bridge maintenance manual

PUB 55 (12-10)

Bridge Maintenance Manual

www.dot.state.pa.us

Publication 55 Bridge Maintenance Manual

Table of Contents

Preface

The purpose of this manual is to provide a reference guide for PENNDOT personnel at the District andCounty levels, and to assist them in understanding the various aspects, methods, materials, and bestpractices related to bridge maintenance and preservation.

This manual has been prepared as a guidance document for in-house department forces to aid them in addressing the most common types of bridge distress by providing an overview of the practical proceduresfor preventive maintenance and repair. It is not meant to be all-inclusive, or to overrule other policies,standards, publications. Although environmental measures are mentioned, this document does not address environmental, historic preservation, traffic control, or safety implications. They may be mentioned for reference only as it pertains to scheduling the operation. Although developed with safetyand minimizing environmental harm in mind, the bridge maintenance procedures presented in this publication may not be appropriate in all situations. The practitioners will be responsible for ensuring that procedures considered are consistent with environmental standards and safety codes within the jurisdictions involved, as well as obtaining the required permits before starting work. This manual is for guidance and information purposes only; it is not regulatory.


Table of Contents

List of Strike-Off-Letters Incorporated into Publication 55

Strike-Off-Letter Subject Section Where Incorporated 431-91-54 MSE Walls Chapter 23

Drilling weep Holes in Existing Walls 431-08-03 Concrete Deck Repair Chapter 17


Table of Contents i

CHAPTER 1: Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-1

CHAPTER 2: BMS2 – How to Get From Inspection to Repairs . . . . . . . . . . . . . . . .2-1

CHAPTER 3: Annual and Strategic Planning . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

CHAPTER 4: Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

CHAPTER 5: Structural Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

CHAPTER 6: SAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

CHAPTER 7: Procurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7-1

CHAPTER 8: Contracts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-1

CHAPTER 9: After-Action Reports (AAR),

Performance Measures, and Follow-ups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-1

CHAPTER 10: Bridge Replacements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-1

CHAPTER 11: Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11-1

CHAPTER 12: Painting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-1

CHAPTER 13: Deck Expansion Joints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-1

CHAPTER 14: Railings/Parapets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-1

CHAPTER 15: Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15-1

CHAPTER 16: Approach Roadway Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-1

Table of Contents

Bridge Maintenance Manual Publication 55

ii Table of Contents

CHAPTER 17: Decks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-1

CHAPTER 18: Deck Drainage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18-1

CHAPTER 19: Timber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19-1

CHAPTER 20: Steel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20-1

CHAPTER 21: Concrete Members . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21-1

CHAPTER 22: Truss . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22-1

CHAPTER 23: Abutments, Wings, Piers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23-1

CHAPTER 24: Culverts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-1

CHAPTER 25: Erosion Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25-1

CHAPTER 26: Construct Temporary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26-1

CHAPTER 27: Miscellaneous Bridge Activities . . . . . . . . . . . . . . . . . . . . . . . . . .27-1

PUB 55 Bridge Maintenance Manual

Introduction: Chapter 1 1-1

Chapter 1: Introduction

ABOUT PUB 55

The purpose of PUB 55 is to provide a BridgeMaintenance reference guide for PennDOTpersonnel at the District and County levels. The objectives are:

To promote an understanding of the bridgeinspection program, regulations and policies and tobridge the gap between the results of a bridgeinspection and recommended bridge maintenance;

To inform about Best Practices for structural repairsand preventive maintenance;To inform about available resources for performingmaintenance, including use of PennDOT forms andprograms;To promote the development of strategic plans forbridge maintenance.

To that end, a process map has been developed (see Figure 1-1) depicting the objectives above.

StructuralPriority

List

DistrictPlanningMeeting

SelectBridge

Activities

StructuralNeeds

Inventory

BMS2 SAP

NBISInspections Asst. Br. Eng

OrBr. Maint. Coord.

MaintenanceWorkOrder

CountyForces

Work

AARPerf. Meas.

PrivateForces

RepairMaint.

PreventMaint.

Emerg.Maint.

ServicePurchaseContract

On-demandOpen-endContract

ECMS

Figure 1-1 - Process Map

This Process Map is presented as a circle becauseof the continuity of the bridge inspection /maintenance process, which becomes a series ofcycles across time. As a practical matter, thebeginning of the Process Map is the place whereany user of the Map recognizes their place in the

process. For the purposes of PUB 55, the processwill begin with BMS2 because BMS2 is therepository of information about bridge conditions,and contains the information used to plan bridgemaintenance. PUB 55 uses information from anumber of PennDOT sources as well as outside

Bridge Maintenance Manual PUB 55

1-2 Introduction: Chapter 1

sources to outline the pathway to achieving ahealthy bridge system through preventivemaintenance and structural repairs. The pathwaygoes from the point of input (i.e. bridge inspectionresults and recommendations) through theprocesses required to manage and resolve theserecommendations. The intent of this publication isto serve PennDOT District and County personnel asa desktop reference and guide. This publicationcontains best practices for use statewide.

Intended UseThe intended audience for this publication includesAssistant District Bridge Engineers for Inspection,District Bridge Maintenance Coordinators,Maintenance Service Engineers, and CountyMaintenance Managers.

JOB TITLES ASSOCIATED WITH BRIDGEMAINTENANCE

While the job titles listed above represent thepersonnel most closely involved with bridgemaintenance operations, other personnel are alsoare involved with bridge maintenance. Following isa list of personnel located at District and Countyoffices who contribute to the processes presentedin PUB 55, along with brief descriptions of theirtasks associated with bridge maintenance.

County

County Maintenance Manager (CMM)

Coordinates with the District Bridge Unit for generation of a Structure Priority List.

Meets with the District Bridge Unit and District Maintenance Coordinator to program bridge maintenance.

Develops an annual plan of work for the upcoming fiscal year, balancing County resources including personnel, equipment, and materials.

Monitors County Maintenance Measurement Tool 18 (CMMT 18) objectives via monthly reports.

Assistant County Maintenance Manager (ACMM)

Receives notifications from the District Bridge Unit through SAP, and develops work orders for maintenance activities.

Supervises Department Force Bridge Foremen.Schedules work for their respective

Counties.

Determines material and equipment needs for maintenance activities and procures those resources as necessary.

Bridge Foreman

Supervises Department Forces.

Percentage of time spent on bridge work measured by CMMT 18, part B.

Department Forces

Performs maintenance activities.

Deck cleaning, typically performed by Department Forces, measured by CMMT 18, Part A.

District Maintenance Unit

Assistant District Executive for Maintenance (ADE – Maintenance)

Monitors CMMT 18 objectives via monthly reports.

District Bridge Maintenance Coordinator (May also be in Bridge Unit)

Meets with the District Bridge Unit and CMM to program bridge maintenance.

Ensures that plans, permits, materials, and equipment are available for scheduled maintenance activities.

Along with the Bridge Unit, considers formwork necessary to complete repairs and designs formwork if necessary.

Monitors CMMT 18 objectives via monthly reports.

Develops repair sketches.

District Bridge Unit

Meets with the District Bridge Coordinator and the CMM to program bridge maintenance.

Generates reports from BMS2 data.

Generates notifications in SAP using BMS2 information.Generates reports from the Structure Needs


Introduction: Chapter 1 1-3

Inventory. This List is generated in cooperation with the CMMs.

Assistant District Bridge Engineer -Inspection

Furnishes dimensions, specifications, and procedures for work.

Furnishes repair design.

Supervises testing of paint for lead and other hazardous materials.

Chapter 1 Best Practices• Maintenance Environmental Planner

prepares waterway permits for maintenance work orders.

• Bridge Unit can provide on-the-job Hydraulics and Hydrology training to a Maintenance Engineer so that Maintenance can perform this function for maintenance work/activities.

• Coordinate effort between design and maintenance units.


BMS2 - How to Get from Inspection to Repairs: Chapter 2 2-1

Chapter 2: BMS2 – How to Get from Inspection to Repairs

StructuralNeeds

Inventory

BMS2 SAP


OrBr. Maint. Coord.

CoAARFigure 2-1 – BMS2 Section of Process Map

IntroductionReferring to the Process Map (Figure 2-1), themajor source of data in the Bridge MaintenanceProcess is BMS2. In essence, BMS2 is a web-baseddatabase containing bridge inspection results andrecommendations. I-forms data (i.e. inspectiondata) feeds the Department’s BMS2. The datacollected and managed by BMS2 can provide thefollowing assistance to the managers of the bridgemaintenance process:

Bridge planning – determining bridge needs on a network basis.

Bridge programming – selection of the correct work item for an individual bridge.

Bridge maintenance management – better use of inspection data for determining maintenance needs and priority for planning and operations.

The information regarding bridge condition,maintenance needs, repair needs, andmanagement of posted or structurally deficientbridges is placed within the database through thecollection of inspection data. Because the datafrom ALL bridge inspections is input into BMS2,future deterioration and corrective bridge costs forvarious maintenance and improvement options canbe better managed. BMS2 uses a planning analysisengine to determine the resources needed on anetwork basis to achieve and maintain the desiredlevel of performance for Pennsylvania’s bridges.

The process of planning and programming bridgemaintenance begins with an inventory of thestructural deficiencies found during routineNational Bridge Inventory Standards (NBIS)inspections. A report is generated by the DistrictBridge Unit using BMS2 data showing the generalcondition of the bridges within the District. BMS2has greatly improved data sharing capabilities with


2-2 BMS2 - How to Get from Inspection to Repairs: Chapter 2

other PennDOT management systems (e.g. RMS,SAP, APRAS, ECMS, and GIS) to assistmanagement decisions.

The following describes how the inspectors get thedata combined in the BMS2 data base.

BRIDGE INSPECTION BASICS

Basic Bridge ComponentsDeckThe deck is the portion of the bridge that providesa surface for vehicular or pedestrian traffic.

SuperstructureThe superstructure is the portion of a bridge aboveand including the bearing device that supports thedeck and vehicular or pedestrian traffic andtransfers the applied loads to the bridgesubstructure. The major components include thedeck, the beams or girders, and the parapets,railings, sidewalks, curbs, drainage features, jointsand bearings.

SubstructureThe portion of a bridge below the bearing device,built to support the superstructure and transmitloads to the foundation. The main components areabutments, wingwalls, piers, bents and footings.

Approach RoadwayThe approach slabs that lead onto the bridge,which are usually concrete.

Traffic Safety FeaturesBridge railings, parapets, approach guiderails,transitions and end treatments.

Inspection FrequencyThe regular inspection cycle in every contract istwo years. Bridges in poorer condition may beinspected annually, with interim inspections ofcritical elements required semi-annually orannually. Typically, regular safety inspections areperformed during the first year of the two-yearcycle, with interim inspections of critical elementsperformed the second year. The second year isoften used as a maintenance year, during which themaintenance recommended in the inspectionreports is performed.

Inspection ReportThe product of a bridge safety inspection is areport showing the condition of a bridge on the dayit was inspected. These inspection reports containelements such as narrative descriptions of thebridge components, photographs, and maintenancerecommendations. However, the single component

that will be common to every Pennsylvania bridgeinspection report is a set of Field Sheets, PennDOTD-450 Forms. This set of Forms contains conditionratings representing the inspectors’ assessment ofthe various bridge components at the time ofinspection. The Forms also include maintenancerecommendations identifying areas of the bridgethat require preventive maintenance or structuralrepairs.

Condition RatingsThe NBIS and AASHTO rating codes and theirdescriptions are shown in the two sections below.It is important to note that the ProfessionalEngineers and Certified Bridge Safety Inspectorsthat perform bridge inspections are well-trained inthe meanings and use of these condition codes,and apply them in their field work according tostrict standards.



The NBIS approach shown above is a consistentstandard for collecting bridge data. However, itdivides each bridge into only four major parts forcondition assessment: superstructure,substructure, deck and culverts. This rating systemleads to a number of problems for a state with asignificant inventory, such as Pennsylvania. First, itis not comprehensive enough to give the full scopeof deficiencies, identify proper repair strategies orestimate costs. Second, the bridge is rated byseverity of deterioration, without identifying thedeterioration process or extent. Third, the NBIScondition ratings are subjective and are notrepresentative when a bridge exhibits mainlylocalized problems.

CoRe element ratings were developed to addressthe shortcomings of NBIS through standardizingthe descriptions and adding a greater level ofdetail. This more generic approach provides thedefinition of each element, the unit ofmeasurement, definitions of a set of three to fivestandardized condition states, and typical feasibleactions for each condition state. During AASHTO'sBridge Subcommittee meeting in May 1995, the

CoRe Element Manual was accepted as an officialAASHTO manual.

PennDOT’s CoRe element coding is found in PUB590 “PA CoRe Element Coding Guide”, whichidentifies as Pennsylvania bridge elements allgirders, trusses, arches, floorbeams, stringers,abutments, piers, pins and hangers, culverts,joints, bearings, railings, decks and slabs. Theelement listing includes a description of theelement, a definition, condition state language, anda unit of measurement. The element descriptionsconsider material composition and, whereapplicable, the presence of protective systems.Condition state language was developed usingstandard engineering terminology to describedeterioration of the element material. As a result,many of the elements have the same conditionstate language. Descriptions of bridge elementsand Smart Flags are followed by theircorresponding condition state language. Thecondition state language is geared towardincreasing levels of deterioration that relate directlyto increasing preventive maintenance throughsignificant structural repair. Thus, the condition

Table 2-1 – NBIS Component-level Coding

(FHWA’s Recording and Coding Guide for the Structural Inventory and Appraisal of the Nation’s Bridges)

Rating Codes Description

N Not Applicable

9 Excellent Condition

8 Very Good Condition – No problems noted.

7 Good Condition – Some minor problems.

6 Satisfactory Condition – Structural elements show some minor deterioration.

5 Fair Condition – All primary structural elements are sound but may haveminor section loss, cracking, spalling, or scour.

4 Poor Condition – Advanced section loss, deterioration, spalling, or scour.

3Serious Condition – Loss of section, deterioration, spalling, or scour mayhave seriously affected primary structural components. Local failures arepossible. Fatigue cracks in steel or shear cracks in concrete may be present.

2

Critical Condition – Advanced deterioration of primary structural elements.Fatigue cracks in steel or shear cracks in concrete may be present or scourmay have removed substructure support. Unless closely monitored, it maybe necessary to close the bridge until corrective action is taken.

1

“Imminent” Failure Condition – Major deterioration or section loss present incritical structural components of obvious vertical or horizontal movementaffecting structure stability. Bridge is closed to traffic but corrective actionmay put back in light service.

0 Failed Condition – Out of service – beyond corrective action.


2-4 BMS2 - How to Get from Inspection to Repairs: Chapter 2

state values provide guidance in typical repairstrategies and provide tools to assist Districts inplanning and programming work in the future.

Incorporating the CoRe Elements into theinspection and evaluation of Pennsylvania’s bridgeswill provide more useful data to those who have to plan, schedule and develop maintenance and repair.

In accordance with PUB 238, one of the functionsof the bridge inspection program is to identify theneeds of bridges with regard to structural repairs,preventive maintenance, preservation,reconstruction and replacement. Bridge owners,generally, and the Department, specifically, needthis information to respond to those criticaldeficiencies warranting immediate attention and forthe long-term management of these criticalinfrastructure assets. The data entered into BMS2will use these major improvement needs andidentified maintenance needs to predict futurecosts to achieve a desired level of service for PA bridges.

BMS2 has a robust software program named“iForms” which supports electronic data collectionof bridge inspections for increased efficiency andeffectiveness in the electronic collection of bridge data through the use of D-450 Forms (see Figure 2-2).

The use of the D-450 Forms within iForms allowsPennDOT to administer program oversight and tomaintain consistency and quality control in view ofthe numerous inspectors within PennDOT and withprivate consultants across the Commonwealth. TheD-450 Forms are used to hold the data gatheredfrom bridge inspections, which includes site data,inventory information on the bridge, conditionratings of the bridge components, and themaintenance needs for that particular bridge. This data is entered into BMS2 database throughthe iForms interface.

The inspectors use the NBIS and AASHTO conditionratings (see Table 2-1) to describe and assess thecondition of the bridge and bridge members.Deficiencies are located and quantified.

Figure 2-2 – I-Forms Entry Screen

In addition to the condition of the bridge members,the inspectors will use the D-450M Form to identifyneeded maintenance items (e.g. on-demandrepairs, preventive maintenance, preservation,etc.) for each bridge using the standard list ofMaintenance Activities on the D-450M Form. Theinspector can edit existing proposed maintenanceitems or create new items, removing completedstructural repairs and updating quantities or addingadditional locations for existing maintenance items.

The D-450M Form provides a means to organizethe basic major improvement information. Oncesubmitted to BMS2, the current inspection’srecommended actions are displayed with allinspections as a cumulative list, displaying currentproposed maintenance as well as planned andcompleted maintenance:

Planned maintenance items are inspector-recommended or other work items that have been approved, tied to a project and programmed.

Completed maintenance items are work items for the structure that are associated with a completed project.

Information that appears on the D-450M Formincludes the:

Type of recommended repair



Location of a recommended maintenance item (near, far, left, right, entire span, etc.)

Estimated quantity of a recommended repair Priority code of a recommended repair

Maintenance Priority Codes listed on the D-450MForm are:

0 – Prompt action required;1 – High Priority, as soon as work can be

scheduled;2 – Priority, review work plan, adjust

schedule as needed;3 – Add to scheduled work;4 – Routine structural can be delayed until

funds are available;and5 – Routine non-structural can be delayed until

programmed.

Maintenance items coded a “0” or “1” should beconsidered high priority maintenance items,requiring immediate attention.

This discussion was intended to provide anunderstanding of the BMS2 system as a tool withseveral uses. The principal use is the storage ofinformation about the conditions and deficiencies ofmany individual bridges, resulting from the variousinspection efforts across the state. Anotherimportant use of BMS2, which will be taken up insubsequent chapters of PUB 55, is that reportsabout the aggregate conditions of bridges in aregion, District, or County may be produced thatguide the planning and programming ofmaintenance activities.

Chapter 2 Best Practices• Maintenance items are extracted from

BMS2 with a Crystal report to develop the preservation projects.

• Inspection crews notify District Bridge Engineer via cell phone of critical structural items needing repair.

• Timely review of new and outstanding Priority 0 and 1 items by bridge inspection supervisor.

• Timely and effective scheduling to perform critical structural repairs.


Annual and Strategic Planning: Chapter 3 3-1

IntroductionIn 2006, FHWA data showed that Pennsylvania’sbridges were fifth in the nation in terms of highestpercent of Structurally Deficient (SD) deck area at20.3%. With 20.7 million square feet of total SDdeck area, Pennsylvania is second to onlyCalifornia. Across the board, as our bridges age, ahigher percentage of them become SD. Thevolume of bridges in each District that requirepreventive maintenance and repair is significant.Posted and closed bridges are a drag on the localeconomy. Local industry, milk, lumber, gas, oil, andagriculture need to get products to markets.Homeowners depend on product and servicedelivery, garbage removal, and heating oil. Mostimportantly, closed or restricted bridges hamperemergency services. The ultimate cost to thecommunity is more than just money orinconvenience – it takes TIME and MONEY toreplace a bridge.

Long-term, the growth rate for SD bridges inPennsylvania is planned to be less than 800,000 SF/ year due to an effective preservation program.However, statistics gathered starting in 2003 showa growth of 1.4 million SF / year. The short-termaverage is heavily influenced by the period2005-2006, due to the re-inspection and re-ratingof non-composite pre-stressed concrete adjacentbox beam bridges with new guidelines and to anumber of large bridges becoming SD. The numberof bridges eliminated from the SD category inPennsylvania as a result of rehabilitation currentlyexceeds the number of newly designated SDbridges, but only by a small margin. Over time,without a conscientious and coordinatedmaintenance program, the increase in the numberof SD bridges will exceed the number of bridgesremoved from the SD category.

Chapter 3: Annual and Strategic Planning

StructuralPriority

List

DistrictPlanningMeeting

SB

Ac

StructuralNeeds

Inventory

BMS2 SAP


OrBr. Maint. Coord.

MainWO

Figure 3-1 – Annual and Strategic Planning Section of Process Map


3-2 Annual and Strategic Planning: Chapter 3

However, looking at a comparison of total PriorityMaintenance 0 and 1 items tallied in 2006 versusthose tallied in 2007 for major bridge areas, thereis cause for concern. The number of Priority 0 and1 bridge maintenance activities identified in 2007on bridge superstructures and substructuresexceed those identified in 2006. The number ofPriority 0 and 1 bridge maintenance activities forscour also rose in 2007. This upward trend isindicative of the aging of Pennsylvania’s bridgesand of the increase in the growth of SD bridgesacross the Commonwealth. Again, the goal is toperform maintenance on bridges before bridgeconditions require Priority 0 or 1 activities tocorrect. Critical to turning the tide will be targetedstrategic planning of improved efforts inmaintenance activities. The sequence of planning isshown in Figure 3-1.

It is clear that careful planning and programmingof bridge maintenance activities is of the utmostimportance. The goal of preventive maintenance is,very simply put, to keep good bridges good. Thisgoal can be accomplished by developing a strategicplan to address bridge maintenance for criticalcomponents of the bridge.

A strategic plan is defined as the process ofarticulating direction and then making decisions onallocating resources. A strategic plan is used asguidance to define functional and divisional plans,which in this case, would be to address theproblem of deficient bridges. While an annual plan(also discussed in this chapter) focuses bridgemaintenance efforts on immediate needs, thestrategic plan looks forward several years, toupcoming and often large-scale needs, as well asroutine maintenance items that do not occur everyyear. If the annual plan can be regarded as a cycleof advancing, yet complementary activities, astrategic plan can be thought of as a cycle ofcycles.

Developing a Strategic PlanBy developing and implementing a strong StrategicPlan, the District can accomplish a major goal,which is to support the reduction of SD bridges byensuring regularly scheduled maintenance.Developing and maintaining a plan for completingcritical preventive maintenance items is a vital stepin ensuring continued serviceability of our bridges.

A well-developed strategic plan does not have tobe large or complicated. Four or five pages thataddress certain components should be sufficient.

The components that should appear in a strategicplan are:

a statement of goals and objectives; routine maintenance cycles; bridge element life cycles; resources; funding; and performance measures.

Further, a well-developed strategic plan shouldprioritize the Districts’ highway structures using theBusiness Plan Networks model. Within this model,the roadway network is prioritized by fourcategories: Network 1 – Interstate highways;Network 2 – NHS highways; Network 3 – Non-NHShighways with ADTs greater than 2,000; and finallyNetwork 4 – Non-NHS highways with ADTs lessthan 2,000. By focusing on Business PlanNetworks 1 and 2, our focus effectively becomescommercial routes, in essence caring for the “trunkof the tree.”

As a concept of cycles and activities for criticalcomponents, a strategic plan can set the scheduleof what work is to be done and at what frequency.The critical components best served by a strategicplan because of their acknowledged life cycle andwell-documented costs and impacts include:

deck overlays, joints, scour, some structural repairs, and painting

Along with a maintenance cycle consisting ofregularly scheduled cleaning of bridge decks,bearings, and joints and preventive maintenance ofstream banks and channel alignments, strategicallyplanned activities such as resealing joints andreplacing deck wearing surfaces can significantlyextend the service life of bridges and prevent theaccumulation of higher priority maintenance itemson a County’s bridge system. It is essential thatmanagement of these activities include trackingand managing the repairs and combiningmaintenance projects for economies of scale.

Pertinent Issues

Clear, concise document.

Cycle of cycles.



County Maintenance Managers (CMMs) must workwith the District Bridge Unit and BridgeMaintenance Coordinator in developing a strategicplan that prioritizes bridge preventive maintenanceactivities within the annual county maintenancework plan. The plan should address routinemaintenance items such as cleaning decks andscuppers as well as preservation, such as jointrepairs, scour mitigation and waterproofing decks(applying membranes, placing latex overlays andfilling grid decks, etc).

For each activity in the strategic plan, carefulanalysis of the required schedule, budget, labor,and equipment is necessary to determine if thework can be completed by the county bridge crewor by contracted forces. Ultimately, developmentshould result in a plan for each critical componentthat looks like the following example:

A district has 25 bridges, with a yearly budgetequaling $20,000The cost to reseal the joints on a single bridge isapproximately $4,000, with labor, equipment,water truck rental, and traffic control.A typical joint seal requires replacement every 5years.Thus, five bridges can be maintained at that yearlybudget. The strategic plan is to replace the joint seals onfive bridges a year for four years. In the fifth year,the cycle starts again on the first bridge.

Developing an Annual Maintenance PlanWhen developing the annual maintenance plan andschedule, consideration must be given to allowingadequate time in budgets and schedules fordeveloping design details (if necessary),procurement of materials and obtaining Erosionand Sedimentation Control and DEP streamencroachment permits, if necessary.

Additionally, bridges on routes which requiresignificant traffic control (such as Interstates andmajor arterials) and/or have particular accessissues (such as over major rivers, railroads, etc.)will require increased budgets and schedules. Ifdesign details cannot be prepared by the DistrictBridge Unit, additional time should be allotted for acontract to be executed between the District and adesign consultant for the work.

For bridge maintenance to be efficientlyimplemented, the county must develop an annualplan that addresses the three major types of bridgemaintenance:

Preventive Maintenance Activities—includes deck

and drainage system cleaning, as outlined inChapter 4;

Priority Bridge Repairs—includes structural repairsto bridge components with Priority Codes 0 & 1, asindicated on the bridge inspection report, asoutlined in Chapters 2 and 8 ;

Non-Regular Maintenance—includes major bridgerepairs and bridge rehabilitation projects, asdiscussed in this chapter.

The CMMs are responsible for coordinating with theDistrict Bridge Unit in establishing a list of projectsfor each of the three bridge maintenancecategories, determining available funding, anddetermining the amount and type of work that canbe accomplished by the county bridge crew or bycontractors. Details on preventive maintenanceactivities are included in Chapter 4 of PUB 55,structural repairs are included in Chapter 5 of PUB55, while procurement and contracts details areaddressed in Chapters 7 and 8, respectively.

NOTE: The importance of scheduling andimplementing preventive maintenance measurescannot be emphasized enough. Preventivemaintenance is considered to be a primarydeterrent to premature deterioration of criticalstructural elements of bridges, and as such,commands high priority in the realm of workplanning, scheduling and accomplishment.

In general, the process for planning annual bridgemaintenance activities is as follows:

Structure Needs InventoryThe process of planning and programming bridgemaintenance begins with an inventory of thestructural deficiencies found during the routineNBIS inspections. A report is generated by theDistrict Bridge Unit using BMS2 data showing thegeneral condition of the bridges within the Districtto develop a picture of what the bridges needwithin the District.

Pertinent Issues

The basic planning process.

Specific improvements?



Structure Priority ListFrom the Structure Needs Inventory the DistrictBridge Unit develops a Structure Priority List. Thislist prioritizes structures requiring work,considering both the needs and sizes of thebridges. This list is developed with communicationand cooperation between the District Bridge Unitand the County Maintenance Managers. Work iscategorized by work force capabilities, that is,determining work to be performed by DepartmentForces and work that should be contracted withprivate firms.

