Field Perspective 2.ppt - virginiadot.org

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