A series of meetings should take place between theDistrict Bridge Unit, the District Maintenance Unitand the County Maintenance Office. The firstmeeting should be held annually in January, andshould include:

Bridge Engineer;Bridge Inspection Engineer;District Bridge Maintenance Coordinator;Maintenance Programs Engineer.

In this meeting, a list of needs based on BMS2data will be identified for all of the County’sbridges. The District Bridge Unit will develop theneeds based on the bridge inspection reports andfeedback from the CMMs. These needs includepreventive maintenance, which is cyclic, andpriority bridge repairs.

A list of projects to be completed by the county inthe coming year should be prioritized and agreedupon. From this list the CMMs later develop theirAnnual Work Plan, which is a plan of work to beperformed by Department Forces during the fiscalyear, beginning July 1. An approximate costestimate for the project should be developed and

compared against the available bridge maintenancefunds as well as the available funds in the countymaintenance budget.

After the budget is approved, a more detailedestimate is developed to determine the personneland equipment requirements to accomplish thework. This estimate is compared to the personneland equipment available within the county. Theneed for certain skills or special equipment must beidentified and accounted for.

If the Department does not have, or is unable toprocure specialized equipment, or if DepartmentForces do not have the particular specialized skillsrequired, a plan should be developed forcontracting these items to private contractors.

A second meeting should take place before Apriland include the following:

Maintenance Program Engineer;District Bridge Maintenance Coordinator;Bridge Unit Representative;County Maintenance Manager;Assistant County Maintenance Manager;County Bridge Foreman.

The purpose of this meeting is to develop anAnnual Work Plan from the list of bridge projectsassigned to the county to complete during theprevious meeting(s). The counties should designthe work plan to have a minimum of eighty percent(80%) of available bridge crew man-hours inmaintenance periods one and three for bridgemaintenance activities. This schedule may include711-7325-01 activities (Repair or Replacement ofstructures under 8' in length). This requirement isnot intended for counties that do not have adedicated bridge crew. The Bridge MaintenanceCoordinator will develop contracts to complete theremainder of the work by contracted forces.

Non-Regular MaintenanceDuring the bridge’s lifespan, rehabilitation orreplacement of certain elements may becomenecessary in order to ensure the bridge remainsserviceable and to prevent advanced deteriorationof critical structural members. In some instances,bridge components become deteriorated to thepoint that replacement of those componentsbecomes the most cost-effective method to keep abridge serviceable.

Pertinent Issues

The basic planning process.

Specific improvements?

Pertinent Issues

Prioritizing bridge work

Work typically done by Department Forces

Work typically contracted out



Evaluating bridge inspection reports to determine ifa major rehabilitation is warranted plus schedulingof large-scale maintenance activities (such asbridge painting) is an important part of theplanning process. The District Bridge Unit willdetermine the type and scope of non-regularmaintenance activities, with input from the DistrictBridge Maintenance Coordinator and CountyMaintenance Manager. These activities can beaccomplished by either the county bridge crew orby contracted forces. Each proposed activity needsto be evaluated to determine if the necessarymanpower and equipment are available in thecounty, and if the work can be effectivelyscheduled into the county bridge crew’s annualwork plan.

Because of the larger scope of these projects,completion may be best accomplished bycontractors with specialized equipment andresources (such as environmental safetyequipment for sandblasting and painting). Thesecontracts are typically prepared by the DistrictMaintenance Unit and completed under thesupervision of the District Construction Unit.County Maintenance Managers must consider thesecontracts when developing the strategic plan andbudget for their county’s bridge network. Refer toChapter 8 for details on the contracting process forbridge maintenance work.

Examples of non-regular maintenance include deckreplacement, underpinning, joint replacement,steel dam deck joint rehabilitation/replacement,extensive superstructure painting, pedestalreplacement, and stringer/beam replacement.Design details for certain activities may need to beprovided by the District Bridge Unit. CountyMaintenance Managers must allocate adequatebudget resources for these activities as part oftheir annual budgeting process.

In general, non-regular maintenance activitiesshould be prioritized based on the Average DailyTraffic (ADT) of the route; the structuralcondition/sufficiency rating of the bridge, includingthe number of high-priority repairs required; theability to incorporate bridge repairs into upcominghighway restoration or improvement projects; andthe anticipated time until replacement of thebridge. Maintenance activities for bridges that havealready been programmed for replacement (seeTransportation Improvement Plans below) shouldhave the goal of maintaining the bridge’s currentserviceability level until the date of replacement.However, high-priority maintenance items that can

affect the safety of the bridge (Priority 0 and 1items) need to be addressed as soon as possibleregardless of the bridge’s rehabilitation orreplacement status.

Transportation Improvement PlansMaintenance projects that may be too large forDepartment Forces, or which can leverage Federalfunding, are sometimes programmed through aregional Metropolitan Planning Organization (MPO)or Rural Planning Organization (RPO)Transportation Improvement Plan (TIP). The TIP isuseful to Districts in several ways; as a means ofprogramming large maintenance projects, and as ameans to remove smaller maintenance projectsfrom annual planning due to an upcomingrehabilitation or replacement project.

A TIP is a four-year program developed by eachMPO, RPO, and one Independent County, that listsall highway, bridge, and public transportationprojects that anticipate federal and state capitalfunds. All the MPO, RPO and Independent CountyTIPs are incorporated into a Statewide TIP (STIP),which is approved by the Federal HighwayAdministration (FHWA), the Federal TransitAdministration (FTA), and the EnvironmentalProtection Agency (EPA).

During the District annual planning meeting the TIPshould be examined for listings that match thebridge list for that District. If a rehabilitation orreplacement project is upcoming, resources forpreventive maintenance may be diverted to otherpriorities. The need for repairs to a bridgeprogrammed for major work should be weighedagainst the critical nature of the repair and thetime until the rehabilitation or replacement isscheduled.

As the Districts update the TIP, the process forprioritization and programming of bridge projectsshall be in accordance with current RiskAssessment Procedures for PennDOT-OwnedBridges and Structures. Risk Assessment providesthe methodology and factors used to calculate arisk score and rank for all 25,000 state-ownedbridges. The key factors include the bridge sizeand physical condition, importance to the highwaysystem, effects on road user costs and implicationsto commerce.



In addition, the Districts, through the RiskAssessment, can establish scopes of work (i.e. fullreplacement, superstructure replacement, deckreplacement, etc), estimated projects costs andgenerate a cash flow analysis. As the Departmentcontinues to improve bridges by rehabilitation andreplacement, the inventory of SD bridges will bereduced and also the risk levels.

The SAFETEA-LU authorization allows the use offederal funds for bridge preservation. Theguidelines are listed in Design Manual, Part 4,Section A, Policy and Procedures, Section 5.6. ThisSection indicates that all highway bridges areeligible to use federal funds for bridge preservationwork so long as the bridges meet the NBIS lengthrequirement. Bridges that do not meet the NBISlength requirement must use state funds forpreservation. Further, all federal aid projects mustbe added to the appropriate TIP. See DM-4 for alist of eligible work items for bridge preservation.

STREAM PERMITTING BASICS

Discussed below is basic stream permittinginformation. The Bridge Maintenance Coordinatormust be familiar with types of permits andmethods for obtaining permits, as they oftenpresent significant impacts to the schedule. Insome districts, the Maintenance EnvironmentalPlanner prepares the waterway permits formaintenance work orders. To ensure all applicableenvironmental clearances are obtained, refer toPUB 294.

TerminologyBog Turtle Habitat ScreeningA screening for bog turtle habitat is required for allprojects that impact wetlands in the followingcounties: Adams, Berks, Bucks, Chester, Carbon(Aquashicola Creek Watershed only) Cumberland,Delaware, Lancaster, Lebanon, Lehigh, Monroe,Montgomery, Northampton, Schuylkill (SwataraCreek Watershed only) and York (PA DEP Document # 3930-PM-WM0550).

Chapter 105The rules and regulations of Title 25(Environmental Protection), Chapter 105 (DamSafety and Waterway Management) as listed in thePA Code (www.pacode.com). A Chapter 105Authorization is the Water Obstruction andEncroachment Permit.

Earth DisturbanceAny activity which disturbs the surface of the land.This includes any excavation or fill within a streamchannel. This includes full-depth reconstruction butexcludes mill & overlay.

FloodwayThe channel of the watercourse and portions of theadjoining floodplains which are reasonably requiredto carry and discharge the 100-year frequencyflood. Unless otherwise specified, the boundary ofthe floodway is as indicated on maps and floodinsurance studies provided by the FederalEmergency Management Agency (FEMA). In anarea where no FEMA maps or studies have definedthe boundary of the 100-year frequency floodway,it is assumed, absent evidence to the contrary, thatthe floodway extends from the stream to 50 feetbeyond the top of the stream bank.

GP-3 (General Permit BDWW-GP-3)General Permit #3 for Bank Rehabilitation, Bankstabilization and (non-vegetated) Gravel BarRemoval (PA DEP Document # 3930-PM-WM0503).

GP-7 (General Permit BDWM-GP-7)General Permit #7 for Minor Road Crossings (PADEP Document # 3930-PM-WM0507).

GP-8 (General Permit BDWM-GP-8)General Permit #8 for Temporary Road Crossings(PA DEP Document # 3930-PM-WM0508).

GP-11 (General Permit BWM-GP-11)General Permit #11 for Maintenance, Testing,Repair, Rehabiliation, or Replacement of WaterObstructions and Encroachments (PA DEPDocument # 3930-PM-WM0511).

HQ/EVHigh-Quality/Exceptional Value stream as definedin PA Code, Title 25 Environmental Protection,Chapter 93 Water Quality Standards.

Joint PermitThe Water Obstruction and Encroachment Permitfor the Chapter 105 permit authorization and USArmy Corps of Engineers for the 404 authorizationissued jointly by DEP (PA DEP Document #3930-PM-WM0036).

Minor Stream CrossingA bridge/road crossing a wetland which disturbsless than 0.1 acre of wetland and crossing lengthover wetlands < 100 ft., or crossing a streamwhere the watershed is less than 1.0 square mile.

PASPGPUSACE Pennsylvania State Programmatic GeneralPermit. Authorizes delegation of issuance of permitto DEP.

PNDIPennsylvania Natural Diversity Inventory search(PA DEP Document # 8100-FM-FR0161) forthreatened and endangered species. This search



and clearance is required for all projects,regardless of permit level.

Programmatic Permits (General Maintenance)Generic Permits issued by PA DEP to each Districtto cover minor repairs and maintenance: E61-9999 for District 1-0; E17-9999 for District 2-0;E41-9999 for District 3-0;E35-9999 for District 4-0;E39-9999 for District 5-0;E23-9999 for District 6-0;E22-9999 for District 8-0;E07-9999 for District 9-0;E32-9999 for District 10-0;E02-9999 for District 11-0;E26-9999 for District 12-0.

Regulated Waters of the CommonwealthWatercourses, streams or bodies of water and theirfloodways wholly or partly within or forming part ofthe boundary of the Commonwealth.

Stocked Trout StreamsRegulated waters of the Commonwealth classifiedby the PA Fish & Boat Commission as watersapproved for trout stocking (TSF).

Stream EnclosureA bridge, culvert or other structure in excess of100 feet in length upstream to downstream.

WatercourseA channel or conveyance of surface water havingdefined bed and banks, whether natural orartificial, with perennial or intermittent flow.

Water ObstructionA dike, bridge, culvert, wall, wingwall, fill, pier,wharf, embankment, abutment or other structurelocated in, along or across or projecting into awatercourse, floodway or body of water.

WetlandsAreas that are inundated or saturated by surfacewater or groundwater at a frequency and durationsufficient to support, and that under normalcircumstances do support, a prevalence ofvegetation typically adapted for life in saturatedsoil conditions, including swamps, marshes, bogsand similar areas. Wetlands must be identified inaccordance with the 1987 USACOE Manual forIdentifying and Delineating Wetlands.

Permit LevelsChapter 105 (State authorization) and Section 404(Federal Waterway) Permits are required for mostbridge maintenance projects.

The three different levels of Permits from DEP, inorder of level of impact and effort, which may berequired for bridge maintenance projects are:

Programmatic Permit (General Maintenance);

General Permit – 11 (Maintenance, Testing, Repair, Rehabilitation or Replacement of Water Obstructions and Encroachments);

Individual (aka standard).

Typically, bridge maintenance projects are coveredby either a Programmatic Permit, (also known as aGeneral Maintenance Permit), or the GeneralPermit – 11 (GP-11). The General MaintenancePermit is an existing authorization issued by PADEP to each District for preventive maintenance,repair and rehabilitation. The GP-11 authorizationis issued for each project individually. The GeneralMaintenance Permit, GP-11, and Individual Permitsare exclusive, meaning only one will be required foreach project. If the maintenance project does notmeet the General Maintenance or General Permitrequirements (ie. an Individual Permit is required),the District Environmental Unit should becontacted. Generally, maintenance projects will becovered by Maintenance or General Permits. Thescope of maintenance projects does not typicallyrequire an Individual Permit from DEP.

Section 404 Federal Waterway Permits areadministered by USACE. USACE has developed aGeneral Permit (PA-SPGP3) for projects with lowenvironmental impacts. USACE has delegatedauthority to DEP to issue its PA-SPGP3 along withDEP’s permit. Therefore, for maintenance projects,DEP is generally the contact for permitting and willissue the necessary waterway permits (JointPermits). If direct contact with USACE is requiredfor a project, DEP and/or USACE will notify theDistrict.

The above permits cover the typical bridgemaintenance project. If the maintenance activityincludes work outside the immediate footprint ofthe structure, some or all of the following DEPpermits may be necessary:

Bank Rehabilitation, Bank Protection and Gravel Bar Removal: General Permit – 3 (GP-3);

Minor Road Crossings: General Permit – 7 (GP-7);

Temporary Stream Crossing: General Permit – 8(GP-8).



These permits are separate from and in addition tothe authorization for the bridge maintenance. Ifthese conditions apply to the maintenance activity,or if the work will be performed by an outsideconsultant, contact the District Environmental Unitfor assistance.

All permitting levels require a PNDI search andclearance that no threatened or endangeredspecies will be impacted by the proposed activity.The clearance process can take 1-2 months ifknown species are present. This clearance must beperformed in advance of submitting the permitapplication.

General Maintenance (Programmatic) PermitExx-9999)For many projects, the District can obtain anauthorization for activities under a standingGeneral Maintenance Permit. This District-widepermit allows for minor stream encroachmentactivities and is intended for use at low-sensitivity,low-impact projects. These projects meet thefollowing criteria:

No wetlands present in project area;

No changes to hydraulic openings as part of the activity;

No HQ/EV (High Quality/Exceptional Value) streams.

ApplicabilityA General Maintenance Permit is valid for:

Minor repairs (deck, wingwalls, footings, etc);

Superstructure replacement;

Channel cleaning within 50’ of bridge.

Stream bed paving

A General Maintenance Permit is NOT valid for anyof the following:

Pier and abutment replacement;

Profile adjustments;

Horizontal and vertical clearance reductions;

Bridge widening;

Wetland impacts.

If the General Maintenance Permit is not valid forthe proposed maintenance activities, evaluate theapplicability of the GP-11.

ProcedureThe requests for authorization to use the GeneralMaintenance Permit are generally submittedthrough a letter of request to the PA Department ofEnvironmental Protection (PA DEP). There are nopermit application forms for the GeneralMaintenance Permit. The request letters areprepared and submitted by the Bridge Maintenancecoordinator with support from the DistrictEnvironmental Unit. A copy of the request letterand plans sent to the PA DEP office must also besent to both the Regional Office of the PA Fish andBoat Commission and the appropriate CountyConservation District Office to inform theseagencies of the proposed project. The applicableoffice locations and addresses for the PA DEP andFish Commission offices are provided in tables 3-1and 3-2. This request must include:

a) A work schedule which includes: the roadway name/route and segment number, the stream name, Chapter 93 designation, any in stream restrictions due to wild or stocked trout or migratory fish, and the date work is to begin and end.

b) A location map showing each project location.c) A written description for each project

including: dimensions of each structure, a complete narrative of all of the proposed activities including measurements and quantities of materials to be removed or placed.

d) A sketch plan for each site which includes/shows: all staging areas, access points/roadways to the work area, all of the areas where work is to be done (including tree and brush removal), the upstream and downstream limits of the proposed activities, a complete listing of the in-stream E&S BMPs to be used and their locations.

e) A valid PNDI search receipt for each site including clearance letters from the appropriate agencies indicating that the work will not adversely impact any species of concern.

For General Maintenance Permits, no Erosion &Sediment Pollution Control plans/authorizations arerequired to be included with the submission to PADEP, even if they are required for the project.

Multiple projects can be submitted with one letterof request by using a table or a single page ofinformation with plans, for each project. Typically, DEP turnaround time for GeneralMaintenance Permit requests is 30 days or less.



Table 3-1 – Department of Environmental Protection Regional Addresses

DEPARTMENT OF ENVIRONMENTAL PROTECTIONREGIONAL OFFICES

PERMITTING AND TECHNICAL SERVICES SECTION

Regional Office County Responsibility

Southcentral Regional Office909 Elmerton Avenue, Second

Harrisburg, PA 17110(717) 705-4707

Adams, Bedford, Berks, Blair, Cumberland,Floor Dauphin, Franklin, Fulton, Huntingdon,Juniata, Lancaster, Lebanon, Mifflin, Perry,

and York

Southeast Regional Office2 East Main Street )

Norristown, PA 19401(484) 250-5970

Bucks, Chester, Delaware, Montgomery, andPhiladelphia

Southwest Regional Office400 Waterfront Drive

Pittsburgh, PA 15222-4745(412) 442-4000

Allegheny, Armstrong, Beaver, Cambria,Fayette, Greene, Indiana, Somerset,

Washington, and Westmoreland

Northwest Regional Office230 Chestnut StreetMeadville, PA 16335

(814) 332-6984

Butler, Clarion, Crawford, Elk, Erie, Forest,Jefferson, Lawrence, McKean, Mercer,

Venango, and Warren

Northeast Regional Office2 Public Square

Wilkes-Barre, PA 18711-0790(570) 826-2511

Carbon, Lackawanna, Lehigh, Luzerne,Monroe, Northampton, Pike, Schuylkill,Susquehanna, Wayne, and Wyoming

Northcentral Regional Office208 W. Third Street, Suite 101

Williamsport, PA 17701(570) 327-3574

Bradford, Cameron, Centre, Clearfield,Clinton, Columbia, Lycoming, Montour,

Northumberland, Potter, Snyder, Sullivan,Tioga and Union

Central Office

Bureau of Watershed ManagementDivision of Waterways, Wetlands and Stormwater Management

P.O. Box 8775Harrisburg, PA 17105-8775

717-787-6827



Table 3-2 – Fish and Boat Commission Regional Addresses

FISH AND BOAT COMMISSION OFFICES

Headquarters Address County Responsibility

NORTHWEST REGION

Regional Manager 11528 Highway 98

Meadville, PA 16335-7320 814-337-0444

Butler, Clarion, Crawford, Erie,Forest, Lawrence, Mercer, Venango,

and Warren

SOUTHWEST REGION

Regional Manager 236 Lake Road

Somerset, PA 15501-1644 814-445-8974

Allegheny, Armstrong, Beaver,Cambria, Fayette, Greene, Indiana,

Somerset, Washington, and Westmoreland

NORTHCENTRAL REGION

Regional Manager P.O. Box 5306

Pleasant Gap, PA 16823814-359-5250

Cameron, Centre, Clearfield,Clinton, Elk, Jefferson, Lycoming,

McKean, Montour, Northumberland,Potter, Snyder, Tioga and Union

SOUTHCENTRAL

Regional Manager 1704 Pine Road

Newville, PA 17241 717-486-7087

Adams, Bedford, Blair, Cumberland,Dauphin, Franklin, Fulton,

Huntingdon, Juniata, Lebanon,Mifflin, Northumberland (MahatangoCreek in Jordan and Lower Mahanoy

Townships only) Perry, and York

SOUTHEAST REGION

Regional Manager Box 8

Elm, PA 17521717 -626-0228

Berks, Bucks, Chester, Delaware,Lancaster, Lehigh, Montgomery,Northampton, Philadelphia, and

Schuylkill

NORTHEAST REGION

Regional ManagerP.O. Box 88

Sweet Valley, PA 18656570-477-5717

Bradford, Carbon, Columbia,Lackawanna, Luzerne, Monroe,

Pike, Sullivan, Susquehanna, Wayne,and Wyoming

DIVISION OF ENVIRONMENTAL SERVICES450 Robinson Lane, Bellefonte, PA 16823

814-359-5147



PennDOT will receive a letter of authorization fromthe PA DEP with the attached copy of the FederalPermit-Pennsylvania State Programmatic Permit(PASPGP-X), if applicable. These authorizations arefor one time use only by PennDOT.

After obtaining the permit and for work planningpurposes, use of the General Maintenance Permitentails adhering to a number of limitations andfulfilling responsibilities that must be satisfiedbefore and during the work effort.

Unless otherwise extended in writing workauthorized in accordance with the proceduresoutlined above must be completed within one yearof the date of authorization.

Notify the appropriate Regional Office of DEP, thePennsylvania Fish and Boat Commission's RegionalHeadquarters, and the appropriate CountyConservation District at least 10 days in advance ofstarting work at each location identified in theproposed work schedule.

Maintain a copy of the work schedule, projectnarrative and sketch plan on site. Access points,limits of work and in-stream E&S BMPS that are tobe used must be clearly indicated on the sketchplan for each site and all activities must becompletely described within the project narrative.

Work in the stream is prohibited for the following,except in emergencies. Emergency work must beapproved by the Department of EnvironmentalProtection in consultation with the PennsylvaniaFish and Boat Commission.

a. migratory fish (MF) during periods of fish migration or spawning

b. stocked trout streams between March 1 and June 15

c. wild trout streams between October 1 and December 31

d. as a part of any avoidance measures required within the PNDI clearance from 1.e.

A listing of stocked and wild trout streams can befound on the Pennsylvania Fish and BoatCommission web page.

Work must be limited within the stream channel 50feet upstream and 50 feet downstream from theface of the bridge or culvert. Exceptions to thismust be specifically identified in the proposed workschedule and shown on the sketch plan along withsupporting data being submitted for DEP approval.

Work should be accomplished by working from thestream banks if at all possible to minimize theoperation of equipment in the water.

In-stream construction area must be enclosed thewithin a cofferdam of sandbags or othernon-erodible, non-polluting material whereverpossible when work involves repairs to piers,footers, wing walls, or retaining structures.De-watering must be done in a manner to preventsedimentation from re-entering the stream.

Channels may be excavated to a width no greaterthan the natural unaffected width of the normal lowflow channel immediately upstream anddownstream of the influence of the bridge orculvert. The remainder of the channel width shallbe maintained as an elevated flood plain and maynot be excavated lower than six inches above thewater level at the time of work.

Disposal of material removed from the channelmust be at a location and in a manner whichprecludes re-entry into the stream. If materialremoved from the channel is needed for backfill orbank restoration, it should be faced to the ordinaryhigh water level with riprap suitably sizedaccording to the anticipated stream velocity. Alldisturbed areas above the level of the riprap mustbe stabilized (vegetative stabilization preferred).Do not deposit excess excavated material in anywetland, river, lake, water course, floodway,floodplain or other regulated waters of thisCommonwealth without first applying for andreceiving the written permit of the Department ofEnvironmental Protection.

Tree and shrub growth on stream banks should notbe disturbed unless absolutely necessary. Anyareas of vegetation to be removed must bedescribed/justified in the project narrative andshown on the sketch plan.

Storm water diversion will be needed if an accessroad is to be constructed to assure water will notflow into the stream or the work area. Show theaccess road location on the sketch plan. Do notimpact wetlands unless permitted to do so inwriting by the grantor of the permit and keep earthdisturbance to a minimum.

Erosion and sediment pollution control measuresmust be employed to minimize erosion and preventsediment from entering the stream channel.Locate the BMPs used in-stream on the sketch planfor each site. All BMPs shall be designed in



accordance with the latest edition of theDepartment's Erosion and Sedimentation PollutionControl Manual or PennDOT's Publication 464-Maintenance Field Reference for Erosion andSedimentation Control. Disturbed areas shall bepermanently stabilized.

Provide a temporary stream crossing whennecessary unless stream flow is shallow and thestream bed consists of solid or non-erodiblematerial. Comply with the conditions of GeneralPermit BDWM-GP-8, Temporary Road Crossings.Fill material provided for temporary crossings shallbe clean granular material and the entire fill areashall be kept to an absolute minimum elevation toavoid obstructing flood flows and/or creating abackwater flooding condition. The Permittee isresponsible for any damages resulting from theobstruction of flood flows by this temporary streamcrossing. Upon completion of the project, removethe temporary crossing and restore the disturbedarea to the original contours. Stabilized the areawith vegetation or other appropriate approvedmethod. Copies of the BDWM-GP-8 are availablefrom the DEP offices listed in Table 3-1.

Provide a separate General Permit application orindividual permit application if required by DEP forany project or portion thereof, which theDepartment determines to have a potentialsignificant effect on safety or protection of life,health, property, or the environment.

General Permit – 11If a project does not qualify for the GeneralMaintenance Permit, the applicability of the GP-11should be evaluated. The GP-11 differs from theGeneral Maintenance Permit in that it is issued perlocation (i.e., each project has its own individualpermit) rather than issued District-wide. Once aGP-11 permit is issued for a location, futuremaintenance may be completed without a newpermit submission to the PA DEP office as long asthe PA DEP office is notified in writing with areference to the issued GP-11 and also providedthat the activity does not substantially change thecharacteristics of the bridge that were originallypermitted. However, this multiple use is limitedbecause of the need for a Federal Permit from theCorps of Engineers. The Corps of Engineers mayrequire a review of the future maintenance andre-issuance of a new Federal permit. Contactshould be made with the U.S. Army Corps ofEngineers before any future maintenance iscompleted.

ApplicabilityA GP-11 is valid for the following projects:

Maintenance, testing, repair, rehabilitation or replacement of existing bridges and culverts;

Minor deviations in the structure’s configuration and roadway profile;

Minor deviations in hydraulic capacity;

Increases in bridge/culvert length up to 12 feet on each side of the bridge;

Channel clearing within 50’ of bridge.

A GP-11 is NOT valid for any of the following:

Stream relocations;

Wetland impacts exceeding 0.05 acre;

Projects likely to impact historical, cultural or archaeological sites;

New structures;Direct/indirect effects on state/federal species of special concern

If the project does not qualify for the GP-11, anIndividual Water Obstruction and EncroachmentPermit is required. Maintenance projects do nottypically require an Individual Permit.

ProcedureThe GP-11 requires the completion of the GP-11application form, located on the DEP website.Applications are prepared and submitted by theBridge Maintenance Coordinator. Proposed projectsshould be reviewed with the District EnvironmentalUnit to determine if GP-11 is suitable for theproject. Sample GP-11 submissions are located onthe PA DEP website. The GP-11 applicationincludes:

Signed and completed GP-11 registration request;

Act 14 Municipal Notification letter;

Sealed sketch plans and cross sections;

Current PNDI run and clearances;

Bog turtle habitat screening (Adams, Berks, Bucks, Carbon (Aquashicola Creek Watershed only), Chester, Cumberland Delaware, Lancaster, Lebanon, Lehigh, Monroe, Montgomery, Northampton, Schuylkill (Swatara Creek Watershed only) or York Counties only);



Engineer’s seal and signature on the engineering drawings;

Erosion & Sediment Control Plan;

Detailed Hydrologic & Hydraulic Study signed and sealed by a licensed Professional Engineer for projects that may increase flooding in the 100-year storm;

Wetland information data sheets if the project impacts wetlands (temporary or permanent);

Location Map (USGS Quad Map);

Photos upstream and downstream of the existing structure.

DEP generally processes a GP-11 application within60 days of receiving the application as long as nodeficiencies are identified concerning theinformation which is submitted by PennDOT. TheFederal Section 404 Permit may or may not be

attached by the PA DEP office depending upon thestatus of PennDOT coordination concerningclearance for the project regarding the bog turtle.Contact with the PennDOT District EnvironmentalUnit is recommended if wetlands are involved witha General Permit Number 11 application.

Existing AuthorizationsExisting authorizations can be located on the PADEP eFacts website (www.dep.state.pa.us/efacts).Normal repairs and maintenance on encroachmentspermitted after July 1, 1979 are authorized underthe existing permit. All other activities require newauthorization as described in Table 3-3.

Emergency ProceduresIf it is determined that the condition of a structureposes an immediate threat to health or safety,notification shall be immediately issued to PA DEPand responsible authorities in adjacent anddownstream communities, including emergencymanagement authorities. Follow PUB 550 "DisasterRecovery Manual" for guidance on emergencyrepairs.

Date Type of Maintenance Permit Requirements

Authorization issued before July1, 1979 . . . All repairs and maintenance. Requires new permit.

Authorization issued after July 1,1979 . . . Normal repairs and maintenance. Authorized under existing permit

Repairs or maintenance involvingmodification from its originalspecifications and a repair orreconstruction involving asubstantial portion of thestructure.

Requires new permit.

Table 3-3 – Activities That Require New Authorization

Chapter 3 Best Practices• Develop Strategic Maintenance Plan• Bridge Maintenance Coordinator attends monthly county manager meetings.• Bridge Maintenance Coordinator and Assistant DBE-Inspection meet with

counties on yearly basis to set work and repair priorities.• Bridge work orders are reviewed by DBE and ADE-Maintenance prior to

meetings with counties.• District Bridge Engineer meets twice a year with county managers. • Assistant DBE - Inspection uses Access database or Excel spreadsheet to

indicate and track bridges that require preservation, such as scour protection, membrane waterproofing, and painting out 20 years.

• Performance Measure to track spending of preservation funds. • Leverage Federal funds for preservation activities via the TIP


Preventive Maintenance: Chapter 4 4-1

IntroductionDeterioration of structures must be minimized toassure the mobility and safety of the travelingpublic, efficient movement of goods, andappropriate return on the nation’s investment in itsbridges. Preventive maintenance is a plannedstrategy of cost-effective treatments to a structureto preserve it in its present condition and to retardfuture deterioration. The objective of preventivemaintenance is to extend the service life of abridge before bridge conditions deteriorate to alevel requiring corrective maintenance, such asstructural repairs. On the other hand, correctivemaintenance involves activities or operationsapplied to fix bridge deficiencies. Preventivemaintenance is applying the right treatment, to theright structure, at the right time. Preventive andcorrective maintenance are both desirable in acomprehensive bridge preservation program, butemphasis should be placed on preventivemaintenance, since costs associated with corrective

maintenance can be significant. The ultimate goalis to perform activities that will preserve bridgecomponents in their present (or intended)condition as well as forestalling development of astructural deficiency. Each of the preventivemaintenance items recommended in D450MMaintenance Needs Data screen contain a BMSactivity number that can be used to reference PUB 55 for further guidance. Figure 4-1 shows the location of Preventive Maintenance in theprocess map.

Typically, we can classify these activities into twogroups:

Scheduled Preventive MaintenanceScheduled preventive maintenance activities areregularly performed at a designated frequency asshown in Table 4-1.

Chapter 4: Preventive Maintenance

SelectBridge

Activities

S

S2 SAP

N


CountyForces

Work

PrivateForces

RepairMaint.

PreventMaint.

Emerg.Maint.



ECMS

Figure 4-1 – Preventive Maintenance Section of Process Map


4-2 Preventive Maintenance: Chapter 4

Response-Type MaintenanceResponse-type maintenance activities are performed on an as-needed basis and identifiedthrough the inspection process:

Resealing expansion joints

Painting structural steel members

Removing debris from waterway channels

Replacing wearing surfaces

Extending or enlarging deck drains

Repairing impact damage

Repairing impact damage to steel girders requiresvery careful attention. Unless corrective measuresare taken, fracture of the beam can occur due toimpact at the original damage location or atanother point on the beam. The corrective measureto prevent fracture is to grind the impact damage.The procedure is as follows:

Grind impact area to bright metal to remove any irregularities and surface defects. Using a sanding disc, smooth area and round over edges. Finish grinding should be done parallel to the stress so this ensures that transverse grind marks are not present.

If the impact is within the proximity of a welded detail, the weld toes should be smoothed with a die grinder to ensure that no microcracks were introduced during the impact. Using a sanding disc, smooth the area and round over edges. Finish grinding should be done parallel to the stress so this ensures that transverse grind marks are not present.

The impact area should be faired back to the material edge at not less then a 1 to 10 slope.

The area should be thoroughly inspected, including any weld toes of details within the vicinity of the impact using ultrasonic or magnetic particle testing as appropriate for the detail.

Introduction to Bridge MaintenanceMuch of the information regarding PreventiveMaintenance is gleaned from PUB 55, titled “BridgeMaintenance Manual,” a reference tool formaintaining state-owned bridges. This manualdescribes the procedures and standards for amultitude of activities related to bridge repair andmaintenance. It is organized into twenty-sevenchapters, each chapter considering a differentstructure element and the repair and/ormaintenance activities associated with it.

Each activity given in PUB 55 follows an outlineconsisting of seven components. The firstcomponent acts to identify the activity. This activityidentifier includes a BMS2 Activity Number, anActivity Title, a Unit of Measurement and aProcedure. The BMS2 Activity Number is the samenumber that appears in Form D-450M for aparticular maintenance activity.

It is encouraged that any preventive maintenancebe scheduled in such a way that it will maximizeeconomies of scale. That is, work that is similarshould be applied to as many locations as possibleor advantage should be taken of similar workefforts. In addition, response-type efforts shouldbe performed when work of a scheduled nature isunderway, such as: when the deck and scuppers ona bridge are being cleaned, the crew should cleanthe expansion joints and troughs as applicable.

Maintenance Item Frequency

Cleaning decks, seats,caps, and salt splashzones

Annually (except inPhiladelphia andAllegheny Counties,where it is performedbiennially) per CMMT18

Cleaning bridgedrainage systems

Annually

Cleaning andlubricating expansionbearing assemblies

Annually

Table 4-1 – Scheduled Preventive Maintenance

Pertinent Issues

The most common response-type maintenance activities statewide

The most common response-type maintenance activities regionally


Preventive Maintenance: Chapter 4 4-3

Chapter 4 Best Practices• Maintain the vast number of masonry

arch bridges through a district-wide masonry repointing contract.

• Reseal all leaking joints on Interstate bridges.

• Bridge Maintenance Coordinator prepares work plans and coordinates with Assistant County Maintenance Manager.

• Bridge Maintenance Coordinator tracks schedules, develops design, performs field surveys and stakeouts, and performs construction inspection for Department Force Projects.

• Preservation work performed by Department Forces can include streambed paving, paving of metal pipes, underpinning, rock protection, joint sealing and installation of waterproofing membranes.


Structural Repairs: Chapter 5 5-1

IntroductionBefore discussing structural repairs, defintionsshowing the difference between structural repairsand preventive maintenance as it relates tomaintaining state-owned bridges must be provided.Structural repairs are defined as those activitiesthat consist of repairing structural deficienciesidentified in the bridge inspection report in order toincrease or maintain the existing capacity of thestructure. Looking back at Chapter 4, recall thatpreventive maintenance is defined as thoseactivities that consist of maintaining structuralelements of a bridge on a regular or cyclic basis inorder to sustain the expected service life of thestructure, forestalling development of a structuraldeficiency. Each of the structural repairsrecommended in D450M Maintenance Needs Datascreen contain a BMS activity number that can beused to reference this manual and PUB 238 forfurther guidance. Figure 5-1 shows that location ofStructural Repairs in the process map.

Top Structural RepairsThis section contains a discussion of the topstructural repairs that are commonly performed onbridges. Additional information is provided in thissection to supplement the information providedchapters 10-27 (see Table 5-1).

Chapter 5: Structural Repairs

SelectBridge

Activities

S2 SAP


CountyForces

WorkPrivateForces

RepairMaint.

PreventMaint.

Emerg.Maint.



ECMS

Figure 5-1 – Structural Repairs Section of Process Map

Pertinent Issues

The most common structural repair activities statewide


5-2 Structural Repairs: Chapter 5

Table 5-1 – Top Structural Repairs

ActivityBMS Activity No.

PUB 55 Page No.

PUB 408Section/Standard Details

Reason for Activity

Steel Stringer orFloorbeam orGirder(Repair/Replace)

A744602OrB744602Or C744602

11-1 1060, 1105 Leaking deck joints of steel stringer bridgesoften result in rusting of the ends of thebeams below the joints. When the results ofthe bridge inspection indicate that significantsection loss to the beam webs has occurred,the load carrying capacity of the beams couldbe compromised. Repairing of the beam websthen becomes necessary. Reducing the waterthat reaches the beam ends should also beaddressed when completing this beam repair.

Galvanizedchannel repair(damaged web)

-- -- -- Leaking deck joints of steel stringer bridgesoften result in rusting of the ends of thebeams below the joints. When the results ofthe bridge inspection indicate that significantsection loss to the beam webs has occurred,the load carrying capacity of the beams couldbe compromised. Repairing of the beam websthen becomes necessary. Reducing the waterthat reaches the beam ends should also beaddressed when completing this beam repair.

Doubler Beam(for damagedstringers)

-- -- -- Leaking deck joints of steel stringer bridgesoften result in rusting of the ends of thebeams below the joints. When the results ofthe bridge inspection indicate that significantsection loss to the beam webs has occurred,the load carrying capacity of the beams couldbe compromised. Adding a supplementalbeam is an option to increase the capacity ofthe member.

Reinforced/Prestressed ConcreteStringer orDiaphragm orOther Members(Repair/Replace)

A744603OrB744603OrC744603

12-1 1001, 1003,1080, 1107,1091BC-783M

Leaking deck joints of reinforced concrete andprestressed concrete beam bridges often leadto concrete spalling at the ends of the beamsbelow the joints. When the bridge inspectionor other report indicates that significantspalling has occurred that exposes thereinforcement bars or prestressing strands,repairing of the beam webs then becomesnecessary. Reducing the water that reachesthe beam ends should also be addressedwhen completing this beam repair.

Bearing PedestalRepair

-- -- -- Cracking or spalling of the bearing pedestalwill result in the need to perform a spallrepair. Spalls are caused by reinforcementbars that have expanded due to rusting andwater freezing in cracks.




PUB 55 Page No.


Reason for Activity

ResettingBearings

-- -- -- Bearings become frozen as a result of lack ofregular lubrication in addition to rusting fromwater intrusion thru the joints, as well asdebris from the deck. A frozen bearingcannot rotate in response to the expansionand contraction of the structure. In the worstcase, the bearing will be pushed or pulledover, ratcheting the bearing and allowingmovement in only one direction as a result ofthe expansion/contraction forces.

Concrete Deck(Repair)

D744303 8-7 1040BC-783M

Deterioration of the top surface of a cementconcrete deck will result in the need toperform a concrete deck repair. Rusting of thetop layer of reinforcement bars, acceleratedby the penetration of chlorides to thereinforcement bars, could lead to theformation of concrete spalls, due to rustingreinforcement bars expanding and waterfreezing.

Abutments (Spall Repair)and BearingSeats (Repair)

B744802AndD744503

14-5 1001, 1002,1003, 1017BC-783M

Spalling of the exposed surface of a concreteabutment backwall, cheekwall, stem, orwingwall will result in the need to perform aspall repair. Rusting of the top layer ofreinforcement bars, possibly accelerated bythe penetration of chlorides to thereinforcement bars due to water leakingthrough deck expansion joints could lead tothe formation of concrete spalls. Spalls arecaused by reinforcement bars that haveexpanded due to rusting and water freezingin cracks.

Pier Repairs -- -- BD-629M(Sheet 15 of 15),SpecialProvision97080600

Spalling of the exposed surface of a concretepier will result in the need to perform a spallrepair. Rusting of the top layer ofreinforcement bars, possibly accelerated bythe penetration of chlorides to thereinforcement bars due to water leakingthrough deck expansion joints could lead tothe formation of concrete spalls. Spalls arecaused by reinforcement bars that haveexpanded due to rusting and water freezingin cracks.

Table 5-1 – Top Structural Repairs (cont.)




PUB 55 Page No.


Reason for Activity

Abutments (Crack Repair)

B744802 14-5 1001, 1002,1003, 1017,1091,SpecialProvision97080600

Settlement of an abutment can lead to acrack. Concrete shrinkage due to curing, ormovement due to temperature change, canalso cause cracking.

The cause of the crack should be determinedfirst. A crack could be a symptom of a largerstructural problem that should be addressed.It is important to determine if the crack isstatic, or is active. If the crack is static, thenperforming only the crack repair will besufficient. However, if the crack is changing inwidth over time, the cause for the movement,such as abutment settlement, needs to beaddressed or the crack will reappear.

Masonry(Repoint)

B744804 14-38 1017 Stone masonry mortar pointing candeteriorate over time due to waterpenetration and freeze/thaw, resulting in aneed for repointing. The mortar bonds thestones together into a solid unit and protectsthe wall from water penetration. Because astone masonry abutment also serves as aretaining wall there is often saturated backfillbehind the wall. Therefore, in some instancesit is advantageous to have some open jointswithout mortar in the wall to act as weepholes to allow water to drain from behind thewall, in which case repointing all of the jointscan be detrimental to the wall unless weepholes are provided.

Footing(Underpin)

E744803 14-34 1001, 1002,1003, 205,850

High velocity stream flow during a high waterevent, an undersized bridge hydraulicopening, and/or an unstable stream bed canresult in scour of the stream bed. If the scourdepth extends below the bottom of footingelevation, a void could form in the soil orerodible rock on which the footing is founded.





PUB 55 Page No.


Reason for Activity

Scour Hole C745301 16-10 703, 205,850

High velocity stream flow during a high waterevent, an undersized bridge hydraulicopening, and/or an unstable stream bed canresult in scour of the stream bed. If the scourdepth extends below the bottom of footingelevation, a void could form in the soil orerodible rock on which the footing is founded.

Repair/ResealDeck Joints andCompressionSeal Deck Joints(Repair/Rehabilitate)

A744101andB744102

4-1 521, 705,SpecialProvisions97050102,97050101,90080101,97050201

Leaking deck joints often lead to deteriorationto beam ends, bearings, and substructureunits. Therefore, minimizing waterpenetration is a very important cost effectivemaintenance repair goal.

StructureMounted Railing(Repair/Replace)

RLGSTRM 5-3 1001, 1002,1003, 1013,1014BD-600MBC-700M

Many older bridges were constructed withstructure mounted metal railings or otherstyles of railings such as open rail concretebarriers. These railings can be damaged fromvehicle collision damage or have section lossdue to steel corrosion or concrete spalling.Bridge inspection reports may alsorecommend railing replacement to improvesafety features.

Other Topics for ConsiderationAlthough PUB 55 covers a multitude of standardstructural repairs, there are other structural repairsthat are fairly common in maintaining today’sbridges. These other structural repairs require adesign by a District Bridge Engineer as well asproject specific supervision. In some instances,PUB 55 does address these other structural repairs,however, it is necessary to clarify that they aremore complex repairs requiring carefulconsideration, design and supervision. Forexample:

Non-composite pre-stressed concrete adjacent boxbeam bridges present a number of structuralrepairs that require careful consideration. TheDecember 2005 collapse of a fascia beam on thebridge carrying S.R. 1014 over Interstate 70highlighted the need for special considerations inmaintaining this structure type. For non-compositepre-stressed concrete adjacent box beam bridgesthe tops of the beams serve as the structural deckwith a bituminous wearing surface applied. Acement concrete deck slab is not used. The lack ofa concrete deck slab can result in an increase in

water penetration especially if a membranewaterproofing is not present.

This type of structure relies on only the shear keysand transverse tie rods or post tensioning strands,for the beams to act together. Longitudinal cracksin the bituminous wearing surface often formabove the beam joints due to independent beamdeflections, resulting in more water penetration. Noconcrete deck also increases fascia beam webcracking below concrete barrier open joints due toan abrupt change in beam stiffness at the barrieropen joints. This abrupt change in stiffness iscaused by the concrete barriers acting compositelywith the fascia beams, except at the barrier joints.These fascia beam web cracks are thereforelocated in the water path below leaking barrierjoints thereby compounding the problem.

Structural repairs include concrete barrierretrofitting to eliminate open joints that causecracks in the beams below these joints, and shearkey re-grouting. In combination with shear keyre-grouting, removing the existing bituminouswearing surface, installing a concrete wearing




surface or composite concrete deck can extend thelife of the structure.

One other related item is cleaning the drain holesin the bottom of the box beams. Although this fallsunder preventive maintenance and should be apart of all bridge inspections, as applicable, it takeson a unique relevance for non-compositeprestressed concrete adjacent box beams. Withonly a bituminous wearing surface, water is morelikely to infiltrate the shear keys and curb areas,eventually entering the beam voids. If the drainholes are not open, the contained water is thensubject to freezing and expansion, resulting inpotential cracking of the sides and bottom of thebox beams. This water adds deadload to thestructure. Therefore, it is of high importance thatall drain holes be cleaned during inspection,documenting which holes contain moisture/wateras necessary.

Modular expansion dam repair warrants specialconsideration as well. Regarding this type of repair,the Engineer’s design and plans as well as theContractor’s method of construction should becoordinated closely with the actual manufacturer ofthe proposed modular expansion dam to ensureproper preparation and installation.

Bridge painting due to lead based paint removalalso warrants special consideration. Most oldersteel bridges contain lead based paint that resultsin the need for strict environmental control. Prior tostarting a bridge painting project, the paint shouldbe tested for lead and other hazardous materialsunder the supervision of the District BridgeEngineer. A project specific lead abatementprogram must be designed for the removal andproper disposal of lead based paint and blastmaterial.

Truss or girder repairs involving a non-redundantstructure load path clearly warrant specialconsideration. By definition, a non-redundantstructure is one that the failure of one membercould result in the collapse of the structure (usuallya structure with only two lines of trusses orgirders). Therefore, repairs of this nature shouldalways include a design and procedure supplied bythe District Bridge Engineer. Furthermore, theDistrict Bridge Engineer should work closely withthe Contractor to ensure the procedure is beingsatisfactorily implemented.Districts can contact the Bureau of ConstructionMaterials and Testing Division, Structural MaterialsSection if assistance is required in developing weldprocedure specifications or non-destructive testingand evaluation of weldments.

Bearing replacement warrants special considerationbecause it entails beam jacking and bearingdesign. An adequate beam/girder jacking schemeneeds to be developed. This scheme should satisfythe design requirements (supporting the applicablebridge loads) and construction requirements(feasible to construct). In addition, this schemeshould be closely coordinated with themaintenance and protection of traffic activities. Inaddition, if bearings are to be replaced, thesereplacement bearings should be designed as well,considering all applicable movements androtations.

Formwork is not in itself a structural repair,nonetheless, it deserves mentioning. Formwork,including prebuilt forms, is an important part ofmost structural repair work and some preventivemaintenance of a bridge. In the past, there hasbeen no clear direction or guidelines provided forwhether formwork needs to be designed or cansimply be provided by Department Forces or aContractor, partly because of its wide variety ofapplications. Many foremen learned to buildformwork using standard tables and guides fromthe tie rod manufacturers or they use metal formswith their own guidance. The sales rep for the tiesystem has tables that make it easy for theforeman to build safe vertical formwork.

If the work is to be completed by DepartmentForces, the District Bridge Maintenance Coordinatorand the Bridge Unit should carefully consider theformwork necessary to complete the givenrepairs/maintenance for the specific bridge. Safetyis the most important consideration whendetermining if formwork needs to be designed orcan simply be provided. If it is apparent that agiven formwork will present a safety concern, dueconsideration should be given to designing thatformwork. Deflection is another consideration thatmay prompt a formwork design. For instance, inarch or box top slabs, the formwork may need tobe designed due to deflection concerns. Finally, thelocation of the formwork should be considered. Thisincludes the overall area to be formed and whetherit is horizontal and/or vertical construction. If theformwork becomes too complex or extensive,consideration should be given to designing theformwork. If standard formwork is to be used, itcan be designed by an Engineer. If prebuilt formsare to be used, most manufacturers providerepresentatives that can assist in checking over thedesign or provide an Engineer to design theprebuilt formwork. The District Bridge MaintenanceCoordinator should work with the Bridge Unit toevaluate, review and design (if necessary) anyformwork to be completed by Department Forces.



If the work is to be completed by a Contractor, it isthe Contractor’s responsibility to determinewhether the necessary formwork needs to bedesigned. The structural repairs to be completed bythe Contractor include the formwork, thus, theContractor is responsible for determining ifstandard formwork would be adequate. If not, theContractor can choose to call a manufacturer (for aprebuilt form) or obtain a design by an Engineer. Ifa prebuilt form is utilized, the Contractor shouldconsider all aspects of the formwork (includingsafety) and if they are uncomfortable with theformwork, they can call the manufacturer and askthem to send a representative out to check over ordesign the formwork before they place theconcrete, if necessary. Whether standard formworkis constructed or prebuilt forms are used, it is theContractor’s responsibility to consider the formworkassociated with the necessary repairs ormaintenance.

Chapter 5 Best Practices• Utilize design squad to prepare

maintenance, preservation projects and Interstate work.

• Repair sketches are developed by the Bridge Maintenance Coordinator in the Bridge Unit

• County bridge crews with substantial capabilities perform emergency type of structural repairs and routine repairs.

• Districts can develop, bid and award bridge maintenance contracts to focus on Priority 1 activities with some bridge replacements.

• Focus maintenance activities on scour, pedestal repairs and beam ends.

• Repair leaking deck joints with two-part silicone system such as XJS deck joint systems.


SAP: Chapter 6 6-1

SAP/Plant MaintenanceSAP is a business-solutions software company thathas developed several software modules used byPennDOT for various services, including a modulecalled “Plant Maintenance” used for managingcertain components of the bridge maintenanceprocess. SAP/Plant Maintenance (SAP) is thesecond of two digital tools for managing bridgemaintenance programs across the state, the firstbeing BMS2, discussed in Chapter 2. An interfacebetween BMS2 and SAP/Plant Maintenance hasbeen developed that allows the sharing ofinformation and the generation of Notifications thatbecome the bases for Work Orders at theEngineering Districts.

Other SAP modules used by PennDOT include R3and Supplier Relationship Management (SRM) forpurchasing, and a financing module used forpayroll. Figure 6-1 shows that location of SAP inthe process map.

Development of a Maintenance Work OrderThe foundation of a Work Order is a Notificationthat appears in SAP. Under most circumstancesNotifications are initiated in BMS2, whichautomatically become Notifications in SAP duringan overnight information sharing process built intothe interface between the two applications.Notifications may be initiated directly in SAP, butthis activity should be reserved for emergencysituations or for counties scheduling routinemaintenance.

Notifications Originating in BMS2For those developing a Notification in BMS2, awell-defined procedure is articulated in thePennDOT PUB 100A, Bridge Management System2, Coding Manual.

SelectBridge

Activities

cturaleedsentory

BMS2 SAP

BISections Asst. Br. Eng

OrBr. Maint. Coord.


CountyForces

Work

AARPerf. Meas.

PrivateForces

Figure 6-1 – SAP Section of Process Map

Chapter 6: SAP


6-2 SAP: Chapter 6

That procedure is reproduced below:

2.6.2. Sending Proposed Bridge MaintenanceActivities to SAP

All proposed work items (bridge, element andflexible actions) will be listed on the MaintenanceApplet, Proposed Work tab. The MaintenanceApplet allows users to view work activities andtrack their status. Districts may also create workNotifications in SAP for county maintenance crewson this screen by following a series of simple steps.This new function in BMS2 supplies SAP withminimum information to initiate the Notification,which then becomes a work order after furtherreview and approval. After the bridge maintenancework is completed and the information is updatedin SAP, BMS2 retrieves select information from SAPand stores it on the Competed Work tab.

Once the District Bridge Maintenance Coordinatorsand County Maintenance crews have decided onwhich bridge maintenance activities are to beworked on in the upcoming year, the Bridge

Maintenance Coordinators may then createNotifications for SAP through BMS2 by doing thefollowing (See Figure 6-2).

1. Navigate to the Maintenance Applet forthe desired bridge.

2. Select the desired maintenance activitythat is to be sent to SAP.

3. Set Item IM07, Status, to “1 – Work planned/ Dept.”

4. Set Item IM08, Target Year, to theapplicable year.

5. Set Item IM11, Work Assign, to “0 –Agency.”6. Save the changes.7. Ensure that the maintenance activity is

highlighted and Click on the “Submit toSAP” button. Item IM07, Status, willchange to “3 – Work Sent to SAP” thenext day after successful submission to SAP.

8. After the button is pressed, themaintenance activity will appear in SAPas a Notification the next day. Furtherinformation and approval is necessarywithin SAP to develop a work order.

Figure 6-2 - BMS2 Maintenance Applet


SAP: Chapter 6 6-3

Only planned work should be submitted to SAP.Districts should confirm that the Notification hasbeen sent to SAP and is ready to be generated intoa work order.

Another, and perhaps preferable, method ofinitiating a Notification in BMS2 is using BMS2 Webrather than the Maintenance Applet as described inPUB 100A and above. BMS2 Web has aMaintenance screen that allows the initiating ofNotification similar to the procedure above, and isavailable to BMS2 Web users with InspectorSupervisor access, and above.

From the BMS2 Web Inventory – Structure Homescreen, select Proposed Maintenance (See Figure6-3). The BMS2 Web Maintenance – ProposedMaintenance screen should appear (See Figure6-4). From this screen a maintenance Notificationmay be initiated by following these steps:

-Select a bridge by its identifier. A list of theproposed maintenance items for that bridge isdisplayed.-Select the desired maintenance activity. A screenshowing the proposed maintenance detail shouldbe displayed. Notice that the “IM_” fields displayedare similar to those in the BMS2 MaintenanceApplet described above.-The desired maintenance activity may be selected.-Clicking the “Submit to SAP” button will make theNotification available to SAP during an overnightsharing of information through the BMS2/SAPinterface.

Figure 6-3 - BMS2 Web Inventory – Structure Screen


6-4 SAP: Chapter 6

Figure 6-4 – BMS2 Web Maintenance – Proposed Maintenance Screen


SAP: Chapter 6 6-5

Notifications and Work Orders in SAPNotifications and Work Orders in SAP are managedusing specific screens for each. Generally, IW2_screens access Notifications. Specifically, an IW24screen is used to create a Notification, an IW22screen changes a Notification, and an IW23 screendisplays a Notification.

Likewise IW3_ screens access Work Orders.Specifically, an IW31 screen is a Work Ordercreation screen, an IW32 screen changes a WorkOrder, and an IW33 screen displays a Work Order.

While the IW31 screen for creating Work Ordersexists, Work Orders should only be developed fromexisting Notifications. In short, the IW31 screenfor initiating Work Orders should not be used.

Also note that the two primary screens for makingchanges are the IW22 screen for Notifications, andthe IW32 screen for Work Orders.

Initiating Notifications in SAPAgain, only rarely are Notifications to originate in SAP. Doing so is generally reserved for emergencies and for routine operations such as

bridge cleaning. However, when circumstancesindicate initiating a Notification in SAP, the processis as follows:

The District Bridge Maintenance Coordinator mayinitiate a Notification directly in SAP. TheNotification is based upon bridge inventory andhistory. An IW24 Screen (See Figure 6-5) is usedto initiate a Notification. An IW23 screen may beused to display the Notification. The IW22 Screenis the screen used to change a Notification,including adding information for routine operationssuch as bridge cleaning. Do not attach a bridge, itis not necessary to bet “credit” on the CMMTMeasures. Also, it is from the IW22 screen that aWork Order is created.

BMS2 and SAP use different identifiers for bridges.BMS2 uses a Functional Location number, whileSAP uses a bridge’s Segment/Offset as itsidentifier, which appears on the RI tab of the IW22screen. To attach a bridge to the Notification, abridge must be selected from pull-down list usingthe Bridges/Pipes tab on the IW22 screen;manually keying the bridge identifier will not attacha bridge to the Notification.

Figure 6-5 – IW24 Screen


6-6 SAP: Chapter 6

Developing a Work OrderWhether the Notification originates in BMS2 or inSAP, the procedure at the District level forreceiving the Notification and moving it through aWork Order to Work appears below:

Typically, the Assistant County MaintenanceManager receives the Notification in SAP andsubsequently converts the SAP Notification to aSAP Work Order by clicking on the appropriate

button in the IW22 screen (See Figure 6-6),creating an IW32 screen and allowing time andmaterials charges by the County. This screenallows changes to be made, and ultimatelyproducing a complete Work Order. The IW32Screen below (See Figure 6-7) shows thepull-down menus used to close a Work Order.



SAP: Chapter 6 6-7



6-8 SAP: Chapter 6

Recording Work and Technically Complete inSAPAs work is completed, the Bridge Foreman informsthe Payroll Clerk of the daily payroll to be charged,who then records that information in the WorkOrder using the IW32 screen. When a job iscomplete, the Bridge Foreman informs theAssistant County Maintenance Manager who thencloses Work Order to additional payroll charges.This places the Work Order in Technically Completestatus. When the Assistant County MaintenanceManager closes a Work Order, SAP automaticallysends a notification to BMS2. SAP automaticallyresends cost information to BMS2 30 days after topick up costs from vendor invoices sent within the30 days. Vendors’ invoices received after 30 daysand up to one year, may be added to a Work Order,but those added costs cannot be transmitted toBMS2. A Technically Complete Work Order remainsopen to vendor invoices for a period of one year.

Closing a Work Order in BMS2After a Work Order has been closed by the ACMMin SAP, PennDOT PUB 100A, Bridge ManagementSystem 2, Coding Manual, articulates theprocedure to close the Work Order in BMS2. TheMaintenance Applet screen has been reproducedbelow (See Figure 6-8):

2.6.3. Coding Completed Maintenance Itemsin BMS2

This section discusses how to code completedmaintenance items that were performed byDepartment Forces and by Contract.

When maintenance is completed and a work orderis closed in SAP, BMS2 will receive notification.Depending on the type of maintenance performed,item IM07, status of the work item, will change toeither a “4 – Review Required” or “5 – Completed /Dept.” For those items whose status is “4 –Review Required,” a follow-up review from theDistrict Bridge Unit or consultant is required toensure that the repair work was completedsatisfactorily. After determining that the work hasbeen performed properly, the reviewer may changethe status to “5 – Completed / Dept” and save thechange in status. No additional review is requiredfor maintenance items whose status is “5 –Completed / Dept.” The date completed, actualquantities and costs (Items IM14, IM18 and IM9)will be taken from SAP / Plant Maintenance.

Figure 6-8 – Closing a Work Order in BMS2


SAP: Chapter 6 6-9

When maintenance work is completed bycontractor forces, Item IM07, Status, must bechanged to “6 – Completed / Contr.” Users mustalso update items IM04 – Estimated Quantity andIM10 – Estimated Cost, with actual values on theProposed Maintenance tab. Once changes to thesefields have been made and saved, the work itemwill be stored in the Completed Work tab.

When maintenance work has been eliminated dueto major rehabilitation or replacement work, thenthe status must be changed to “7 – Superceded,”and the actual date of the work should be coded initem IM14.

This same procedure may also be accomplished inBMS2 Web using the Maintenance – CompletedMaintenance screen (See Figure 6-9).

Figure 6-9 – Closing a Work Order in BMS2 Web Completed Maintenance Screen

Chapter 6 Best PracticesEstablish formal work order process.Utilize standard letter for maintenance workorders.Maintenance items are extracted from BMS2with a Crystal report to develop themaintenance and preservation projects.


Procurement: Chapter 7 7-1

IntroductionIn addition to having maintenance activitiesperformed by forces either inside or outside theDepartment, often Department forces requireadditional support to accomplish work orders, suchas equipment, specialized tools, or materials. Theequipment and materials used may be provided byprivate suppliers. As such, a thoroughunderstanding of contracting with private suppliersis important. This section, along with the nextsection on contracting provides an overview ofprocurement issues as they pertain to bridgemaintenance. Figure 7-1 shows the Procurementfunction location in the process map.

Maintenance Work OrderThe use of Department forces for bridgemaintenance begins with a complete work order.Work orders describe and enumerate the personnelto work on a given project, the equipment to beused or procured, and the materials to be used or

procured. Work orders are prepared by CountyMaintenance Managers and are based uponnotifications generated by the District Bridge Unitthrough SAP using information from BMS2.

ManpowerManpower considerations include employee safety,work procedures, and job assignments. From aprocurements perspective, after employees havewhat they need to be safe, the focus becomes jobassignments. The scheduling of work requiresconsideration of the appropriateness of personnelskills to the particular work being scheduled,vacations, sick leave, and training schedules.However, the scheduling of Department Forcesdoes remain within the domain of the Countyoffices, usually with the ACMMs.

g

SelectBridge

Activities

2 SAP


CountyForces

WorkPrivateForces

RepairMaint.

PreventMaint.

Emerg.Maint.



ECMS

Figure 7-1 – Procurement Section of Process Map

Chapter 7: Procurement


7-2 Procurement: Chapter 7

ServicesCertain maintenance activities such as bridgecleaning may be contracted with private servicesuppliers. If deemed appropriate, services may beprocured with private suppliers within three generalcategories of procurement methods, based uponthe costs of services. The three categories are:

Small, No Bid Procurement

Small, Informal Bid Procurement

Formal, Competitive Sealed Bidding through either the Department itself or DGS, depending on the dollar amount

For a complete description of the proceduresrequired for each of these categories, refer toPennDOT PUB 1, Supplies and Services PurchasingGuides; PennDOT PUB 358, PennDOT’s PurchasingManual; and the DGS Procurement Handbook,current editions.

EquipmentEvery work crew is expected to carry afull-complement of standard tools. However,specialized tools may be required for particularmaintenance projects. ACMMs should noteequipment needs, with consideration for back-up incase of equipment failure.

Having determined equipment needs for aparticular project, the ACMM and the CountyEquipment Manager should determine if theequipment is available through the Departmentfleet. If the equipment is available, then the use ofthat equipment may be scheduled via the CountyMaintenance Manager.

If the equipment needed for a particular project isnot available through the Department fleet, theACMM should determine if the equipment isavailable through an open rental contract. If so,then the equipment may be procured through thestipulations of that open contract and its usescheduled.

If the equipment needed for a particular project isnot available through an open rental contract, theACMM should obtain local bids from private firmsthat can provide the needed equipment.

Having obtained those bids, a provider may beselected and contracted to provide the needed equipment. Once under contract, the use of thatequipment may be scheduled.

Materials Estimates of required materials may be supportedby past experience with similar projects, or byperformance standards. Estimates should alsoaccount for a reserve of materials to be available tobe sure there is sufficient lead time for thepurchase of materials.

Having determined the materials needs for aparticular project, the ACMM should determine ifthe material is available through an open-endcontract. If so, a purchase order can be drawn upand the material acquired.

If the material for a particular project is notavailable through an open contract, the ACMMshould then obtain local bids from private firmsthat can provide the needed material. Havingobtained those bids, a provider may be selectedand contracted to provide the needed material.Once under contract, the use of that material maybe scheduled.

Like Services, supplies procured through contractswith private agencies fall within three generalprocurement categories:

Small, No Bid Procurement

Small, Informal Bid Procurement

Formal, Competitive Sealed Bidding though either the Department itself or DGS, depending on the dollar amount.

For a complete description of the proceduresrequired for each of these categories, refer toPennDOT PUB 1, Supplies and Services PurchasingGuides; PUB 358, PennDOT’s Purchasing Manual;and the DGS Procurement Handbook, currenteditions.

Chapter 7 Best PracticesEstablish contract for cleaning bridge decksand beam seats in addition to removingbrush from around the abutments andwingwalls. Establish on-demand Bridge MaintenanceContract.


Contracts: Chapter 8 8-1

IntroductionThe numbers of bridges in each District thatrequire preventive maintenance and repair makescareful planning and programming of those bridgemaintenance activities of utmost importance. Inthis section the tools and processes available toDepartment personnel at the District and Countylevels are presented. While the planning andprogramming of bridge maintenance activities arecarried out by Department personnel, themaintenance activities themselves may be carriedout by Department Forces or by privatecontractors. Even when maintenance activities arecarried out by Department Forces, the equipmentand materials used may be provided by privatesuppliers. As such, a thorough understanding ofcontracting with private suppliers is important. Thissection presents an overview of contracting andissues as they pertain to bridge maintenance. SeeFigure 8-1 for the location of the contracts functionlocation in the process map.

Bridge Activities SelectionPrioritization CriteriaThe highest completion priorities are placed onthose deficiencies with Maintenance Priority Codesof 0, 1, or 2 by bridge inspectors. Priority 0 itemsneed to be repaired or mitigated within 7 days, andPriority 1 items within 6 months. The DistrictMaintenance Coordinator is responsible forensuring that bridge plans, permits, materials, andrented equipment are available prior to thescheduled bridge maintenance activities.

Contract work forces may be selected for certainwork based upon several criteria including:

Funding sources such as Federal, State, or Local size of the project

g

SelectBridge

Activities

2 SAP


CountyForces

WorkPrivateForces

RepairMaint.

PreventMaint.

Emerg.Maint.



ECMS

Figure 8-1 – Contracts Section of Process Map

Chapter 8: Contracts


8-2 Contracts: Chapter 8

Resources of the Department such as equipment, manpower, the skills of the Department Forces

Work backlog of the Department Forces

A project that is sufficiently large to requirespecialized equipment not owned by theDepartment or otherwise requires equipment thatmust be rented may be contracted with privatecontractors. Department Force capabilities, interms of skills or manpower may also trigger thediversion of work to private contractors. Work mayalso be contracted with private contractorsdepending upon the backlog of the DepartmentForces and the urgency of the structuraldeficiencies.

Contracting Methods Used by PennDOTPennDOT uses three primary methods to contractwith private service providers for the labor,equipment, and materials used for bridgemaintenance operations. As a practical matterthese methods may overlap, however they arepresented here as separate categories to betterarticulate their particular characteristics. Thesethree competitively bid methods are:

Contracts or purchase orders for services

On-demand agreements

ECMS system

The Commonwealth Procurement Code and theDGS Procurement Handbook both define servicesas “the furnishing of labor, time or effort by acontractor not involving the delivery of a specificend product other than drawings, specifications orreports which are merely incidental to the requiredperformance. The term shall include the routineoperation or the maintenance of existingstructures, buildings or real property”.

Roadside spraying and mowing and electrical andplumbing work at maintenance sites are examplesservices.

On-demand agreements are useful for obtaining“on demand” contractors’ services forpredetermined work items on structures. On–Demand Contracts are awarded based oncontractors’ total costs for a variety of bridge repairactivities on several structures within a givengeographical area. Examples of work traditionallyincluded in “on demand” contracts include: deckrepairs, scour repairs, rock abutment/pierrepointing, underpinning, and welding services.

Typically, the Department designs and preparesspecifications for the work, which is thenperformed by contracted private firms. (ECMSNUMBERS 77520 and 76423)Another use of Open-end agreements is to contractwith a design consultant that preparesmaintenance designs, as requested, through workorders. The maintenance work is then performedby Department forces or contractors.

An important advantage to open-end agreementsor on-demand contracts is that response times forstructure repair activities are significantly reduced.Contractors can be deployed relatively quickly,depending on the terms of their respectivecontracts. An important disadvantage of thesecontracts is that funding for the contracts isobligated upfront and these funds are not availablefor other uses if the contracts are not used duringthe contract period. Potential budgetary needsshould be considered before entering into thesekinds of agreements.

ECMS contracts are the traditional method ofobtaining construction services for highways andbridges. These projects have proceeded throughpreliminary and final design processes and areawarded to the low bidder based on competitivebidding. Pre-qualified certified business partnercontractors submit bids through the Department’sECMS system and projects are awarded based onlowest responsible bid. These kinds of contractsmay include significant bridge repairs,rehabilitation, or replacement, but may also includemore preventive maintenance items for multiplebridges, or categories of repair/maintenance, suchas repointing stonework for several bridges.

ECMS contracts may apply to specific sites andclearly outline the work to be done by thecontractor, using the Department’s design, of bidas a design/build contract. This procedure may alsoapply to categories of work, such as a contract forbearing-cleaning on several bridges. For smallerbridges, if the cost of the labor exceeds the cost ofthe materials, an SPC may be employed to securea contractor, but for larger bridges requiringspecialized equipment, an ECMS contract may beused.

Emergency contracts are another method; contactthe District or Central Office contracting section.


Contracts: Chapter 8 8-3

Contract TypesContracting with private firms for services,equipment, or material is a well-regulated processor set of processes that must be consideredcarefully. There are several kinds of contractstypically used for work such as bridgemaintenance, and several methods used byPennDOT for arranging contracts. Which contracttype and method to use depends upon the needs ofthe Department, and the characteristics of thework.

There are four contract types that may beappropriately used for contracting maintenancework. These are:

Unit Price

Lump Sum

Cost Reimbursement

Negotiated Contracts

Unit Price contracts pay contractors for the actualamount of work completed, with the contractingagency retaining control over the extent of thecontract. For example, a contract might requirespall repair and pay for those repairs based uponthe square feet of repair completed. This kind ofcontract also allows the contracting agency toenumerate potential variables and offer varyingpayments, depending on the conditions foundon-site.

Lump Sum contracts are best used when there issome assurance that most or all possible projectcontingencies can be and have been anticipated.The kinds of bridge maintenance projects suitablefor a lump sum contract are completereplacements of structure elements. This type ofcontract requires sufficient detail in the designplans and specifications to preclude inaccurateinterpretation. If interpretation of plans andspecifications is possible or potential variable exist,bidding contractors will suggest prices that accountfor the worst case, driving up the price of thecontract.

Cost Reimbursement contracts assignpredetermined rates to labor, equipment, andmaterials used to perform the contracted service.This kind of contract requires careful inspection andauditing to avoid disputes over quantities of workunits applied to the project. Some contractingagencies have successfully used this contract typefor supplementing agency forces with specializedpersonnel or equipment where needed. Contractor

Force Account allows the contractor to be paidbased on time and materials with specifiedoverhead profit.

Negotiated contracts are a good way to get thebest value for certain kinds of services, such asprofessional engineering support. However, otherservices may be contracted using this type ofcontract. Negotiated contracts may be used whenonly one qualified service provider is available(sole-source contract), or in emergencies when oneprovider may be the best choice. Prior approval isrequired to use this method.

The Costs of ContractingCare must be taken when considering contractingwith private service providers to account for thecosts of contracting. The Department will incur itsown costs associated with contract developmentand deployment, and these costs should beweighed against the costs of using DepartmentForces for the work, if possible. Department costsinclude administrative costs associated withproposals, bid documents, and plans, negotiations,inspections, record-keeping, and verification.Against these costs must be weighed the costs ofDepartment Forces such as overhead, payrollmaintenance during inclement weather, theoperational costs of equipment, and liability.

Chapter 8 Best Practices• Include Bridge Preservation funding on

the TIP.• Develop a joint repair contract for

Interstate bridges.• Establish a preservation contract in each

county to repair specific items.• Districts can develop, bid and award

bridge maintenance contracts to focus on Priority 1 activities in conjunction with some bridge replacements.


After-Action Reports (AAR), Performance Measures, and Follow-Ups: Chapter 9 9-1

After-Action Reports (AAR’s)Once work is completed for the year, anAfter-Action Report (AAR) is to be developed by theCounty in order to evaluate the maintenanceactivities performed during the year and how wellthe county met the goals established in CMMT 18for bridge maintenance. Areas of satisfactoryperformance that can be sustained as well as areaswhere improvement is necessary should be notedand discussed, with a corrective course of actiondeveloped for areas requiring improvement. TheAAR should be promptly completed and maintainedat the appropriate location for review byappropriate personnel. Figure 9-1 shows thelocation of AAR’s in the process map.

An annual meeting should be conducted right afterall work is completed in the fall (Nov, Dec or Jan)in each county with the County Maintenance

Manager, the District Bridge MaintenanceCoordinator, the Assistant District MaintenanceEngineer, and additional personnel as required.During this meeting, the following items should bereviewed and discussed:- Overview of the county’s preventive maintenanceactivities performed- Intent or objectives of the county (i.e., cleaning100% of bridge decks built after 1961 or theDistrict Bridge Engineer’s Plan)- Actual results of project (i.e., percentage of decksactually cleaned)- What performance items can be sustained fromthis project (goals completed/measurement criteriaachieved)?- What performance items were substandard onthis project and what can be improved on futureprojects?

SeleBridg

Activi

StructuralNeeds

Inventory

BMS2 SAP


OrBr. Maint. Coord.

MaintenWorOrde

CountyForces

Work

AARPerf. Meas.

PrivateForces

Figure 9-1 – AAR, Performance Measures and Follow-ups Section of Process Map

Chapter 9: After-Action Reports (AAR), Performance Measures, and Follow-ups


9-2 After-Action Reports (AAR), Performance Measures, and Follow-Ups: Chapter 9

The results of the meeting must be documented onthe AAR form provided by the District Office.Corrective action, if any, must be implemented bythe appropriate authority to ensure a continuouslevel of improvement.

AAR’s can also be completed on an interim basis foremergency issues and special projects as requiredby the ADE-Maintenance or County MaintenanceManager.

In order to ensure that county Maintenanceorganizations are completing the required amountof bridge preventive maintenance each year, theDepartment created a series of CountyMaintenance Measuring Tools (CMMT) to measurethe effectiveness of each county with regard toperformance of certain maintenance tasks. Inparticular, CMMT 18 specifically addresses bridgepreventive maintenance activities and countybridge crew utilization and measures thepreventive maintenance activities of each countyby percentage complete of the following tasks:

No District Bridge Engineer’s Approved CleaningPlan;- Percentage of Bridge Decks, Scuppers, andDownspouts Cleaned/Flushed for structures notprogrammed for replacement within the currentfiscal year and: 1) were built since 1961 or 2) werebuilt prior to 1961 but which have had deckreplacement. 100% of eligible structures should becleaned annually, except for Philadelphia andAllegheny counties (cleaned every two years). - Percentage of Bearing Seats Cleaned/Flushed forall structures built since 1961 except arches,adjacent box beams, concrete frames, slabs,encased I-beam, and box culverts. 20% of eligiblebridges should be cleaned annually, exceptPhiladelphia and Allegheny counties (10% ofeligible bridges). - Percentage of Time Spent on Bridge Work by theCounty Bridge Foremen During Periods 1 & 3. Allbridge foremen and their crew are expected tospend a minimum of 80% of their time on bridgemaintenance activities.

District Bridge Engineer’s Approved Cleaning Plan; - Follow the scope and frequency of the Plan 100%for 01 and 02.- Percentage of Time Spent on Bridge Work by theCounty Bridge Foremen During Periods 1 & 3. Allbridge foremen and their crew are expected tospend a minimum of 80% of their time on bridgemaintenance activities.

The objectives of CMMT 18 are to assure bridgecleaning gets completed in accordance with theBOMO guidelines in order to extend the bridge’sservice life, and ultimately to reduce the backlog ofhigh priority bridge maintenance needs identifiedby bridge inspectors. Compliance with theguidelines set in CMMT 18 ensures that the countyis spending the appropriate amount of effort inbridge preventive maintenance, as well asmaintaining a “state of good repair” onsatisfactorily-rated bridges. Part A focuses on deckcleaning and Part B focuses on Bridge Foremen.Typically, Department Forces perform deckcleanings, which can be recorded in the “PlantMaintenance” module of SAP. This module allowsdata entry recording and action code for the work,the duration of the task, the S.R. number as wellas the segment and offset. Equipment andmaterials used may also be entered into “PlantMaintenance.” Further, “Plant Maintenance”interfaces with the SAP finance module, allowingmonitoring of payroll, equipment costs, andmaterials costs by PennDOT’s Central Office.Every year, the county will be provided aspreadsheet listing the structures that requirecleaning. Progress in meeting the objectives inCMMT 18 must be monitored by the CountyMaintenance Manager, Bridge MaintenanceCoordinator, and the ADE-Maintenance via monthlybridge cleaning reports and monthly bridgeforeman’s activity reports.

Compliance with the guidelines in CMMT 18 by thecounty is critical in ensuring that the requiredyearly preventive maintenance is being completedon the county’s bridge inventory. Additionally,meeting or exceeding the goal of having bridgecrews spend 80% of their time on bridgemaintenance indicates the efficiency of the countyin assigning proper resources to bridgemaintenance needs. Combined, these twomeasures will help to reduce the backlog of prioritybridge repairs in the county.

Additional tools to help measure the efficiency ofthe county’s bridge maintenance program are theperformance metrics HA (Highway Administration)14a and 14b. HA 14a measures the percentage ofcompleted bridge structural maintenance needswith priority 0 or 1, while HA 14b measures thepercentage of completed maintenance needs withpriorities 0 or 1 (except bridge cleaning). Meetingor exceeding the performance targets indicatesthat the county is spending the appropriate amount


After-Action Reports (AAR), Performance Measures, and Follow-Ups: Chapter 9 9-3

of effort in completing priority bridge repair andmaintenance items.

Ultimately, County Managers should work with theBridge Maintenance Coordinator in developing awork plan that addresses as many priority bridgerepair items as possible. Completion oflesser-priority items should be completed to thebest extent possible given the budget andresources available to the county.

Chapter 9 Best Practices• Maintenance work is tracked using

Cmmt#22 the goal of all priority 0 items is to be completed within 7 days, priority 1’s in 6 months.

• In some Districts, the goal is to have 90% of bridge crew’s time spent on bridge work. Measure performance for letting dollars on bridge preservation projects per year.

• During winter months, construction staff member can be assigned to verify maintenance repairs are completed including documentation by photographs.

• Completed structural repairs are noted in a monthly report from maintenance to the Bridge Unit


Bridge Replacement: Chapter 10 10-1

Chapter 10: Bridge Replacements

Table of Contents

7325-01 REPAIR OR REPLACEMENT OF BRIDGE UNDER 8' IN LENGTH . . . . . . . . . . . . .10 - 3

7425-01 TOTAL REPLACEMENT OF BRIDGE OVER 8' IN LENGTH . . . . . . . . . . . . . . . . . .10 - 8


10-2 Bridge Replacement: Chapter 10

[This page intentionally left blank]



REFERENCES

PennDOT Specifications (PUB 408)

Section - 1000 Structures

1001 Cement Concrete Structures

1002 Reinforced Bars

BC-700 Bridge Construction StandardsBD-600 Bridge Design Standards

SCHEDULING CONSIDERATIONS

Based on need as indicated by bridgeinspections. Work can be most efficientlyperformed during periods of low water, which aremost likely to occur in late summer or early fall.

WORK AREA

Entire structure including footings, abutments,wingwalls, superstructure, and deck. Also includesincidental roadway work including repaving of theroadway, and needs may require total replacementguiderail installation.

ACTIVITY DESCRIPTION SUMMARY

This activity includes all actions related to therepair or replacement of a masonry, concrete, orwood structure (arch culvert. box culvert- slab orwood deck structure, masonry, structure. etc.)under 8 feet in length and which cannot be chargedto activity 711-7324 pipe or metal culvertreplacements. All including cleaning, painting,repainting, under pinning, deck repair orreplacement, abutment repair or replacement,wing wall repair or replacement, etc. is to becharged to this activity. Complete replacementshall be accomplished with the approval of theAssistant District Engineer for Maintenance andshall be charged to this activity even if thereplacement structure increases the span length togreater than 8 feet. After completion, the structureover 8 feet shall be assigned a structure I. D.number and future maintenance work charged tothe appropriate bridge activity cost function. Thetemporary traffic control set up shall be erected inaccordance with PUB 213. This activity is stationaryand may be either short or long term in duration.Environmental concerns such as wetlands, erosion

control, waterway pollution are to be addressed inthe disposal of excavated and waste materials.Refer to Maintenance Manual PUB 23, Chapter 20,Page 20-8. Waste materials shall not be placed inwetlands or waterways. Waste materials must bestabilized. Rolling is acceptable stabilization.

PROCEDURE

1. Review plan and order materials well inadvance of the project has started.Depending on the type and cost of materialsthe Department of General Services may beinvolved.

2. Install and maintain water diversion anderosion and sediment controls in accordancewith the approved erosion and sedimentplan.

3. Remove existing structure including footersas required for the construction of the newbridge. Dispose of excavated material andold structure in accordance with currentwaste disposal regulations.

4. Build replacement structure according to theapproved plan and applicable section of PUB408.

5. Remove any water diversion and erosion andsediment controls that have been placed.

6. Provide rock protection as required.

7. Construct roadway and guiderail asdesigned.

8. Seed and mulch areas disturbed duringconstruction.

9. Remove siltation devices when growth isestablished.

Note: Comply with all applicable permit andprocedural requirements of the Depart mentof Environmental Protection, Penn sylvaniaFish and Boat Commission and localConservation Districts in accomplishing thisprocedure.

SAP ASSEMBLY NUMBER: 711-7325-01 BMS2 Flex-Action: NONE

ACTIVITY TITLE: REPAIR OR REPLACEMENT OF BRIDGE UNDER 8’ IN LENGTH

UNIT OF MEASUREMENT: EACH BRIDGE

PROCEDURE: GENERAL PROCEDURE



ACTIVITY REQUIREMENTS

LABOR EQUIPMENT MATERIAL

NUMBER CLASSIFICATION NUMBER TYPE AMOUNT DESCRIPTION

As Required As Required As Required

PRODUCTION UNITS/HOURS PLANNING UNITS PERFORMANCE STANDARD

E.B. N.E. N.E.



Box Culvert Replacement Example:

PennDOT District 8-0York CountyS.R. 3047 over Tributary to Beaver Creek

Single cell box culvert replaced with a precastconcrete box culvert with precast end sections.

Design: Consultant Design (Open EndAgreement) including application for stream permitConstruction: Precast Concrete Box Fabricationand Placement by Contract (Bid in DGS).Excavation, backfill, paving, and safety features byDepartment Forces.Duration of Construction: 2 WeeksMaintenance and Protection of Traffic: Detour

Equipment List:ExcavatorPumps, temporary pipes for stream diversionPaverCompaction Equipment

Material List:AASHTO No. 8 bedding and No. 2A backfill with geotextileRiprapBituminous PavementGuiderail, posts, and end treatmentsCement Concrete (Curb & End Block)Reinforcing Steel (Curb & End Block)Membrane Waterproofing (Post-Tensioning byFabricator)

Installation of Erosion and Sedimentation Controldevices and removal of existing bridge byDepartment Forces

Fish baffles required (above) by Fabricator in shop



Consultant designed box culvert

Fabrication, delivery, and placement of precast boxculvert and end sections by contract.

Post-tensioning required. By Fabricator

Backfill by Department Forces



Riprap placement, paving, and installation of trafficsafety features by Department Forces.

Procurement:Bids are solicited through an existing contract.4 contractors on current contract.Lowest bidder selected.Tracked in SAP



REFERENCES

PennDOT Specifications (PUB 408)Section - 1000 Structures

1001 Cement Concrete Structures1002 Reinforced Bars

BC-700 Bridge Construction StandardsBD-600 Bridge Design Standards


Based on need as indicated by bridge inspec -tions. Work can be most efficiently performedduring periods of low water, which are most likelyto occur in late summer or early fall.

WORK AREA

Entire structure including footings, abutments,wingwalls, superstructure, and deck. Also includesincidental roadway work including repaving of theroadway, and minimum guiderail installation.

ACTIVITY DESCRIPTIONThis activity includes the removal of all existing

structure elements including footings, abutments,wingwalls, concrete or steel superstructure anddeck, and the construction of the replacementstructure. The activity also includes the installation,maintenance, and removal of all erosion andsediment pollution control devices as described inthe approved Erosion and Sediment PollutionControl Plan. The reconstruction of the roadwayapproaches on the existing alignment and theinstallation of minimum approach guiderail.

This activity will usually require a "5" numberedplan signed by the District Bridge Engineer, onapproved Erosion and Sediment Pollution Controlplan, and a Waterways Encroachment Permitissued by the Pennsylvania Department ofEnvironmental Resources an H & H Study andUtility Clearance (D-419).

PROCEDURE

1. Review plan and order materials well inadvance of the project has started.Depending on the type and cost of materialsthe Department of General Services may beRFQ involved.

2. Install and maintain water diversion anderosion and sediment controls in accordancewith the approved erosion and sedimentplan.

3. Remove existing structure including footersas required for the construction of the newbridge. Dispose of excavated material andold structure in accordance with currentwaste disposal regulations.

4. Build replacement structure according to theapproved plan and applicable section of PUB408.

5. Remove any water diversion and erosion andsediment controls that have been placed.

6. Provide rock protection as required.


8. Seed and mulch areas disturbed duringconstruction.

9. Remove siltation devices when growth isestablished.

Note: Comply with all applicable permit andprocedural requirements of the Departmentof Environmental Protection. PennsylvaniaFish and Boat Commission and localConservation Districts in accomplishing thisprocedure.

SAP ASSEMBLY NUMBER: 711-7425-01 BMS2 Flex-Action: NONE

ACTIVITY TITLE: REPAIR OR REPLACEMENT OF BRIDGE OVER 8’ IN LENGTH








As Required As Required As Required


E.B. N.B. N.B.



PROCEDURE DESCRIPTION

1. Establish a detour, notify all involved, andcheck for utilities.

2. Construct sluices or other devices to divertthe stream/ install siltation devices.

3. Remove the existing structure and excavateto design elevations.

4. Establish the working point locations asshown on the design.

5. Form tie rebar and place class A concrete.

6. For fills 2’-0" or less, install membranewaterproofing on the top slab of the box and6" down each side.

7. Membrane on joints top & sides 2’ width

8. Remove the sluices or other devicesdiverting stream.

9. Do not exceed a 2’ difference in fill

elevations on the sides during the placementof backfill.

10. Provide rock protection, class R-6 minimum,at each end of the box or apron up to 5’beyond the wings. The rock protection is tobe 2’-6" nominal depth for the full width ofthe channel.

11.Construct roadway and guiderail asdesigned.

12.Seed and mulch areas disturbed duringconstruction.

13.Remove siltation devices when growth isestablished.

NOTE: Comply with all applicable permitand procedural requirements of theDepartment of Environmental Resources,Pennsylvania Fish and Boat Commission andlocal Conservation Districts in accomplishingthis procedure.

SAP ASSEMBLY NUMBER: 711-7425-01 BMS ACTIVITY NUMBER: NONE

ACTIVITY TITLE: TOTAL REPLACEMENT-BRIDGE OVER 8’ LENGTH


PROCEDURE: CAST IN PLACE BOX CULVERT

TYPICAL BOX SECTION

NO SCALERefer to BD-632 for Details

3'' IF CLAY LINER PLATES USED.










7. Do not exceed a 2’ difference in fillelevations on the sides during the place mentof backfill.

8. Provide rock protection, class R-6 minimum,at each end of the box or apron up to 5’beyond the wings. The rock protection is to

be 2’-6" minimum depth for the full width ofthe channel.




NOTE: Comply with all applicable permitand procedural requirements of theDepartment of Environmental Protection,Pennsylvania Fish Commission and localConservation Districts in accomplishing thisprocedure.

SAP ASSEMBLY NUMBER: 711-7425-01 BMS2 FLEX-ACTION: NONE



PROCEDURE: CAST IN PLACE ARCH CULVERT









6. For fills 2’-0" or less, install membranewaterproofing on the top slab of the box and6" down each side.

7. Membrane on joints top & sides 2’ width


9. Do not exceed a 2’ difference in fill

elevations on the sides during the placementof backfill.

10. Provide rock protection, class R-6 minimum,at each end of the box or apron up to 5’beyond the wings. The rock protection is tobe 2’-6" nominal depth for the full width ofthe channel.




NOTE: Comply with all applicable permitand procedural requirements of theDepartment of Environmental Resources,Pennsylvania Fish and Boat Commission andlocal Conservation Districts in accomplishingthis procedure.

SAP ASSEMBLY NUMBER: 711-7425-01 BMS2 FLEX ACTION: NONE



PROCEDURE: CAST IN PLACE RIGID FRAME CULVERT




1. Establish and confirm a delivery date.

2. For purchased precast projects Fabricatorresponsible for culvert placement.


4. Schedule the survey corp to establishworking points with offset reference.

5. Schedule rental equipment for demolitionand removal of the existing structure.

6. Construct sluices or other devices to divertthe stream and install siltation devices.

7. Excavate to depths indicated on the design.

8. Prepare aggregate bedding or constructconcrete footings as indicated on the designfor the type of culvert to be used.

9. Prepare and follow a sequence of operationsfor setting and connecting the culvert and forwater proofing if called for in the design.

10.Remove the sluices or other devices thatdiverted the stream.

11. Form, tie rebar, and place class A concrete inendwalls and wings or construct slopedendwalls.

12. Place and compact backfill in lifts uniformlyon both sides of the culvert not to exceed 2’difference in fill elevations during backfill.

13. Provide rock protection class R-6 minimumat each end of the culvert.




NOTE: Comply with all applicable permitand procedural requirements of theDepartment of Environmental Protection,Pennsylvania Fish and Boat Commission andlocal Conservation Districts in accomplishingthis procedure.




PROCEDURE: PRECAST / PREFABRICATED CULVERTS






PROCEDURE: R.C. BOX CULVERT

BAFFLES 1-CELL ONLYIN 2-CELL BOX

DEPRESS 1ʼ W/FISH BAFFLES






PROCEDURE: R.C. BOX CULVERT

Bridge Maintenance Manual PUBlication 55


PROCEDURE: METAL CULVERT - CONCRETE ENDWALL

PUBlication 55 Bridge Maintenance Manual


PROCEDURE: METAL CULVERT - SLOPED END CONDITION



Bridge Replacement

BRIDGE REPLACEMENT – PRECAST CONCRETECHANNEL BEAMS ON PRECAST CONCRETEBLOCK ABUTMENTS

PennDOT District 1-0Crawford and Mercer Counties

S.R. 4011 (Crawford) and S.R. 1028 (Mercer) inMeadville over Cussewago Creek

Single span bridge replacement with single spanreinforced concrete channel beam bridge supportedon reinforced concrete block abutments.

Design: In-House by District personnelConstruction: Crawford County Bridge CrewDuration: 6 weeksMaintenance and Protection of Traffic: Roadclosure with detour.

Cost: $110,390

Equipment List:Excavator(s)CraneConcrete FormsSurvey EquipmentWater Pumps (E&S)

Material List:Reinforcing SteelClass A, AA, and AAA Cement ConcreteStructure backfill and geotextilePrecast RC Blocks (by Department Forces)Precast RC Channel Beams (by Department forces)Riprap

PUBlication 55 Bridge Maintenance Manual


Removal of existing bridge and installation of cast-in-place spread footing by Department Forces

Installation of precast concrete block stem andwingwalls.

Installation of prestressed concrete channel beamsby department forces.

Placement of barriers and bituminous overlay (non-composite), backfill, paving, and installation oftraffic safety features by Department Forces.



Precast Concrete Blocks cast by Department Forces3 feet x 3 feet x 3 feet6 feet x 3 feet x 3 feet9 feet x 3 feet x 3 feet12 feet x 3 feet x 3 feet (consider handling)

Precast channel beams cast by Department Forcesup to 35 feet long. May be composite ornon-composite. Design from BD Standard.

Reinforced Concrete Block Abutments

Lessons Learned:

1 - Joints are not sealed to allow drainage (in place of weepholes).

2 - Consider handling when determining block sizes.

3 - Beam seat must be CIP.

4 - Width of precast blocks may allow for elimination of CIP footer. District 1-0 is investigating structure with no footer.

5- For additional width, a wide shear key (up to 1 foot) may be cast between two interior beams. Formwork must be supported from beneath.

Other precast structures available:

Con-Span Arch (Shorter Span)Bebo Arch (Longer Span)Box Culvert


Cleaning: Chapter 11 11-1

Chapter 11: Cleaning

Table of Contents

7431-01 DECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 - 4

7431-01 SCUPPERS/DOWNSPOUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 - 6

7431-02 BEARING/BEARING SEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 - 8

7431-02 STEEL HORIZONTAL SURFACES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 - 10

7431-03 OPEN GRID DECKS AND THEIR

SUPPORTING STRUCTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11 - 12


11-2 Cleaning: Chapter 11




Introduction to Cleaning

All Districts should have an annual Preventative Maintenance Plan. This Plan is vital to extending theserviceability and life cycle of bridges. Regular cleaning and preventive maintenance can extend servicelife of bridges and prevent accumulation of higher priority maintenance items. Preventive maintenanceactivities include deck and drainage system cleaning, cleaning and lubricating expansion bearings, andsealing concrete decks or substructures. The goal is to keep the bridge health in stage 1 as long aspossible.

The importance of scheduling and implementingpreventive maintenance measures cannot beemphasized enough. Preventive maintenance isconsidered to be a primary deterrent to prematuredeterioration of critical structural elements of bridges,and as such, commands high priority !in the realm ofwork planning, scheduling, and accomplishment.



REFERENCES

None

SCHEDULING CONSIDERATIONSShould be performed at least once annually,

after winter maintenance operations have beencompleted. Additional times based on need. Inareas where salt and anti-skid applications areparticularly heavy, additional cleanings as weatherpermits during the winter should be considered.Coordinate cleaning activities with the PennsylvaniaDepartment of Environmental Protection and thePennsylvania Fish and Boat Commission tominimize flushing activities during periods of heavyuse for fishing, boating or other water sports. Avoidbridge cleaning on stocked trout streams from April10 through June 10. For cleaning activitiesinvolving native trout streams, consult with thePennsylvania Department of EnvironmentalProtection and the Pennsylvania Fish and BoatCommission for spawning periods prior to initiating work.

WORK AREAEntire deck between backs of the abutment

backwalls including joints, gutters, curbs,sidewalks, parapets, railings, concrete medianstrips, and the portions of appurtenances, such aslight and sign standards, that can be reachedwithout special lift equipment. Deck joints includeboth the upper exposed surface attached to theconcrete as well as the area beneath the joint thatis intended to remove water from the deck, and thetop and upper edge of the compression sealsjoints.

ACTIVITY DESCRIPTIONRemoving all salt, anti-skid, dirt, debris, and

other deleterious material from the work area bybrooming, shoveling, or mechanical means.Removing any residual material by flushing, asappropriate for maximum efficiency.


1. Sweep loose material from parapets, railings,and sidewalks onto bridge deck by manual ormechanical means. Utilize mechanicalremoval devices (i.e., street sweepers) inareas where the equipment is available.

2. Sweep and collect material from the deck.Do not deposit material in drainage facilitiesor joints. Minimize discharge of loosematerial, grit and debris into the waters ofthe Commonwealth.

3. Remove remaining dirt and debris from deckjoints and drains. Use high pressure air, or,when necessary, high pressure water, toremove dirt and gravel from strip seal glandsand tooth dam troughs and compressionjoints to ensure water flows freely and thatthe seals don’t get broken. Clean debris anddirt from top and edge of compression joints.Do not touch the seal with the wand nozzle.If using Anti-icing truck tankers, make surethe tanks have been cleaned and are free ofsalt before using to flush bridge decks.

4. Dispose of collected cleanings at a properdisposal or fill site.

5. Use clean water when flushing the deck.Water should be obtained from the samewater body that the bridge being cleanedspans. For small streams, where a significantdecrease in stream flow is likely, water maybe brought to the site providing it is of equalor better quality than the background stream quality.

6. Minimize the amount of debris entering thewater body. For instance, where feasible,cover or plug scuppers to prevent debris andcleaning water from entering the stream.Exercise special care when cleaning bridgesover High Quality (HQ) or Exceptional Value(EV) waterways.

7. When cleaning open grid decks flushsupporting structural members also.

8. Use temporary silt fencing and other erosioncontrol measures where necessary toprevent stream bank sediments fromentering the stream.

SAP ASSEMBLY NUMBER: 711-7431-01 BMS2 Flex-Action: A743101

ACTIVITY TITLE: CLEAN/FLUSH DECK








1 Foreman 1 Sweeper Water2 Crew Members 1 Water Tank with1 Special Crew Member pressure hoses

(Operator) or compressor1 Front End Loader


_ Bridge */HR 3 Bridges/DAY 8 MH/Bridge

* average bridge of 25’ x 100’



REFERENCES

None


Should be performed at least once annually,after winter maintenance operations have beencompleted, and is normally accomplishedconcurrently with cleaning of the deck. Additionalcleanings, as necessary, to keep scuppers anddownspouts clear and drainage water flowingfreely. In areas where salt and antiskid applicationsare particularly heavy, additional cleanings asweather permits during the winter months shouldbe considered. Coordinate cleaning activities withthe Pennsylvania Department of EnvironmentalProtection and the Pennsylvania Fish and BoatCommission to minimize flushing activities duringperiods of heavy use for fishing, boating or otherwater sports. Avoid bridge cleaning on stockedtrout streams from April 10 through June 10. Forcleaning activities involving native trout streams,consult with the Pennsylvania Department ofEnvironmental Protection and the Pennsylvania Fishand Boat Commission for spawning periods prior toinitiating work.

WORK AREA

All scuppers and downspouts

ACTIVITY DESCRIPTION

Removing all salt, anti-skid, dirt debris and otherdeleterious material from scuppers and drains byhand or mechanical means. Removing any residualmaterial by flushing, air blasting or mechanicaldevices, as appropriate for maximum efficiency.


1. Remove debris from grating and lift gratingfrom scupper.

2. Remove debris and sediment from scupperbox and pipe.

3. Flush pipe and downspouting with water. Donot use high-pressure water that maydamage joints or anchors. Minimizedischarge of loose material, grit and debrisinto the waters of the Commonwealth.

4. If debris has accumulated in down spouting,remove cleanout plugs as necessary anddislodge with water, snakes, or "roto-rooter"type devices.

5. Replace grating and cleanout plugs.


7. Use clean water when flushing scuppers anddownspouts. Water should be obtained fromthe same water body that the bridge beingcleaned spans. For small streams, where asignificant decrease in stream flow is likely,water may be brought to the site providing itis of equal or better quality than thebackground stream quality.

8. Minimize the amount of debris entering thewater body. Utilize best managementpractices (BMPs) when cleaning bridges overHigh Quality (HQ) or Exceptional Value (EV)waterways.

SAP ASSEMBLY NUMBER: 711-7431-01 BMS2 Flex-Action: B743101

ACTIVITY TITLE: CLEAN/FLUSH SCUPPERS AND DOWNSPOUTS








1 Foreman 1 Water tank Water2 Crew Members 1 Snakes or1 Special Crew Member Roto-rooter

(Operator)


2 Bridge/HR 3 Bridges/DAY 2 MH/Bridge

(assuming 4 Scuppers/down-spouting per bridge.)



REFERENCES

None


Should be performed at least once annually,after winter maintenance operations have beencompleted, on work areas underneath open joints,finger joints and other floor expansion joints whichpermit the passage of water carrying salt, anti-skidand other debris. Additional times, as necessary,under open floor joints and under sealed joints tokeep bearings and areas around them free ofdeleterious materials. Coordinate cleaning activitieswith the Pennsylvania Department ofEnvironmental Protection and the Pennsylvania Fishand Boat Commission to minimize flushingactivities during periods of heavy use for fishing,boating or other water sports. Avoid bridgecleaning on stocked trout streams from April 10through June 10. For cleaning activities involvingnative trout streams, consult with the PennsylvaniaDepartment of Environmental Protection and thePennsylvania Fish and Boat Commission forspawning periods prior to initiating work.

WORK AREA

All bearings and bearing seats at all piers andabutments.


Removing all salt, anti-skid, dirt, debris andother deleterious material from the work area byscraping, brushing, or by other hand or mechanicalmeans. Removing any residual material byflushing, as appropriate for maximum efficiency.


1. Set up scaffolding or ladders, or positionmanlift or snooper truck as required.

2. Manually dry clean the bearing and bearingseats, by scraping, brushing or chipping allaccumulated debris. Material should becollected and disposed of at a properdisposal or fill site.

3. Remove loose paint by dry brushing. Collectand dispose of at an approved disposal site.

Avoid paint chips from entering waterbodies.

4. Thoroughly flush all bearings and bearingseats at piers and abutments withpressurized water to remove salt, dirt anddebris, that could not be removed by manualcleaning methods.

5. Limit wet cleaning to (5) feet on either sideof the joint at the pier, unless debris in otherareas require further cleaning. Clean (5) fivefeet from each abutment.

6. Use clean water when flushing the bearingsand bearing seat. Water should be obtainedfrom the same water body that the bridgebeing cleaned spans. For small streams,where a significant decrease in stream flowis likely, water may be brought to the siteproviding it is of equal or better quality thanthe background stream quality.

7. Minimize the amount of debris entering thewater body. Exercise special care whencleaning bridges over High Quality (HQ) orExceptional Value (EV) waterways.


9. Refer to Chapter 15 for Bearing lubrication.Perform at regular intervals. The work areais all contacted metal surfaces that are notpermanently lubricated. Clean contactsurfaces, surrounding area of rust, and oldlubricant. Place new penetrating spraygrease.

SAP ASSEMBLY NUMBER: 711-7431-02 BMS2 Flex-Action: C743102

ACTIVITY TITLE: CLEAN/FLUSH BEARING/BEARING SEAT








1 Foreman 1 Water Tank with Water2 Crew Members pressure hoses1 Special Crew Member or compressor

(Operator) As Required Access Equip


1/2 Bridge */HR 3 Bridges/DAY 8 MH/Bridge

(* average bridge of 25’ x 100'.)



REFERENCES

None


Should be performed at least once annually,after winter maintenance operations have beencompleted, on surfaces exposed to watercontaminated by deicing chemical, and in placeswhere anti-skid collects. As required on othersurfaces to remove dirt, debris, bird droppings, andother deleterious materials which can reduce paintlongevity and/or promote corrosion. Coordinatecleaning activities with the PennsylvaniaDepartment of Environmental Protection and thePennsylvania Fish and Boat Commission tominimize flushing activities during periods of heavyuse for fishing, boating or other water sports.Bridge cleaning on stocked trout streams from April10 through June 10 is discouraged. For cleaningactivities involving native trout streams, consultwith the Pennsylvania Department ofEnvironmental Protection and the Pennsylvania Fishand Boat Commission for spawning periods prior toinitiating work.

WORK AREA

All horizontal surfaces of structural steelmembers except the top surfaces of beams andstringers to which open grid flooring is directlyattached. The cleaning of these surfaces shall beincluded with Activity A743101, Clean/Flush Deck.


Removing all salt, anti-skid, dirt, debris andother deleterious materials from the work area byscraping, brushing or by other hand or mechanicalmeans. Removing any residual material byflushing, as appropriate for maximum efficiency.


1. Set up scaffolding or ladders or positionmanlift or snooper truck as required.

2. Manually dry clean the horizontal surfaces,by scraping, brushing or by other hand ormechanical means all accumulated debris.Material should be collected and disposed ofat an approved disposal site.

3. Remove loose paint by dry brushing. Collectand dispose of at an approved disposal site.Avoid paint chips from entering waterbodies.

4. Thoroughly flush all horizontal surfaces ofstructural steel members, with pressurizedwater to remove salt, dirt and debris, thatcould not be removed by manual cleaningmethods.

5. Limit wet cleaning of steel horizontalsurfaces to five (5) feet on either side of thejoint at the pier and five (5) feet out fromthe abutment, unless debris in other areasrequire further cleaning. Fascia beams maybe flushed their entire length.

6. Use clean water when flushing steelhorizontal surfaces. Water should beobtained from the same water body that thebridge being cleaned spans. For smallstreams, where a significant decrease instream flow is likely, water may be broughtto the site providing it is of equal or betterquality than the background stream quality.

7. Minimize the amount of debris entering thewater body. Utilize Best ManagementPractices (BMPs) when cleaning bridges overHigh Quality (HQ) or Exceptional Value (EV)waterways.


SAP ASSEMBLY NUMBER: 711-7431-02 BMS2 Flex-Action: D743102

ACTIVITY TITLE: CLEAN/FLUSH STEEL HORIZONTAL SURFACES








1 Foreman 1 Water Tank with Water2 Crew Members pressure hoses1 Special Crew Member or compressor

(Operator) 1 Access Equip


1/2 Bridge /HR 3 Bridges/DAY 8 MH/Bridge




REFERENCES

None


Should be performed at least once annually,after winter maintenance operations have beencompleted. Additional times based on need. Inareas where salt and anti-skid applications areparticularly heavy, additional cleanings as weatherpermits during the winter should be considered.Coordinate cleaning activities with the PennsylvaniaDepartment of Environmental Protection and thePennsylvania Fish and Boat Commission tominimize flushing activities during periods of heavyuse for fishing, boating or other water sports. Avoidbridge cleaning on stocked trout streams from April10 through June 10. For cleaning activitiesinvolving native trout streams, consult with thePennsylvania Department of EnvironmentalProtection and the Pennsylvania Fish and BoatCommission for spawning periods prior to initiatingwork.

WORK AREA

Entire deck between the backs of the abutmentbackwalls including gutters, curbs, sidewalks,parapets, railings, and the portions ofappurtenances, such as light and sign standards,that can be reached without special lift equipment.


Removing all salt, anti-skid, dirt, debris, andother deleterious material from the work area bybrooming, shoveling, or mechanical means.Removing any residual material by flushing, asappropriate for maximum efficiency.


1. Remove loose material from horizontal steelsurfaces, parapets, railings, and devices(i.e., vacuum) in areas where the equipmentis available.

2. Minimize discharge of loose material, gritand debris into the waters of theCommonwealth.

3. Remove remaining dirt and debris from deckjoints and drains.


5. Use clean water when flushing the deck andsupporting structure. Water should beobtained from the same water body that thebridge is being cleaned spans. For smallstreams, where a significant decrease instream flow is likely, water may be broughtto the site providing it is of equal or betterquality than the background stream quality.

6. Minimize the amount of debris entering thewater body. Exercise special care whencleaning bridges over High Quality (HQ) orExceptional Value (EV) waterways.

7. When cleaning open grid decks flushsupporting structural members also.



ACTIVITY TITLE: CLEAN/FLUSH OPEN GRID DECKS AND THEIR SUPPORTING STRUCTURES








1 Foreman 1 Sweeper Water2 Crew Members 1 Water tank with1 Special Crew Member pressure hoses

(Operator) or compressor1 Front end loader


1/2 Bridge* /HR 3 Bridges/DAY 8 MH/Bridge



Painting: Chapter 12 12-1

Chapter 12: Painting

Table of Contents

7432-01 SUPERSTRUCTURE - SPOT/ZONE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 - 3

7432-01 SUBSTRUCTURE - SPOT/ZONE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12 - 5


12-2 Painting: Chapter 12




REFERENCESPennDOT Specifications (PUB 408)Section 1060 - Shop Painting Structural Steel

1070 - Painting Existing Structural Steel1071 - Painting Existing Structural Steel

Using Aluminum Mastic SystemPUB 445 Safety Policy Manual

SCHEDULING CONSIDERATIONSBased on need as indicated by bridge in -

spections, although the requirement for spotpainting should be anticipated on a cyclic basis forplanning purposes. Before a final decision to spotpaint is made, existing paint coats should beevaluated to determine the percent of the area thatis rusting, the presence of rust scaling and pitting,the adhesion of the existing paint coat, thecoatibility of existing coats with the paint system(s)proposed for use, and Perform lead paint/toxicheavy metal assessment. If lead paint/toxic heavymetals are present spot painting is notrecommended (workers will need respirators/PPEfor personel protection, containment and hazardouswaste disposal for environmental concerns). Installenvironmental controls and comply with permitrequirements provided by the District BridgeMaintenance Coordinator and/or EnvironmentalPlanner during all phases of the painting activity.

WORK AREAAll painted superstructure elements of a

structural steel bridge above the bridge seats,including the bearings. Generally, the total areaspot painted does not exceed 20% of the totalpainted area.

ACTIVITY DESCRIPTIONPreparing surfaces and painting limited local

areas where existing paint systems havedeteriorated or have been damaged to the extentthat they no longer provide protection againstcorrosion. The work can include, but is not limitedto, providing scaffolding, work platforms or othermeans to give access to the work; removingdeteriorated paint and rust by blast cleaning and/orusing assorted hand and power tools to provide asurface finish suitable for applying the paint systemselected for use; cleaning existing type paint

systems, which will be repainted, by using solventsor biodegradable cleaners; applying a prime coaton bare surfaces; and applying intermediate andfinish coats of paint in accordance with therequirements of the paint system selected for use.

In addition to spot painting, also report the workof applying intermediate and final coats of paint toareas prime coated under other activities and zonepainting to this activity. Zone painting is thepainting of certain selected areas particularlysubject to conditions where accelerated corrosion isexpected to occur, such as beam ends under openfloor joints. Zone painting may involve the use of adifferent paint system than is used on theremainder of the structure.


1. Power tools shall be used to clean corrodedspots to bright metal.

2. Take measures to allay dust, if necessary.

3. Take measures to protect adjacent property,vehicles, pedestrians, concrete surfaces, andwaterways.

4. Insure that temperature is above 40ºF,relative humidity is less than 85%, andsurface is not hot or damp. Painting may beperformed under cover in cold or dampweather.

5. Paint neatly with brush, roller, or sprayer.

6. Work paint into all crevices, if appropriate.

7. No coat shall be applied until preceding coathas dried.

8. Test thickness of paint.

Note: Comply with applicable permit andprocedural requirements of the Department ofEnvironmental Protection, Pennsylvania Fish andBoat Commission and local Conservation Districtsin accomplishing this procedure and for containingand disposing of paint chips, sand and shot. If leadpaint/toxic heavy metals are present and work isinitiated, follow worker Health and SafetyStandards by OSHA and in PUB 445. Wear theproper Personal Protective Equipment contact yourDistrict Safety Coordinator before starting work toensure all safety measures have been established.

SAP ASSEMBLY NUMBER: 711-7432-04 Aluminum BMS2 Flex-Action: A743201

711-7432-03 Zinc

717-7432-01 General

ACTIVITY TITLE: SPOT/ZONE PAINTING-SUPERSTRUCTURE








1 Foreman As Required Power Chippers As Required Paint3 Crew Members As Required Power Brushes

As Required Sand Blaster

As Required Paint BrushesAs Required RollersAs Required Paint SprayerAs Required Paint ThicknessAs Required TesterAs Required Access

Equipment


.02 Each/HR .1 Each/DAY 240 MH/Each



REFERENCESPennDOT Specifications (PUB 408)

Section 1060 - Shop Painting Structural Steel1070 - Painting Existing Structural Steel1071 - Painting Existing Structural Steel

Using Aluminum Mastic SystemPUB 445 Safety Policy Manual

SCHEDULING CONSIDERATIONSBased on need as indicated by bridge in -

spections, although the requirement for spotpainting should be anticipated on a cyclic basis forplanning purposes. Before a final decision to spotpaint is made, existing paint coats should beevaluated to determine the percent of the area thatis rusting, the presence of rust scaling and pitting,the adhesion of the existing paint coat, thecompatibility of existing coats with the paintsystem(s) proposed for use, and Perform leadpaint/toxic heavy metal assessment. If leadpaint/toxic heavy metals are present spot paintingis not recommended (workers will needrespirators/PPE for personel protection,containment and hazardous waste disposal forenvironmental concerns). Install environmentalcontrols and comply with permit requirementsprovided by the District Bridge MaintenanceCoordinator and/or Environmental Planner duringall phases of the painting activity.

WORK AREAAll painted substructure components of a bridge.

Generally the total area spot painted does notexceed 20% of the total painted area.

ACTIVITY DESCRIPTIONPreparing surfaces and painting limited local

areas where existing paint systems havedeteriorated or have been damaged to extent thatthey no longer provide protection againstcorrosion. The work can include, but is not limitedto, providing scaffolding, work platforms or othermeans to give access to the work; removingdeteriorated paint and rust by blast cleaning and/orusing assorted hand and power tools to provide asurface finish suitable for applying the paint systemselected for use; cleaning existing type paintsystems, which will be repainted, by using solvents

or biodegradable cleaners; applying a prime coaton bare surfaces; and applying intermediate andfinish coats of paint in accordance with therequirements of the paint system selected for use.

In addition to spot painting, also report the work ofapplying intermediate and final coats of paint toareas prime coated under other activities and zonepainting to this activity. Zone painting is thepainting of certain selected areas particularlysubject to conditions where accelerated corrosion isexpected to occur, such as beam ends under openfloor joints. Zone painting may involve the use of adifferent paint system than is used on theremainder of the structure.


1. Power tools shall be used to clean corrodedspots to bright metal.

2. Take measures to allay dust, if necessary.

3. Take measures to protect adjacent property,vehicles, pedestrians, concrete surfaces, andwaterways.

4. Insure that temperature is above 40ºF,relative humidity is less than 85%, andsurface is not hot or damp. Painting may beperformed under cover in cold or dampweather.

5. Paint neatly with brush, roller, or sprayer.

6. Work paint into all crevices, if appropriate.

7. No coat shall be applied until preceding coathas dried.

8. Test thickness of paint.Note: Comply with all applicable permit andprocedural requirements of the Departmentof Environmental Protection, PennsylvaniaFish and Boat Commission and localConservation Districts in accomplishing thisprocedure and for containing and disposingof paint chips, sand and shot. If leadpaint/toxic heavy metals are present andwork is initiated, follow worker Health andSafety Standards by OSHA and in PUB 445.Wear the proper Personal ProtectiveEquipment contact your District SafetyCoordinator before starting work to ensureall safety measures have been established.

SAP ASSEMBLY NUMBER: 711-7432-06 Aluminum BMS2 Flex-Action: B743201

711-7432-05 Zinc

717-7432-01 General

ACTIVITY TITLE: SPOT/ZONE PAINTING-SUBSTRUCTURE








1 Foreman As Required Power Chippers As Required Paint3 Crew Members As Required Power Brushes

As Required Sand Blaster

As Required Rollers1 Paint Sprayer1 Paint Thickness

testerAs Required Access equip


.02 Each/HR .1 Each/DAY 240 MH/Each


Bridge Expansion Joints: Chapter 13 13-1

Chapter 13: Deck Expansion Joints

Table of Contents

7433-01 RESEAL ...........................................................................................................13 - 3

7433-02 REPAIR/RESEAL .............................................................................................13 - 6

7433-02 OTHER DAM TYPES (REPAIR/REHABILITATE) .................................................13 - 8

7433-02 COMPRESSION SEAL (REPAIR/REHABILITATE).............................................13 - 10

7433-02 MODULAR DAM (REPAIR/REHABILITATE) .....................................................13 - 13

7433-02 STEEL DAMS (REPAIR/REHABILITATE) .........................................................13 - 20


13-2 Bridge Expansion Joints: Chapter 13




Preventive Maintenance Resealing Joints

Perform based on need:

• 2-part silicone – 3-5 year l.c.• Asphaltic plug – 3-5 year l.c.• Strip seal – 10 year (min.) l.c.

Work area:

Joints of less than 1 inch Remove damaged, deteriorated sealingmaterialClean/prepare surfacesPour/place new sealing material



REFERENCES

PennDOT Specifications (PUB 408)Section521 -Transverse Joint Sealing and Cleaning

705 -Joint Material


Based on need as indicated by bridgeinspections. Joint must be dry and temperature ator above 40oF.

WORK AREA

All joints of less than one inch between portlandcement concrete (PCC) deck elements includingconstruction joints and joints between precast slabelements having limited movement that can beaccommodated by poured sealing material. Thejoints can be located anywhere within the entirewidth of the superstructure for the entire length ofthe bridge between the backs of the backwalls.


Resealing joints using poured material at anylocation within the work area. The work includesremoving damaged, deteriorated, or non-adheringexisting sealing material; cleaning and preparingthe surfaces of the concrete against which thesealing material will be poured, placing a backerrod or bond breaker, if appropriate; and pouringnew joint sealing material.


1. Clean joint of all existing sealer and backerrod using a plow. Do not remove joint fillerunless it is deteriorated. If necessary, resawjoint to between 3/8" and 5/8".

2. Remove all sealer material from the jointfaces by using wire brushes and remove allloose material from the joint by blowing withan air compressor.

3. Place foam joint backer rod into joint andpush down approximately 3/4" below thesurface of the deck. The backer rod shouldbe approximately 1/8" wider than the joint.

4. Pour sealant into joint to within 3/8" ofsurface of deck surface.


ACTIVITY TITLE: RESEAL DECK JOINTS (LIQUID ONLY)

UNIT OF MEASUREMENT: LINEAR FEET OF DECK JOINT







1 Foreman 1 Air Compressor As Required Backer Rod3 Crew Members 1 Concrete Saw As Required Silicone or

Rubberized JointMaterial


Foot/HR Foot/HR Foot/HR



Structural Repairs Repair/Reseal Joints

Perform based on need

Work area: All joints of less than 1 inch with associated adjacent damaged concrete:

• Remove damaged, deteriorated existing sealing material and concrete• Form and place new concrete • Pour new sealing material



REFERENCES


Section521 - Transverse Joint Sealing and Cleaning

705 - Joint Material

1001 - Cement Concrete Structures

1040 - Concrete Bridge Deck Repair


Based on need as indicated by bridgeinspections. Joint must be dry and temperature ator above 40ºF for placing joint sealing material.After concrete joint has started to deteriorate, theaffected area tends to increase rapidly if exposedto traffic. The resulting high live load impact candamage other parts of the structure, so workshould not be delayed unnecessarily.

WORK AREA

All joints of less than one inch between PortlandCement Concrete (PCC) deck elements havinglimited movement that can be accommodated bypoured sealing material. The work area includesboth the joint and the adjacent concrete whichmust be removed and replaced to repair the joint.Report repairs to concrete outside of this work areaunder other appropriate activities such as ActivityD744303, Concrete Deck (Repair), even if the workis being done at the same time.


Repairing and resealing joints using pouredmaterial at any location within the work area. Thework can include, but is not limited to, removingdamaged, deteriorated, or non-adhering existingsealing material; removing deteriorated concrete;retying or replacing reinforcing steel: constructingforms; placing concrete; placing a backer rod orbond breaker, when appropriate; and pouring newjoint sealing material.


1. Remove all old joint material and backer rod.

2. Mark all areas of damaged concrete to beremoved.

3. Remove concrete by saw cutting and jackhammering.

4. Put temporary form in joint and placeconcrete.

5. After concrete cures, remove temporaryform and clean joint of any loose material.

6. Place foam joint backer rod into joint andpush down so top of filler is approximately3/4" below the surface of the deck. The fillershould be approxi mately 1/8" wider than thejoint.

7. Pour sealant into joint to within 3/8" ofsurface of deck surface.


ACTIVITY TITLE: REPAIR/RESEAL DECK JOINTS

UNIT OF MEASUREMENT: LINEAR FEET OF DECK JOINTS




SAP ASSEMBLY NUMBER: 711-7433-02 BMS2 Flex-Action: E744102

ACTIVITY TITLE: REPAIR OTHER DAM TYPES

UNIT OF MEASUREMENT: LINEAL FEET OF JOINT REPAIRED

PROCEDURE: OTHER

REFERENCES


Section1001 - Cement Concrete Structures



Bases on need as indicated by bridgeinspections.

WORK AREA

All expansion joints, regardless of movementclassification, using a joint system other thancompression seals, strip seals, modular dams, orsteel dams.


Repairing or replacing the existing joint system,either partially or totally, with a joint system notcovered under another activity. The work caninclude but is not be limited to the removal of theexisting joint repair of the concrete adjacent to thejoint if needed, and placement of the new joint system.

The new joint systems include Dow Corning XJS,Silcoflex, Jennie Joint, asphalt plugs, and otherproprietary or experimental joint systems.

The joint system to be used should be approvedby the District Bridge Engineer.


The installation procedure will vary with the typeof joint system to be used. The manufacturershould furnish specific installation instructions forthe joint system. A manufacturer's representativeshould be on the job during initial installation ofdemonstration or experimental joint systems.






1 Foreman 1 Air Compressor As Required LF Joint Backing3 Crew Members 1 Jack Hammer Material

1 Concrete Saw As Required Silicone or1 Concrete Mixer As Required Rubberized

Concrete


3 LF/HR 18 LF/DAY 1.3 MH/LF

SAW CUT JOINT




ACTIVITY TITLE: COMPRESSION SEAL DECK JOINTS (REPAIR/REHABILITATE)

UNIT OF MEASUREMENT: LINEAR FEET OF COMPRESSION SEAL DECK JOINT

PROCEDURE: REPLACE EXISTING COMPRESSION SEAL

REFERENCES


Section705 - Joint Material


1002 - Reinforcement Bars

1008 - Preformed Neoprene CompressionJoint Seal for Bridges

1021 - Armored Preformed NeopreneCompression Dam


BC-766M Compression Seal Joint


Based on need as indicated by bridgeinspections. Preformed compression seals can beinstalled more efficiently during cooler, but notbelow freezing, temperatures. Surfaces againstwhich seals are placed must be dry, althoughconcrete surfaces may be "damp-dry".

WORK AREA

All armored and unarmored joints in the deck inwhich preformed compression seals have been orwill be placed. The work area includes both thejoint and deteriorated or damaged concreteadjacent to unarmored joints which must beremoved and replaced to repair the joint. Reportconcrete repairs adjacent to armored joints andrepairs to armor in joints to Activity D744102,Steel Dam Deck Joints (Repair/ Rehabilitate).Concrete repairs not directly necessary forunarmored joint repairs should be reported underActivity D744303, Concrete Deck (Repair).


Repairing or rehabilitating existing preformedcompression seal deck joints or replacing pouredseals with preformed compression seals at anylocation within the work area. The work caninclude, but is not limited to, removing all orportions of an existing preformed seal that hasdeteriorated, has been damaged, or is no longerproviding a watertight seal; removing all of anexisting poured seal and modifying the joint toaccept a preformed seal; removing deteriorated

concrete; retying or replacing reinforcing steel; constructing forms; placing concrete; sawing sealgrooves; and installing preformed compressionseals.


1. Remove existing compressible joint materialfrom joint.

2. Clean joint of any foreign material usingcompressed air.

3. Remove and replace any deterioratedconcrete.

4. Cut new compressible material to fit thejoint. If joint extends beyond deck to curbsor medians, then cut according to sketch.

5. Apply lubricant adhesive to the faces of thejoint.

6. Position seal over joint opening, compressand insert into joint while the adhesive is stillwet. Install seal within the joint to therequired depth of application, usually 1/4 to1/2 inch below the deck surface.






1 Foreman 1 Air Compressor 1 LF Preformed2 Crew Members 1 Concrete Mixer Neoprene

1 As Require Compression1 Seal and

LubricantAdhesive


5 LF/HR 30 LF/DAY .6 MH/LF




ACTIVITY TITLE: COMPRESSION SEAL DECK JOINTS (REPAIR/REHABILITATE)

UNIT OF MEASUREMENT: LINEAR FEET OF COMPRESSION SEAL DECK JOINT

PROCEDURE: MODIFY POURED SEAL JOINT AND RESEAL WITH COMPRESSION SEAL


1. Remove existing poured joint material anddebris from joint.

2. Saw - cut the joint to a uniform dimensionacross the bridge deck to the prescribedwidth and depth for the anticipated deckmovement.

3. Grind chamfer on edges of joint from curb tocurb.

4. Clean dirt and debris from the joint usingcompressed air.


6. Position seal over joint opening, compressthe bottom of the seal and insert into thejoint while the adhesive is still wet.

7. Complete the installation by positioning theseal within the joint to the depth required,usually 1/4 to 1/2 inch below the decksurface.




1 Foreman 1 Concrete Saw 1 LF Preformed2 Crew Members (Double Bladed) Neoprene

1 Air Compressor As Required Compression1 Seal and

LubricantAdhesive






ACTIVITY TITLE: MODULAR DAM DECK JOINTS (REPAIR/REHABILITATE)

UNIT OF MEASUREMENT: LINEAR FEET OF MODULAR DAM DECK JOINT


REFERENCES

PennDOT Specifications (PUB 408)Section705 - Joint Material

1001 - Cement Concrete Structures1002 - Reinforcement Bars1040 - Concrete Bridge Deck Repair1105 - Fabricated Structural Steel1021 - Neoprene Compression Dam


Based on need as indicated by bridge inspectionsand deficiencies observed and reported by otherpersonnel. Effective and economical repairs tomodular dam deck joints are often only possiblewhen the repairs are initiated while the defective ordamaged portion of the dam is relatively small.Repairs may be facilitated when temperatures aremoderate.

WORK AREA

All modular dams, their connections to adjacentconcrete or structural steel members, and concreteadjacent to the dam which must be removed andreplaced to repair or rehabilitate the joint. Reportrepairs to concrete outside of this work area toappropriate activities.

ACTIVITY DESCRIPTIONRepairing or rehabilitating modular dam deck

joints within the work area. The work can include,but is not limited to, removing all or portions of anexisting modular dam deck joint; disassemblingportions of an existing joint; removing concreteadjacent to the joint to replace deterioratedconcrete and/or to gain access to the damconnections; retying or placing reinforcing steel;replacing deficient parts of an existing joint;modifying an existing joint; constructing forms;reinstalling the repaired or modified joint; andplacing concrete.


1. Remove defective component or section ofmodular dam from joint.

2. Mark all areas of defective concrete at jointto be removed including around anchors tobe replaced or reset.

3. Remove all unsound concrete.

4. Set forms for concrete or position armorededges or anchors as necessary.

5. Place concrete.

6. Repair salvageable dam components bywelding, strengthening, grinding, etc.

7. Replace modular dam sections or com -ponents in joint.

NOTE: Welding details for this repair shouldbe furnished by the District Bridge Office andthe welding should be accomplished bypersonnel certified for the type and positionof the weld required






1 Foreman 1 Concrete Saw 1 LF Modular Dam2 Crew Members 1 Welding Equip. Joint or1 Special Crew member 1 Air Compressor Component

(Certified Welder) 1 Concrete Mixer








PROCEDURE: ELASTOMETRIC OR BELL TYPE EXPANSION DAMS


1. Remove existing poured joint material anddebris from joint.

2. Saw - cut the joint to a uniform dimensionacross the bridge deck to the prescribedwidth and depth for the anticipated deckmovement.

3. Grind chamfer on edges of joint from curb tocurb.

4. Clean dirt and debris from the joint usingcompressed air.


6. Position seal over joint opening, compressthe bottom of the seal and insert into thejoint while the adhesive is still wet.

7. Complete the installation by positioning theseal within the joint to the depth required,usually 1/4 to 2 inch below the deck surface.




1 Foreman 1 Welding Equip. 1 LF Modular Dam2 Crew Members Joint or1 Special Crew Member Component

(Certified Welder)








1 Foreman 1 Welding Equip. 1 LF Strip SealSystem

2 Crew Members 1 Air Compressor As Required WeldingMaterials

1 Special Crew Member 1 Concrete Mixer As Required Concrete(Certified Welder) As Required Reinforcing Steel

1LF L 8" x6" x1/2"W 3/4" x 5" slots As RequiredStuds andAnchor bolts






PROCEDURE: REPLACE EXISTING JOINT WITH STRIP SEAL (REHABILITATE/OVERLAY)


1. Remove existing expansion dam andadjacent concrete or fingers of steel fingerdam.

2. Attach armored edge extrusions to concreteand reinforcing steel or weld to modifiedplate of finger dam.

3. Place concrete behind joint.

4. Place overlay.

5. Place strip seal gland using adhesive andspecial tools as recommended by themanufacturer.

6. NOTE: Welding details for this repair shouldbe furnished by the District Bridge Office andthe welding should be accomplished bypersonnel certified for the type and positionof the weld required.

Reference PUB 408 Section: 1026 & 1027



Strip Seal Dam Replacement






PROCEDURE: REPAIR STRIP SEAL SYSTEMS


1. Remove deteriorated sections of gland.Heating the seal may be necessary to meltadhesives. Special tools from the sealmanufacturer may facilitate seal removal andreplacement.

2. Reanchor or replace as necessary any loosesections of the extrusion by removing andreplacing deteriorated concrete and

extrusion.

3. Replace gland using adhesive and specialtools as recommended by the manu facturer.

Reference BC-767M Neoprene Strip Seal Dam

PUB 408 Section 1029




1 Foreman 1 Welding Equip. 1 LF Modular Dam2 Crew Members Joint or1 Special Crew Member Component

(Certified Welder)








PROCEDURE: REPAIR STRIP SEAL SYSTEMS




ACTIVITY TITLE: STEEL DAM DECK JOINTS (REPAIR/REHABILITATE)

UNIT OF MEASUREMENT: *LINEAR FEET OF STEEL DAM


REFERENCES


Section1001 -Cement Concrete Structures

1002 -Reinforcement Bars

1021 -Armored Preformed NeopreneCompression Dam

1040 -Concrete Bridge Deck Repair

1105 -Fabricated Structural Steel

BC-762M Standard tooth exp. dam


Based on need as indicated by bridge inspectionsand deficiencies observed and reported by otherpersonnel. Effective and economical repairs to steeldams are often only possible if the repairs areinitiated while relatively small portions of the damare deficient.

WORK AREA

All steel dams, their connections to adjacentconcrete or structural steel members, and concreteadjacent to the dam which must be removed andreplaced to repair or rehabilitate the dam. Reportrepairs to concrete outside of this work area toappropriate activities, such as Activity D744303,Concrete Deck Repair. Report the placing of thepreformed neoprene compression seal to ActivityB744102, Compression Seal Deck Joint (Repair/Rehabilitate).

*Special Measurement Note: Work on eachdam or each side of a joint shall be measured forreporting work on this activity.


Repairing or rehabilitating or installing steeldams within the work area. The work can include,but is not limited to, removing concrete adjacent tothe dam to permit removal of the dam or to gainaccess to the connections used to secure the damto concrete or steel; repairing or replacing aportion of the dam or its structural connections;straightening and aligning the dam; retying orplacing reinforcing steel; securing the dam toproper line and grade; constructing forms; andplacing concrete.


1. Remove steel dam and supports asnecessary by cutting anchors or dam withcutting torch.

2. Remove unsound concrete by saw cuttingand jack hammering.

3. Place forms for concrete and anchor systemfor dam.

4. Set dam in place.

5. Place and finish concrete.

6. Complete assembly of dam or removetemporary shipping and erection braces asnecessary.

7. Place new neoprene compression seal,drainage trough or water collector asnecessary.






1 Foreman 1 Air Compressor 1 LF Steel Dam2 Crew Members and Hammers Assembly1 Special Crew Member 1 Welding Equip1 (Certified Welder) 1 Concrete Mixer


1.5 LF/HR 9 LF/DAY 2.7 MH/LF1

DRAINAGE TROUGH





UNIT OF MEASUREMENT: LINEAR FEET OF STEEL DAM

PROCEDURE: REPLACE EXISTING JOINT WITH ARMORED COMPRESSION SEAL


1. Cut or remove sliding plate or other joint asshown.

2. Place new armored joint reinforcing.

3. Place concrete around joint or overlay deckas required.

4. Place preformed neopropene compressionseal.




1 Foreman 1 Air Compressor 1 LF Modular Joint2 Crew Members 1 Welding Equip. As Required Concrete1 Special Crew Member 1 Concrete Mixer

(Certified Welder)


1.5 LF/HR 9 LF/DAY 2.7 MH/LF1

BITUMINOUS OVERLAY










1 Foreman 1 Air Compressor 1LF Preformed2 Crew Members 1 Light Air Neoprene1 Special Crew Member Hammer As Required Compression

(Certified Welder) 1 Welder Seal1 Special Crew Member 1 Cutting Torch Seal & Lubricant

(Certified Welder) 1 Concrete Mixer 2LF AdhesiveAs Required Steel 8"x6" Angle

As Required Anchor StudsConcrete


1.5 LF/HR 9 LF/DAY 2.7 MH/LF






PROCEDURE: REPAIR ARMORED EXPANSION JOINT


1. Locate portion of expansion that is loose andrattling.

2. On 18-in. centers, lay off 12 in. x 8 in.rectangle immediately adjacent to the dam.

3. Outline area of concrete to be removed witha 1-in. deep concrete saw cut.

4. Remove concrete with air hammer.

5. Cut slot in top flange of dam.

6. Weld Z-strap in slot and to reinforcing steel.

7. Place concrete behind dam.




1 Foreman 1 Air Compressor 1LF 1/4"x1" Steel2 Crew Members 1 & Air Hammers As Required Concrete1 Special Crew Member 1 Welding Equip.

(Certified Welder) 1 Concrete Mixer








PROCEDURE: REPAIR SLIDING PLATE EXPANSION JOINT


1. Burn hole through top flange of expansion dam.

2. Drill 1 - 1/4" hole at a 45º angle through theconcrete deck below the burned hole.

3. Score a 6" X 6" area of concrete 1" deepwith saw around bottom of hole. Removeconcrete to bottom mat of reinforcing steel.

4. Place bolt in position and weld to top flangeof dam with a full penetration weld.

5. Place latex modified concrete l/2" thick inbottom of 6" X 6" hole around bolt end.

6. Position 1/4" X 4" X 4" steel plate, addwedge washer and nut, then tighten.

7. Coat removed concrete area with epoxybonding compound and fill with latexmodified concrete.

8. Drill and tap flange close to bolt location,install zerk fitting and pump epoxy.

9. Remove and fill zerk fitting holes with weldmaterial. Grind and smooth welds on topflange.

NOTE: Epoxy should fill area around bolt andunder expansion dam where bond betweendam and concrete has been lost. Severalzerk fittings may be required to fill voidbeneath dam.






1 Foreman 1 Welding Equip As Required 12" Bolt with 2 Crew Members 1 Concrete Mixer wedge1 Special Crew Member 1 As Required Washer & Nut

(Certified Welder) 1 As Required 1/4" X 4" SteelPlate

Latex ModifiedConcrete



REPAIR SLIDING PLATE ARMORED EXPANSION JOINT


Railings / Parapets: Chapter 14 14-1

Chapter 14: Railings / Parapets

Table of Contents

7434-01 BRIDGE PARAPET (REPAIR/REPLACE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 - 3

7434-01 STRUCTURE MOUNTED GUIDERAIL

(REPAIR/REPLACE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 - 7

7434-01 PEDESTRIAN (REPAIR/REPLACE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 -11

7434-01 MEDIAN BARRIER (REPAIR/REPLACE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14 - 13


14-2 Railings / Parapets: Chapter 14




REFERENCES


Section1013 - Aluminum Bridge Railing

1014 - Steel Bridge Railing


Based on need as indicated by bridge in spectionsor reports of accidental damage. When damage isextensive, temporary installation of signs, lights,barricades or other safety/warning devices may berequired.

WORK AREA

All parapet mounted metal railing includinganchor bolts between the backs of abutmentbackwalls, plus such railing on straight returnabutment wings measured by the linear foot on thebridge and/or abatement wings. Report repairing orreplacing the parapets other than minor leveling orsmoothing of parapet concrete at railpost locationsto Activity F744303, Concrete Curb/Parapet(Repair).


Repairing or replacing all or portions of a parapetmounted metal railing. The work can include, but isnot limited to, removing damaged or deterioratedportions of the railing; placing and securing anchorbolts preparatory to placing concrete; drilling andgrouting or otherwise securing anchor bolts intohardened concrete: installing railing; and cleaningrailing after installation is completed.


1. Remove damaged or deteriorated section ofexisting parapet mounted metal rail,salvaging reusable parts. Flame cutting maybe neces-sary.

2. Remove concrete around damaged anchorbolts with a 30 lb hammer.

3. Cast new concrete to original lines

4. Drill holes in concrete for anchor bolts

5. Install anchor bolts with grout or approvedadhesive. Fill any remaining space withepoxy material.

6. Prior to installation, thoroughly coat surfacesof aluminum in contact with other metals,stone masonry, or concrete with caulkingcompound.

7. Install new railing

8. Burr threads on anchor bolts to preventloosening of nuts.

9. Clean railing with an acceptable solvent

SAP ASSEMBLY NUMBER: 711-7434-01 BMS2 Flex-Action: RLGBRPR

ACTIVITY TITLE: BRIDGE/PARAPET RAILING (REPAIR/REPLACE)

UNIT OF MEASUREMENT: LINEAR FEET OF RAILING

(INCLUDING TOP AND BOTTOM RAILS AS ONE UNIT)







1 Foreman 1 30 Lb. Hammer As Required Concrete1 Crew Members 1 Welding Torch L.F. As Replacement

Special Crew Member Equipment Required Railing1 (Certified Welder) 1 Concrete Drill





REFERENCES


Section 706- Concrete Bonding Compound

1001- Cement Concrete Structures

1002- Reinforcement Bars

1003- Dowel Holes

1025- Modification of Existing Barriers


Schedule based on need as indicated byinspection reports. If fracture will occur due todeflection joint, then this corrective action will bedone immediately.

WORK AREA

Deflection Joints on Adjacent Non-CompositePre-stressed Concrete Box Beam Bridges.


Remove deflection joints in the parapets byremoving the concrete to expose the rebar as perplans on each side of the existing joint.Install/.splice additional rebar to form continuousreinforcement of the parapet. Form and pourcement concrete in the area of excavated parapet.


1. Set up traffic control as per the proper PATAapproved by the traffic Unit.

2. Saw cut 1” deep as per approved plans atthe specified distance from the joint for asmooth uniform surface. Remove existingconcrete without damaging existing rebar.

3. Splice new rebar as per plans to formcontinuous reinforcement of the parapet.

4. Once all additional rebar is installed clean alldebris and or grease or de-bonding agentsfrom existing concrete surfaces then placeconcrete bonding agent to all concretesurfaces.

5. Construct form work as indicated and asshown on standard drawing/approved plan.Check to make sure rebar clearancecoverage conforms to approved plans orstandard drawing.

6. Place Class AA cement concrete in the form.

SAP ASSEMBLY NUMBER: 711-7434-01 BMS2 Flex-Action: RLGBRPR

ACTIVITY TITLE: BRIDGE / PARAPET RAILING (REPAIR / REPLACE)

UNIT OF MEASUREMENT: EACH

PROCEDURE: ELIMINATE DEFLECTION JOINTS IN ADJACENT NON-COMPOSITE

PRESTRESSED / CONCRETE BOX BEAM BRIDGE



REFERENCES




1003 - Dowel Holes

1013 - Aluminum Bridge Railing

1014 - Steel Bridge Railing


Based on need as indicated by bridge inspectionsor reports of accidental damage. When damage isextensive, temporary installation of signs, lights,barricades, or other safety/warning devices may berequired.

WORK AREA

All structure mounted metal and concreterailings, including anchor bolts or reinforcing barsconnecting railing posts to the structure betweenthe backs of abutment backwalls, plus such railingson straight return abutment wings measured bythe linear foot on the bridge and/or abutmentwings. Small areas of concrete directly at the postswhich require minor amounts of leveling or surfacepreparation before the posts can be installed arealso included within the work area. Report repairsoutside the work area, such as casting newconcrete to support the railing or other relativelymajor efforts to an appropriate activity, ActivityD744303, Concrete Deck (Repair), for example.


Repairing or replacing all or portions of astructure mounted railing. The work can include,but is not limited to, removing damaged ordeteriorated railing; repairing or replacingelements of metal railing; placing and securinganchor bolts preparatory to placing concrete;drilling and grouting or otherwise securing dowelsor anchor bolts into hardened concrete;construction forms, installing reinforcing bars andplacing concrete in concrete posts and railingelements; and installing metal railings.


1. Remove damaged or deteriorated structuremounted railing.

2. Remove elements of the structure asnecessary, salvaging reusable parts.


4. Cast new concrete to original lines inconcrete parapets or to match existing linesfor metal rails.

5. Drill holes in concrete for replacementanchor bolts.

6. Install anchor bolts with grout or anapproved adhesive.


8. Install new railing.

9. Burr threads on anchor bolts to prevent loos-ening of nuts.

10.Clean railing with an acceptable solvent.

NOTE: Details of repair/replacement ofstructure mounted railing should be providedby the District Bridge Engineer.

SAP ASSEMBLY NUMBER: 711-7434-01 BMS2 Flex-Action: RLGSTRM

ACTIVITY TITLE: STRUCTURE MOUNTED RAILING (REPAIR/REPLACE)








1 Foreman 1 30 Lb. Hammer LF Replacement Rail2 Crew Members 1 Concrete Drill Elements or

1 Hammer and sectionsChisel As Required Concrete

As Required Anchor Bolts


1.5 LF/HR 8 LF/DAY 3 MH/LF






PROCEDURE: STEEL GUIDERAIL MOUNTED TO CONCRETE






PROCEDURE: STEEL GUIDERAIL MOUNTED TO CONCRETE

structure mounted guide rail installation

NOTE: Welding and other details to be furnished by the District Bridge Engineer. Weldingshould only be accomplished by a welder certified for the type and position of thewelds required.

DIAPHRAGM



REFERENCES


Section 1012 - Pedestrian Railing


Based on need as indicated by bridge inspectionsor reports of accidental damage. When damage isextensive, temporary installation of signs, lights,barricades or other safety/warning devices may berequired.

WORK AREA

All pedestrian railing, including anchor boltsconnecting the railing to the structure between thebacks of abutment backwalls, plus such railing onstraight return abutment wings measured by thelinear foot on the bridge and/or abutment wings.Small areas of concrete directly at the post whichrequire minor amounts of leveling or surfacepreparation before posts can be installed are alsoincluded within the work area. Report repairsoutside of the work area such as casting newconcrete to support the railing or other relativelymajor efforts to an appropriate activity. Anexample is activity E744303, Concrete Sidewalk(Repair).


Repairing or replacing all or portions of apedestrian railing. The work can include, but is notlimited to, removing damaged or deterioratedrailing; salvaging reusable parts; repairing orreplacing elements of the railing; placing andsecuring anchor bolts preparatory to placingconcrete; drilling and grouting or otherwisesecuring anchor bolts into hardened concrete; andinstalling railing.


1. Remove damaged or deteriorated pedestrianrailing.

2. Repair or replace elements of the railing asnecessary, salvaging reusable parts.


4. Cast new concrete to original lines.

5. Drill holes in concrete for replacementanchor bolts.

6. Install anchor bolts with grout or approvedadhesive.


8. Install new railing.

9. Burr threads on anchor bolts to preventloosening of nuts.

10.Clean railing with an acceptable solvent.

SAP ASSEMBLY NUMBER: 711-7434-01 BMS2 Flex-Action: RLGPEDN

ACTIVITY TITLE: PEDESTRIAN RAILING (REPAIR/REPLACE)








1 Foreman 1 Air Compressor LF As Replacement Rail3 Crew Members 1 Concrete Drill Required Elements or

sectionsAs Required ConcreteAs Required Anchor BoltsAs Required





REFERENCES


Section 621 - Metal Median Barrier

623 - Concrete Median Barrier

1003 - Dowel Holes


Based on need as indicated by bridge inspectionsor reports of accidental damage. When damage isextensive, temporary installation of signs, lights,barricades or other safety/warning devices may berequired.

WORK AREA

All median barriers including anchor bolts orother devices securing the barriers to the structurebetween the backs of abutment backwalls. Smallareas of deck directly at the barrier which requireminor amounts of leveling or surface preparation topermit satisfactory repair or installation of thebarriers are also included within the work area.Report repairs outside of this work area to otherappropriate activities.


Repairing or replacing all or portions of a medianbarrier. The work can include, but is not limited to,removing damaged or deteriorated median barrier;salvaging or replacing parts of a metal barrier;placing and securing anchor bolts preparatory toplacing concrete; drilling and grouting or otherwisesecuring anchor bolts or dowels into hardenedconcrete; constructing forms for concrete medianbarriers; placing concrete; and installing metalrailing.


1. Remove existing deteriorated section ofmedian barrier with a 30 lb hammer.

2. Level deck in barrier location and drill holesfor anchors into deck taking care not topunch through if through bolts are not to beused.

3. Set section of barrier on a leveling bed ofmortar to bring the barrier into propr line.

4. When using through bolts, insert galvanizedbolts, washers, and nuts and tightensufficiently to retain grout poured throughthe access hole. If screw anchors are used,permanently tighten nuts after the anchorand bolts are grouted in and grout has set.

5. Pack bolt pocket with non-shrink mortar.

SAP ASSEMBLY NUMBER: 711-7434-01 BMS2 Flex-Action: RLGMEDB

ACTIVITY TITLE: MEDIAN BARRIER (REPAIR/REPLACE)


PROCEDURE: PRECAST MEDIAN BERRIER






1 Foreman 1 Crane LF As Precast parapet3 Crew Members Air Compressor Required Section1 Special Crew Member 1 with Hammer As Required Epoxy Mortar

(Operator As Required AnchorageSystem




Bearings: Chapter 15 15-1

Chapter 15: Bearings

Table of Contents

7435-01 LUBRICATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 - 3

7435-02 STEEL (REPAIR/REHABILITATE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 - 5

7435-02 STEEL (REPLACE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 - 7

7435-02 EXPANSION (RESET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 - 9

7435-03 PEDESTAL/SEAT (RECONSTRUCT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15 - 14


15-2 Bearings: Chapter 15




REFERENCES


Section 1060 - Painting Structural Steel


Primarily a periodic activity, with elapsed timebetween lubrications based on circumstances andconditions at each structure. Bearings below openjoints require more frequent cleaning andlubrication than ones below sealed joints. The timebetween lubrications can also be revised as a resultof bridge inspection reports.

WORK AREA

All bearings having surfaces involving metal tometal movement where the metal surfaces are notpermanently lubricated. The bearings can belocated at abutments, piers, and in pin or pin andlink assemblies for cantilever/suspended spans.


Cleaning and lubricating bearing assemblies. Thework can include, but is not limited to, temporarilymodifying superstructures to accept jacking loads,providing temporary supports for jacking;removing loads from bearings by either jackingfrom below or using needle/carrier from above;disassembling bearings; cleaning and lubricating allmoving parts; reassembling bearings; and paintingbearings with a prime coat.


1. Modify superstructure to accept jackingloads, if necessary.

2. Construct temporary bent or other supportsfor jack support or install needle/carrierbeam.

3. Jack superstructure and remove the bearingassembly.

4. Disassemble bearing

5. Clean, paint and lubricate bearing.

6. Reassemble the bearing and reinstall thebearing.

7. Remove jacks or needle/carrier beams.


ACTIVITY TITLE: LUBRICATE BEARINGS

UNIT OF MEASUREMENT: EACH BEARING







1 Foreman 1 Crane As Required Temporary Bent3 Crew Members As Jacks As Required or Needle/Carrier1 Special Crew Member Required Wire Brush As Required Lubricate

(Operator) 1 As Required Paint


.25 EA/HR 1.5 EA/DAY 16 MH/LF

Preventive MaintenanceLubricate Bearings

Perform at regular intervalsWork area:

Contacted metal surfaces that are not permanentlylubricated. Clean contact surfaces, surroundingarea of rust and old lubricant. Place new lubricant.



REFERENCES

PennDOT Specifications (PUB408)

Section1105 -Fabricated Structural Steel

1060 - Painting Structure Steel


Based on need as indicated by bridgeinspections. A thorough inspection and evaluationcan be most easily accomplished followingcompletion of Activity C743102, Clean/FlushBearing/Bearing Seat.

WORK AREA

All steel bearings, both fixed and expansion, atabutments and piers and pin or pin and linkassemblies for cantilever/suspended spans.


Repairing or rehabilitating steel bearingassemblies of all types and sizes. The work caninclude, but is not limited to, temporarily modifyingsuperstructures to accept jacking loads; providingtemporary supports for jacking; removing loadsfrom bearings by either jacking from below orusing needle/carrier beams from above;disassembling bearings; prefabricating replace mentparts; repairing, rehabilitating or replacing parts ofbearings; reassembling bearings; and paintingbearings with a prime coat.

The work of lubricating bearings and resettingexpansion bearings is included in this activity.When it is performed as part of a repair orrehabilitation, separate reports to activitiesA743501, Lubricate Bearings, and activityC744502, Expansion Bearings (reset), should notbe made.




3. Jack superstructure and remove the bearing.

4. Disassemble bearing

5. Install prefabricated replacement parts.

6. Clean, paint and lubricate other parts.

7. Reassemble bearing.



ACTIVITY TITLE: STEEL BEARINGS (REPAIR/REHABILITATE)








1 Foreman 1 Crane As Required Temporary Bent3 Crew Members 1 Jacks As Required or Needle/Carrier1 Special Crew Member 1 Wire Brush As Required Lubricate

(Operator Paint





REFERENCES



1003 - Dowel Holes

1105 - Fabricated Structural Steel


Based on need as indicated by bridgeinspections.

WORK AREA

All steel bearings, both fixed and expansion, atabutments and piers and pin or pin and linkassemblies for cantilever/suspended spans. Smallareas of the pedestals/seats at and directlyadjacent to masonry plates are also included formaking minor repairs, leveling or adjusting theelevation of the contact surfaces, and installation ofnew anchor bolts.

Report major repairs of existing concrete toappropriate activities, such as Activity D744503,Bearing Pedestal/Seat (Reconstruct) or ActivityB744802, Abutments (Repair).


Replacing steel bearings with bearings of thesame or different types. The work can include, butis not limited to, temporarily modifying thesuperstructures to accept jacking loads; providingtemporary supports for jacking; removing loadsfrom bearings by either jacking from below orusing needle/carrier beams from above;prefabricating new bearings; removing bearings;preparing the surface of the bridge seat/pedestalfor new bearings; drilling for and installing newanchor bolts; and installing new bearings.

The work of increasing the elevations of bridgeseats/pedestals to accommodate different types ofbearings is included in Activity 744503, BearingPedestal/Seat (Reconstruct), if the work defined inthat activity is also required.




3. Jack superstructure.

4. Remove existing bearing.

5. Remove existing anchor bolts, if necessary,by drilling or other approved methods. Groutnew bolts.

6. Prepare concrete surface for new bearing.

7. Install new bearing and lubricate.


NOTE: Consideration should be given to replacerocker bearing with neoprene pads instead ofreplacing in kind.


ACTIVITY TITLE: STEEL BEARINGS (REPLACE)


PROCEDURE: GENERAL REPLACEMENT PROCEDURE



Activity requirements



1 Foreman 1 Crane 1 New Bearing3 Crew Members 1 Jacks As Required Concrete1 Special Crew Member 1 Drill As Required Grout

(Operator) As Required Anchor BoltsAs Required Temporary Bent

or needle/carrierBeam

As Required Lubricant


.17 EA/HR 1 EA/DAY 30 MH/LF



REFERENCES

PUB 238





Based on need as indicated by bridgeinspections. Requirement for resetting oftenindicates substructure movement. If substructuremovement continues, investigation should bescheduled.

WORK AREA

All expansion bearings at abutments and piers.Small areas of the pedestals/seats at and directlyadjacent to masonry plates are also included formaking minor repairs, leveling or adjusting theelevation of the contact surfaces, and installingnew anchor bolts. Superstructure members at thebearings are included to permit modification oradjustment required as a result of the resetting.


Resetting and relocating expansion bearings byadjusting the location of masonry plates on thebottom of bearing assemblies or, alternatively,relocating sole plates on top of bearing assemblies. If using alternate method consider relocatingbearing stiffners, to accept relocated bering loads.The work can include, but is not limited to,temporarily modifying the superstructure to acceptjacking loads; providing temporary supports forjacking; removing loads from bearings by eitherjacking from below or using needle beams fromabove; disassembling bearings; cutting off anchorbolts; preparing concrete contact surfaces forrelocation of masonry plates; locating masonryplates so that bearings will be properly positionedfor the temperature at time of resetting; drillingholes for and grouting in new anchor bolts andreassembling bearings; or, as an alternative torelocating masonry plates, disconnecting soleplates from superstructure members; modifyingsuperstructure members to accept relocatedbearing loads; and reconnecting sole plates to

super-structure members so that bearings will beproperly positioned for the temperature at time ofresetting. Consider replacing rocker bearing withneoprene bearing if possible.


1. Jack the bridge to a height required to resetor reposition bearings. A detailed jackingplan shall be developed by the District BridgeEngineer based on structure details.Precautions shall be taken to preventdamage to the bridge during the resetting orrepositioning of the bearings.

2. Reset rocker bearings so that the total travelit experiences can be divided equally by itsmedian position. A table based on the lengthof bridge expanding at the bearing shall bedeveloped by the District Bridge Engineer forvarious temperatures.

3. Bearing areas shall be so reconstructed asnecessary that no water accumulates orstands at any point. The bearing surfaceshall be smooth and level. Fill minordepressions with an accepted low-viscosityepoxy, applied with a squeegee.

4. Remove jacks.

BACK GROUND

Rocker bearings are generally designed to be setat 68° F, which means that the rocker bearingsshould be vertical (no tilt) at 68°F by design.However, due to fabrication and constructiontolerances, rocker bearings in the vertical positionat ambient temperatures up to 15°F higher andlower that 68°F would still be acceptable. Thenormal behavior of rocker bearings is to tilt awayfrom the fixed bearing for that span unit whentemperatures rises and to tilt toward the fixedbearing for that span unit when the temperaturefalls.


ACTIVITY TITLE: EXPANSION BEARINGS (RESET)


PROCEDURE: RESET ROCKER BEARINGS






1 Foreman 2 Access Equip. As Required Epoxy3 Crew Members As Required Jacks





Realign Steel Rocker Bearings

Resetting Rocker Bearings

Renewed focus on rocker bearing alignment due toBirmingham Bridge.

If you see misalignment, notify Bridge Engineer.

Resetting Rocker BearingsPennDOT District 1-0Erie CountyS.R. 4012 over Interstate 90

4 span steel girder bridge with composite concretedeck. Steel rocker bearings over two piersmisaligned.

October 2008

Design: In-House by District personnel.Construction: Erie County Bridge CrewDuration of Construction: 7 daysMaintenance and Protection of Traffic:Half-width to close lanes over bearings being repaired.

Cost: $10,000

Example of Failed Rocker




Equipment List:• Hydraulic Jack (Hand Operated)• Timber Cribbing• Scaffold• Grinder• Welder

Each beam jacked as shown and rocker bearingassembly removed from beam.

Rocker bearing assembly moved along beam toalign with masonry plate.

Rocker bearing assembly welded to bottom flangein new location as shown.

Jacks removed and bearing assembly re-painted.




Lessons Learned:

1-Timber blocking interfered with removal of bearing assembly.

2-Fixed this by cutting 3 sides of the weld prior to jacking.

3-Reduced construction duration from 5 days at Pier 1 to 2 days at Pier 2.

Alternate Method:Extend concrete pedestal and install neoprenebearing pads (must design bearing pad)



REFERENCES




1003 - Dowel Holes



WORK AREA

Bridge seats and/or pedestals at abutments andpiers to a maximum depth of approximately 1-1/2times the length of the anchor bolts. Report moreextensive repairs entirely to Activity B744802,Abutments (Repair), or Activity D744802, Piers(Repair) as appropriate.


Reconstructing bearing pedestals and/or bridgeseats. The work can include, but is not limited to,temporarily modifying super structures to acceptjacking loads; providing temporary supports forjacking; removing loads from bearings either byjacking from below or by using a needle beam fromabove; disassembling bearings and/or providingmeans to support the bearings or portions of thebearings from the superstructure members;removing deteriorated or damaged concrete andreinforcing steel; drilling and grouting or otherwisesecuring dowels into existing concrete; placing andtying reinforcing steel; constructing forms;installing anchor bolts; placing concrete; preparingcontact surfaces of concrete; and replacing bearingassemblies. When work under this activity isaccomplished, necessary tasks as described underActivities A743501, Lubricate Bearings; A744501,Steel Bearings (Repair/Rehabilitate; B744501,Steel Bearings (Replace); and C744502, ExpansionBearings (Reset) are to be performed, but separateactivity reports are not necessary. All requiredwork is to be reported under this activity,D744503.


1. Construct temporary bent for supportingjacks and blocking if jacking from abutmentor pier elements cannot be accomplished.

2. Place jacks and lift beam until bearingpressure is completely relieved.

3. Remove the deteriorated concrete tohorizontal and vertical planes.

4. Form as required apply epoxy bondingcompound to prepare the surfaces ofsheared beam seats and cast new concrete.

5. After the concrete has reached requiredstrength, remove forming, blocking, jacksand temporary supports.


ACTIVITY TITLE: BEARING PEDESTAL/SEATS (RECONSTRUCT)

UNIT OF MEASUREMENT: EACH PEDESTAL/SEAT







1 Foreman 1 Concrete Mixer As Required Concrete3 Crew Members 1 Air Compressor As Required Epoxy bonding

with Hammer As Required MaterialAs Required Jacks As Required Reinforcing SteelAs Required Access Equip.





Structural RepairsBearing Pedestal Spall Repair

Perform based on need

Work Area: bearing pedestal

• Remove deteriorated or damaged concrete, reinforcing steel or masonry

• Drill and install dowels; install reinforcing steel; construct forms

• Place concrete

• Involve District Bridge Engineer for design




1. Construct temporary bent for supportingjacks and blocking if jacking from abutmentor pier elements cannot be accomplished.

2. Place jacks and lift beam until bearingpressure is completely relieved.

3. Remove deteriorated concrete to horizontaland vertical planes.

4. Add new reinforcing steel where required.

5. Form as required. Apply epoxy bondingcompound to prepared surface of shearedbeam and cast new concrete.

6. After concrete has reached requiredstrength, remove forming, blocking, jacksand temporary supports.








1 Foreman 1 Concrete Mixer As Required Concrete3 Crew Members 1 Air Compressor As Required Epoxy bonding

with Hammer As Required MaterialAs Required Jacks As Required Reinforcing SteelAs Required Access Equip.






1. Prefabricate the pedestals.

2. Jack the bridge to the height required toinstall the new pedestals. A detailed jackingplan shall be developed by the District BridgeEngineer based on structural details.Precautions shall be taken to preventdamage to the bridge during jacking.

3. Remove any temporary blocking, install 1/4in. preformed fabric pad on the bearingsurface, and place the permanent pedestalsin position. The fabric pad and bearingsurface should be swabbed with red leadpaint.

4. Install cross bracing or other type bracing;field weld or bolt as required and make anynecessary adjustments; anchor the pedestalto the pier or abutment.

5. Reposition the beam bearing assemblies ontop of the pedestals.

6. Lower the span to bear evenly on thepedestal bearings.

7. Complete all field welding and/or make otherfinal adjustments; tighten all anchor bolts.

8. Remove jacking equipment, cribbing etc.

9. Excavate behind the abutment backwalls andwingwalls to a depth sufficient to facilitatethe removal of concrete as required toensure bond to the existing reinforcing steel.

10.Construct back and wingwalls to the newelevation as required.

11.Backfill abutment and wingwalls; re constructbridge approaches as required.




PROCEDURE: PEDESTAL INSTALLATION TO ELEVATE BRIDGE PROFILE




1 Foreman As Required Staging Equip. 1 Prefabricated3 Crew Members As Required Access Equip. Pedestals

1 Fabric Pads


.17 EA/HR 9 EA/DAY 2.7 MH/LF






PROCEDURE: PEDESTAL INSTALLATION TO ELEVATE BRIDGE PROFILE


Approach Roadway Work: Chapter 16 16-1

Chapter 16: Approach Roadway Work

Table of Contents

7442-01 APPROACH SLAB (REPLACE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 - 3


16-2 Approach Roadway Work: Chapter 16



Approach Roadway Work: Chapter 16 16-3

REFERENCES


Section501 -Reinforced Cement ConcretePavements

505 -Bridge Approach Slabs

516 -Concrete Pavement Patching

Standard Drawings RC-23


Based on need as indicated by bridgeinspections. Deterioration is often more extensivethan is apparent from observation alone.

WORK AREA

Entire Reinforced Cement Concrete ApproachSlab from the backs of the abutment backwalls tothe first Transverse Joint in the approach roadway.


Repairing or replacing all or any portions of aReinforced Cement Concrete Approach Slab. Thework can include, but is not limited to removingdeteriorated or damaged concrete; removingdeteriorated or damaged reinforcing steel; retyingexisting reinforcing steel; supporting and tying newreinforcing steel; and placing new concrete.


1. Saw cut the boundaries of the deterioratedor damaged concrete to be replaced. Beforesawing, use a pachometer to locate thereinforced bars and avoid cutting them.

2. Remove the deteriorated concrete with jackhammers. Cut and remove deterioratedreinforced steel. Provide minimum 3/4"clearance around all reinforcing steel in topmaterial regardless of concrete deterioration.

3. Place replacement reinforcing steel by tyinginto existing sound steel.

4. Place side forms for concrete whereappropriate.

5. Erect the concrete screed to permit finishingthe plastic concrete of the proper elevation.

6. Pour concrete in one continuous operation.

7. Finish and texture the Slab and cure theconcrete.

8. Remove side forms if applicable.


ACTIVITY TITLE: APPROACH SLAB (REPLACE)

UNIT OF MEASUREMENT: SQUARE YARDS



16-4 Approach Roadway Work: Chapter 16




1 Foreman 1 Concrete Mixer As Required Reinforced Steel3 Crew Members 1 Air Compressor As Required Concrete

with JackHammer approp-riate to depthto be removed


2.3 SY/HR 14 SY/DAY 2.2 MH/SY


Decks: Chapter 17 17-1

Chapter 17: Decks

Table of Contents

7443-01 BITUMINOUS DECK WEARING SURFACE

(REPAIR/REPLACE) .....................................................................................17 - 3

7443-01 TIMBER DECK (REPAIR/REPLACE)..................................................................17 - 5

7443-01 OPEN STEEL GRID (REPAIR/REPLACE) ...........................................................17 - 7

7443-01 CONCRETE DECK (REPAIR) .............................................................................17 - 9

7443-01 PRECAST DECK (REPAIR/REPLACE) ..............................................................17 - 13

7443-02 CONCRETE SIDEWALK (REPAIR)...................................................................17 - 16

7443-02 CONCRETE CURB/PARAPET (REPAIR) ...........................................................17 - 17


17-2 Decks: Chapter 17




REFERENCES


Section 409 - Super Pave422 - Bituminous Wearing Course

460 - Bituminous Tack Coat

467 - Heavy Duty Membranes

469 - Crack Filling and Sealing

705 - Joint Material

962 - Painting Traffic Lines & Markings


Based on need as indicated by bridgeinspections. Permanent repirs should not normallybe attempted when the air or surface temperatureis at or below 40ºF or when the surface is wet.Permanent replacement of wearing course is not tooccur from October 1 to March 31 depending onthe District (Refer to PUB 408, Section 409.3b1)

WORK AREA

Entire bituminous concrete wearing surface onbridge between curbs and the backs of abutmentbackwalls. Concrete or timber decks below thewearing surface are not included in this work areaso report the repair of any defects in decksrevealed by the removal of the wearing surface tothe appropriate deck repair activity. End dams andscuppers against which the bituminous concretewearing surface is to be placed are included withinthe work area for the purposes of cleaning contactsurfaces, applying tack coat, or making minoradjustments.

If major modifications or replacements of theseitems are required however, the work is to bereported under the appropriate activity such asActivity B744401 Drain/Scupper (Install) or ActivityD744102, Steel Dams (Repair/ Rehabilitate).


Repairing or replacing all or portions of abituminous concrete wearing surface. The work caninclude, but is not limited to, excavatingdeteriorated or defective material and preparingsurfaces against which new material is to beplaced; placing new bituminous concrete inprepared excavations; placing new bituminousconcrete overlay to improve skid resistance;repairing or replacing of waterproofing membrane;crack filling; and caulking or sealing the jointbetween the bituminous concrete wearing surfaceand curb faces.


1. Remove existing deck wearing surface bymilling or pneumatic hammering to concreteor timber deck or desired depth of existingbituminous surface.

2. Patch spalled or cracked areas.

3. Raise end dams and scuppers as necessary.Clean contact surfaces of end dams andscuppers.

4. Apply bituminous tack coat to the decksurface and contact surfaces of end damsand scuppers.

5. Place heavy duty membrane as required.

6. Place and compact bituminous wearingcourse to the required thickness.

7. Apply paint traffic lines and markings afterthe wearing course has cured in accordancewith the paint manufacturer's recom menda -tion.

SAP ASSEMBLY NUMBER: 711-7443-01 BMS2 Flex-Action: BITWRGS

ACTIVITY TITLE: BITUMINOUS DECK WEARING SURFACE (REPAIR/REPLACE)

UNIT OF MEASUREMENT: SQ. YARDS OF BITUMINOUS CONCRETE WEARING SURFACE







1 Foreman 1 Paver 1 SY Bituminous

1 Rollers & hand Concrete

3 Crew members compaction equip .05 gal./SY Tack Coat

1 Air compressor 1 SY Heavy Duty

3 Special Crew Members with jack hammer Membrane

(Operator) 1 Milling Machine

1 Asphalt Distributor

As Required Dump trucks for

bituminous

concrete


18 SY/HR 110 SY/DAY .4 MH/SY



REFERENCES


Section 1031 - Timber Structures


Based on need as indicated by bridgeinspections. Work can be performed during anyseason and at any temperature which is reasonablefor outdoor work. Scope of work can increasesubstantially as work progresses, so time allottedshould not be too restrictive.

WORK AREA

Entire timber deck between the backs ofabutment backwalls, including deck; timber curbs;timber sidewalks; timber railings or timber portionsof composite railings; or nailing strips, or bolsters,on top of steel stringers.


Repairing or replacing all or any portion of atimber element within the work area. Work canalso include replacing or supplementing theconnections between existing members by spikingor bolting. Placing a bituminous wearing surface ona timber deck should be charged to item BITWRGS.


1. Remove and store deck mounted curbs,parapets, wheel guards and railing.

2. Remove existing deteriorated decking thatcan be repaired or replaced in the same day.

3. Clean and paint top flanges of stringers.

4. Place pressure-treated lumber on thestringers parallel to the abutment. Lumbershould be placed with the smallest dimensionon the stringer. No stick shall bear on fewerthan three stringers and joints should bestaggered.

5. Spike each stick in place with spikes spacedas specified by the District Bridge Engineer.

6. Place Anchor plates spaced as specified bythe District Bridge Engineer along everystringer, alternating sides of the stringerflange with every stringer.

7. Apply wood preservative to the ends of anystick that is field cut.

8. Place preformed membrane waterproofing ifauthorized by the District Bridge Engineerand place the bituminous wearing surface ifauthorized.

9. Replace deck mounted appurtenances (afterwearing surface applied if applicable).


ACTIVITY TITLE: TIMBER DECK (REPAIR/REPLACE)

UNIT OF MEASUREMENT: SQUARE YARDS OF TIMBER DECK

PROCEDURE: GENERAL REPAIR/REPLACEMENT PROCEDURE






1 Foreman No Special As Required Pressure Treatedequipment Timber Spikes

3 Crew Members required As Required Anchor PlatesAs Required Treated timber to

match existing if a repair or in

accordance withdesign ifreplacement





REFERENCES


Section1105 - Fabricated Structural Steel


Based on need as indicated by bridge inspectionsand deficiencies observed and reported by otherpersonnel. For maximum effectiveness, deficienciesin steel grid floors and their connections tostringers should be corrected promptly to limit thearea of the deck which is affected.

WORK AREA

Entire steel grid deck between the backs ofabutment backwalls, including curbs and sidewalks,and connections to steel stringers, to includefasteners and shim plates.


Repairing or replacing all or any portions of anopen steel grid deck. The work can include, but isnot limited to, removing deteriorated or damagedsections and replacing them; removing and

replacing an entire open steel grid deck; reweldingelements of a deck; rewelding a deck to steelstringers; installing shims to reduce extraneoustension loads on welded connections; increasingskid resistance by serrating or adding studs to thetop of the grid: and repairing or replacingstructural elements of curbs and sidewalks.


2. Locate damaged sections of grid, brokenwelds between grid and stringers and otherareas requiring repair.

3. Cut and remove damaged steel as required.Repairs should be continuous over at leastthree stringers.

4. Weld replacement steel and/or reweld deckto stringers. Insure splice joints are over asupporting stringer.

NOTE: Welding detail for this repair shouldbe furnished by the District Bridge Office andthe welding should be accomplished bypersonnel certified for the type and positionof the weld required.


ACTIVITY TITLE: OPEN STEEL GRID DECK (REPAIR/REPLACE)

UNIT OF MEASUREMENT: SQUARE YARDS OF OPEN STEEL GRID DECK

PROCEDURE: GENERAL REPAIR/REPLACEMENT PROCEDURE




1 Foreman 1 Welding Equip. 1 SY Steel Plates as3 Crew Members As Required Necessary1 Special Crew Members As Required Welding Rod

(Certified Welder)


.3 SY/HR 2 SY/DAY 12MH/SY




1. Ensure replacement grid deck sections areon hand prior to beginning work.

2. Remove existing deck and set steel beams.

3. Erect steel grid and weld to steel beams todevelop composite action. Follow anyrecommendations of the grid systemmanufacturer.

4. If the grid system includes a wearingsurface, place concrete.

Note: Welding detail for this repair shouldbe furnished by the District Bridge Office andthe welding should be accomplished bypersonnel certified for the type and positionof the weld required.


ACTIVITY TITLE: OPEN STEEL GRID DECK (REPAIR/REPLACE)

UNIT OF MEASUREMENT: SQUARE YARDS OF OPEN STEEL GRID DECK

PROCEDURE: GENERAL REPLACEMENT PROCEDURE




1 Foreman 1 Welding Equip. SY As required Steel Grid Deck2 Crew members 2 Crane or Lifting2 Special Crew Members Equipment As Required Welding Rod

(Certified Welder) 1 Concrete Mixer(Optional)


.3 SY/HR 2 SY/DAY 12MH/SY



REFERENCES

PennDOT Specifications (PUB408)

Section1001- Cement Concrete Structure

1002- Reinforcement Bars

1040- Concrete Bridge Deck repair


Based on need as indicated by bridge inspectionsor by work order issued on an emergency basis.Deterioration is often more extensive than isapparent from observation alone, so allotted timeshould not be too restrictive.

WORK AREA

Entire structural concrete slab out-to-out of thesuperstructure between the backs of abutmentbackwalls. Portland cement concrete (PCC) wearingsurfaces are also included, but any repairs orreplacements to bituminous concrete wearingsurface or membrane waterproofing necessitatedby this activity are to be included under ActivityBITWRGS, Bituminous Deck Wearing Surface(Repair/Replace)


Repairing or replacing all or any portions of astructural deck or wearing surface. The work caninclude, but is not limited to, removing deterioratedor damaged concrete; removing deteriorated ordamaged reinforcing steel; constructing forms;retying existing reinforcing steel; supporting andtying new reinforcing steel; and placing newconcrete.

DOCUMENT REQUIREMENT

The foreman must complete the attached BridgeConcrete Deck Patching Documentation Form atthe end of the work day and submit the completedform to the District Bridge MaintenanceCoordinator so that the form can be filed in theDistrict Bridge Inspection Unit.

For temporary deck patching using coldbituminous mix or hot mix, the foreman must fillout the Bridge Deck Patching Documentation Formprovided in PUB 113 (Activity number 711-7121-04“Road Paved Spray Patch, Manual or Mechanized”)

PROCEDURE DESCRIPTIONType 1 repair - Deteriorated concrete extends to

½ inch above the top mat of the reinforcementbars. If reinforcement bar is exposed, this isconsidered a Type 2 condition.

Type 1 repair is to be rarely used. Use Type 2repairs in most situations.

Type 2 repair - Deteriorated concrete extends 1 inch below the top mat of reinforcement bars.

1. Outline the perimeter of the deterioratedconcrete to be patched with a ¾ inch deepsaw cut.

2. Remove deteriorated or damaged concretewith jack hammer (30 lb. maximum classsize). Cut and remove deterioratedreinforcing steel. Provide a minimum ¾ inchclearance around all reinforcing bars in thetop mat, regardless of concretedeterioration.

3. Place replacement reinforcing steel by tyinginto existing sound steel at a minimum of 18inch overlap.

4. Place concrete patch in one continuousoperation when possible.

5. Finish and texture the deck and cure theconcrete.


ACTIVITY TITLE: CONCRETE DECK REPAIR

UNIT OF MEASUREMENT: SQUARE YARDS OF CONCRETE DECK

PROCEDURE: GENERAL REPAIR PROCEDURE



Type 3 repair - Deteriorated concrete extends toa depth more than half of the deck thickness.

1. Outline the perimeter of the deteriorated ordamaged concrete to be replaced with a ¾inch deep saw cut.

2. Provide shielding to prevent debris fromfalling below the deck. Prevent damage tothe underlying beam.

3. Remove deteriorated concrete with jackhammer (30 lb. maximum class size).

4. Full depth deck repairs over stringers shouldbe performed for a width from centerline tocenterline of the stringers.

5. Use removable formwork of sufficientstrength to prevent vertical deflection. Fordeck overhang areas, provide side formworkwith drip strip and chamfering asappropriate.

6. Place replacement reinforcing steel by tyinginto existing sound steel at a minimum of 18inch overlap.

7. Place concrete patch in one continuousoperation when possible.

8. Finish and texture the deck, and cure theconcrete.

9. Remove formwork






1 Foreman 1 Welding Equip. As Required Reinf. Steel3 Crew members 1 Concrete Mixer As Required Concrete1 Special Crew Members 1 Air Compressor

(Operator) with Jack HammerAppropriate to Depthto be removed





DATE:____________________TIME:____________________WEATHER:________________NAME: ___________________

REPAIR COMMENTS

TYPE CONDITION:r TYPE 1 r TYPE 2 r TYPE 3

TYPE REPAIR:r TYPE 2 r TYPE 3

PREVIOUSLY PATCHED:r YES r NO r UNKNOWN

TEMPORARY PATCH WITH:r QUICKSET CONCRETE,NAME____________________r HAND MIX CONCRETETRUCK MIX CONCRETE:r AAAr AA

DIMENSIONS OF PATCH AREALENGTH:_________________WIDTH:__________________

DEPTH:__________________

SPAN LOCATION:1 2 3 4 5 6 (CIRCLE ONE)

EST. AMT OF MAT.USED_________________SY

EXISTING ASPHALT OVERLAY:r YES r NO

DEPTH OF OVERLAY:________________________

COUNTY:_________________S.R.:____________________SEGMENT:________________OFFSET:__________________FEATUREINTERSECTED:______________________________________




1. Precast deck sections or purchase fromsupplier.

2. Remove deteriorated concrete deck sectionwith jack hammers. Cut and removedeteriorated reinforcing steel.

3. Prepare the abutments or beams for theprecast units.

4. Place precast deck sections.

5. Fill stud void areas or panel connectingjoints.— Grout keyways.


ACTIVITY TITLE: CONCRETE DECK (REPAIR)

UNIT OF MEASUREMENT: SQUARE YARDS OF CONCRETE BLOCK

PROCEDURE: PRECAST CONCRETE DECK REPLACEMENT




1 Foreman 1 Air Compressor As Required Precast panel2 Crew members with Jack Section2 Special Crew Members Hammer As Required Epoxy Motar or

(Certified Welder) 1 Welding Equip. Concrete1 Crane


2.3 SY/HR 2 SY/DAY 12 MH/SY







PRECAST CONCRETE PANELS PLACED LONGITUDINALLY







PRECAST CONCRETE PANELS PLACED TRANSVERSELY



REFERENCES







WORK AREA

Entire Portland cement concrete (PCC) sidewalkbetween the backs of abutment backwalls.Includes supporting curbs and any beams,diaphragms, brackets, or other structuralsuperstructure members which are exclusively forthe purpose of supporting a sidewalk on vehicularbridges. The repair of main supporting beams orgirders on pedestrian bridges are to be included inthe appropriate activity under timber, steel, orreinforced concrete/prestressed concrete stringeror girder items.


Repairing or replacing all or portions of a PCCsidewalk within the work area. The work caninclude, but is not limited to, removing deterioratedor damaged concrete; removing deteriorated ordamaged reinforcing steel; constructing forms;retying existing reinforcing steel; supporting andtying new reinforcing steel; repairing or replacingsidewalk supporting members; and placing newconcrete.


1. Remove existing deteriorated sections ofsidewalk to sound concrete.

2. Place replacement reinforcing mesh or barsby tying them into reinforcing in soundconcrete.

3. Place forms for concrete.

4. Place and cure concrete.

NOTE: Welding details for this repair shouldbe furnished by the District Bridge Office andthe welding should be accomplished bypersonnel certified for the type and positionof the weld required.


ACTIVITY TITLE: CONCRETE SIDEWALK (REPAIR)

UNIT OF MEASUREMENT: SQUARE YARDS OF CONCRETE SIDEWALK (REPAIR)




REFERENCES




1003 - Dowel Holes

1025 - Modification of Existing Parapets



Based on need as indicated by bridge inspectionsor reports of accidental damage. When accidentaldamage is extensive, temporary installation ofsigns, lights, barricades or other safety/warningdevices may be required until repairs arecompleted.

WORK AREA

Curbs and/or parapets for the entire length of abridge between the backs of abutment backwalls.The work area also includes the slab directlyunderneath and adjacent to the curbs or parapetswhen minor repairs or adjustments must be madeto the slab to accomplish this activity. Report otherrepairs to the slab to Activity D744303, ConcreteDeck (Repair).


Repairing or replacing all or portions of Portlandcement concrete (PCC) curbs and parapets. Thework can include, but is not limited to, removingdeteriorated or damaged concrete and reinforcingsteel; drilling and grouting or otherwise securingdowels into existing concrete; placing and tyingreinforcing bars; constructing forms; and placingnew concrete.


1. Remove existing deteriorated section ofparapet and curb with light hammer.

2. Level deck in parapet location and drill holesfor anchors into deck. Do not penetrate deckunless approved.

3. Set section of parapet on a leveling bed ofmortar to bring the parapet into proper line.

4. Insert galvanized bolts, washers, and nutsand tighten sufficiently to retain pouredgrout through the access hole (Method I).Permanently tighten nuts (Method I).

5. Pack bolt pocket with non-shrink, non-staining mortar.

SAP ASSEMBLY NUMBER: 711-7443-02 BMS2 Flex-Action: F744303

ACTIVITY TITLE: CONCRETE CURB/PARAPET (REPAIR)

UNIT OF MEASUREMENT: SQUARE YARDS OF CURB OR PARAPET (REPAIR)

PROCEDURE: PRECAST CONCRETE PARAPET






1 Foreman 1 Air Compressor As Required Concrete3 Crew Members with Hammer As Required Reinforcing Steel1 Special Crew Members 1 Welding Equip.

(Certified Welder)


.5 SY/HR 3 SY/DAY 10 MH/SY






1 Foreman 1 Crane As Required Precast parapet3 Crew Members 1 Air Compressor section1 Special Crew Members 1 with hammer As Required Epoxy mortar

(Operator) As Required Anchorage system



PRECAST PARAPET ANCHORAGE - METHOD I


Deck Drainage: Chapter 18 18-1

Chapter 18: Deck Drainage

Table of Contents

7444-01 SCUPPER GRATE (REPLACE) ..........................................................................18 - 3

7444-01 DRAIN/SCUPPER (INSTALL)..........................................................................18 - 5

7444-01 DOWNSPOUTING (REPAIR/REPLACE) ...........................................................18 - 15


18-2 Deck Drainage: Chapter 18




REFERENCESPennDOT Specifications (PUB 219M)

BC-751


Based on need as indicated by bridgeinspections. Consideration should be given toreplacing damaged or deteriorated scupper gratesin early spring in areas where bicycling is common.

WORK AREA

All existing scuppers between backs of abutmentbackwalls.


Removing existing grates; preparing scuppers forinstallation of new grates; fabricating replacementgrates or obtaining prefabricated grates; andinstalling replacement scupper grates.


1. Prepare replacement grate by fabricatingnew grate, modifying an existing grate orobtaining a prefabricated grate.

2. Remove existing grate.

3. Repair or modify scupper as necessary forreplacement grate.

4. Place grate on scupper.


SAP ASSEMBLY NUMBER: 711-7444-01 BMS2 Flex-Action: DRNGRAT

ACTIVITY TITLE: SCUPPER GRATE (REPLACE)

UNIT OF MEASUREMENT: EACH SCUPPER GRATE







1 Foreman 1 Welding Equip IEA Replacement2 Crew Members grate assembly3 Special Crew Member

(Certified Welder)


1 EA/HR 6 EA/DAY 4 MH/EA



REFERENCES


Section1040 - Concrete Bridge Deck Repair

1052 - Metal Curb Drain

PennDOT Specifications (PUB 219M)

BC-751



WORK AREA

All locations at curbs or parapets selected forinstallation of a scupper between backs ofabutment backwalls. Included in the work area is asufficient portion of the deck so that the installationcan be accomplished. Also included is a sufficientnumber of the superstructure members so that anyconnection required by the design of the drain canbe attached. Installing grates and down spoutingincidental to installation of a new or replacementscupper are included in this activity.


Installing scuppers and drains. The work caninclude, but is not limited to, removing sufficientwearing surface if present, to permit drilling a holein the deck and shaping the surface to facilitate theflow of drainage water; drilling a hole of the correctsize in the concrete deck to accommodate the drainpipe; grouting the pipe into position; connectingthe pipe to the concrete or steel superstructureelements; replacing the wearing surface; and

placing grate bars if they are not part of theprefabricated scupper.


1. Drill hole or holes through the deck to act asdrain or to remove sufficient material toplace grate, drain, or scupper assembly.Carefully cut and bend any reinforcing barsencountered to permit placement of thedrain or scupper.

2. Place grate, drain or scupper.

3. Recast deck around grate, drain or scuppershaping the deck to facilitate drainage.

4. Attach any down spouting supports to beamas necessary.

5. Install down spouting as necessary.

6. Place riprap or splash blocks under drains ordown spouting.

7. Plug any old existing drain holes with epoxyor rapid-set concrete patching material.



ACTIVITY TITLE: DRAIN/SCUPPER (INSTALL)

UNIT OF MEASUREMENT: EACH DRAIN/SCUPPER







1 Foreman 1 Welding Equip IEA Replacement2 Crew Members grate assembly3 Special Crew Member

(Certified Welder)


1 EA/HR 6 EA/DAY 4 MH/EA




1. Drill holes through deck and removesufficient concrete to set grate of epoxycoated No. 6 reinforcing bar.

2. Set drain pipe and grate bar with epoxy orrapid set concrete patching material.


4. Place riprap or splash blocks as requiredunder drains.




PROCEDURE: PVC DECK DRAIN




1 Foreman 1 Compressor As Required 6" diameter PVC

3 Crew Members 1 Pneumatic Drill schedule 40 pipe

1 Concrete Mixer 2 ft. No. 6 epoxy coated

reinforcing bar

As required Concrete patching

material


.5 EA/HR 3 EA/DAY 8 MH/EA




1. Remove existing concrete parapet and deckas required.

2. Cut metal drain section to proper length(typically 2'-3') and butt weld together.

3. Place metal drain in proper position.

4. Place concrete around drain and replaceconcrete in parapet deck as required.





PROCEDURE: METALS DRAINS THROUGH PARAPETS




1 Foreman 1 Concrete Mixer As Required C 8x 4.253 Crew Members 1 Welding Equip aluminum or1 Special Crew Member C 8x 11.5' A36

(Certified Welder)








PROCEDURE: METALS DRAINS THROUGH PARAPETS




1. Drill holes through the deck and removesufficient material to place the drainassembly. Carefully cut and bend anyreinforcing bars encountered to permitplacement of the drain.

2. Place drain assembly and weld support to beam web.

3. Recast deck around drain shaping the top ofthe deck to facilitate drainage.

4. Replace wearing surface around drain asnecessary.


6. Place riprap or splash blocks under drains asrequired.





PROCEDURE: DECK DRAIN USING ECCENTRIC REDUCERS




1 Foreman 1 Welding Equip 1 Eccentric reducer2 Crew Members 1 Concrete Mixer assembly with1 Special Crew Member As Required Access Equip grate

(Certified Welder) As Required 6" diameterstandard withsteel pipe

1 Splash block orriprap








PROCEDURE: DECK DRAIN USING ECCENTRIC REDUCERS




1. Drill holes through the deck and removesufficient material to place the standardscupper. Carefully cut and bend anyreinforcing bars encountered to permitplacement of the scupper.

2. Place scupper assembly and weld or bolt support to beam web.

3. Recast deck around scupper. Shape deck tofacilitate drainage.

4. Plug any old existing drain holes with epoxy or rapid-set concrete patching material.

5. Install down spouting as necessary.

6. Place riprap or splash blocks under drains asnecessary.





1 Foreman 1 Welding Equip 1 Standard Scupper

2 Crew Members 1 Concrete Mixer assembly

1 Special Crew Member 1 Concrete Mixer As Required Concrete

(Certified Welder) As Required Access Equip As Required 6" diameter

standard with

steel pipe

As Required Pipe supports,

straps, hangers

1 Splash block or

riprap






PROCEDURE: STANDARD SCUPPER






PROCEDURE: STANDARD SCUPPER



REFERENCES



1051 - Down Spouting




WORK AREA

All down spouting and connections of downspouting to superstructure and substructureelements. The work area also includes sufficientareas of the superstructure and substructureelements to make minor repairs to them whennecessary and/or to remove existing downspouting anchorages and install new ones.


Repairing or replacing portions or all of bridgedown spouting. The work can include, but is notlimited to, removing deteriorated or damaged dandanchorages to superstructure or substructureelements; repairing portions of superstructure orsubstructure elements damaged at the downspouting anchorage points using standard concreteor structural steel repair methods, as appropriate;prefabricating all or portions of the down spoutingas required; drilling and installing anchorages tothe bridge superstructure and substructure; andinstalling repaired or replacement down spouting.


1. Remove pipe supports, hangers, drain boxesand pipe sections as necessary.

2. Drill new anchor holes in concrete or steelsurfaces.

3. Fasten supports to concrete surfaces withexpansion anchor bolts or other approvedfastner. Fasten supports to steel surfaceswith bolts or by welding.

4. Install new pipe sections and attach tosupports and hangers.

5. NOTE: Welding details for this repair shouldbe furnished by the District Bridge Office andthe welding should be accomplished bypersonnel certified for the type and positionof the weld required.


ACTIVITY TITLE: DOWNSPOUTING (REPAIR/REPLACE)

UNIT OF MEASUREMENT: EACH DOWNSPOUT







1 Foreman 1 Welding Equip As Required 6" diameter2 Crew Members 1 Concrete Mixer standard pipe1 Special Crew Member As Required Access Equip As Required Anchor fittings

(Certified Welder) As Required As Required Concrete




Timber: Chapter 19 191

Chapter 19: Timber

Table of Contents

7446-01 STRINGER (REPAIR/REPLACE) ......................................................................19 - 3

7446-01 OTHER MEMBERS (REPAIR/REPLACE)............................................................19 - 8


19-2 Timber: Chapter 19



Timber: Chapter 19 19-3

REFERENCES


Sections 1031 - Timber Structures

Sections 1032 - Timber Stringers



WORK AREA

Timber stringers, cross bracing attached tostringers being repaired or replaced, and fastenersto decks.


Repairing or replacing timber stringers. The workcan include, but is not limited to, providingtemporary supports for jacking; jacking stringersand/or portions of the deck; removing fasteners

between stringers and the deck and cross bracing;removing existing stringers; fabricating andinstalling new stringers; treating cuts and holeswith wood preservative; replacing existing crossbracing, if necessary, and fastening cross bracingto stringers; and fastening new stringers to thedeck. The work can also include all work necessaryfor installing sister beams which does not involveremoving existing stringers. Report replacing orrepairing cross bracing not associated withreplacing and repairing stringers under ActivityB744601, Other Timber Members (Repair/Replace).Report work on timber deck not directly associatedwith stringer repair or replacement under ActivityB744301, Timber Deck (Repair/Replace).


1. Use template to locate holes on cap and scab

2. Drill holes and treat holes

3. Insert rings in cap

4. Install scab.


ACTIVITY TITLE: TIMBER STRINGERS (REPAIR/REPLACE)

UNIT OF MEASUREMENT: EACH STRINGER

PROCEDURE: REPAIR OF SPLIT STRINGER






1 Foreman 1 Saw As Required Prefabricated3 Crew Members 1 15 lb hammer Straps Concrete

1 Concrete/Asphalt As Required 3/4”Dia PlatesSaw As Required 3/4” Dia Bolts

As Required with Nuts andAs Required WashersAs Required Bituminous

PatchingMaterial


.67EA/HR 4 EA/DAY 6 MH/SY

(3/4'' dia min)

(3/4'' plate min)




1. Use a template to locate holes on cap and scab.

2. Drill holes for draw-up bolts and treat.

3. Insert rings in the cap.

4. Install scab.

5. Install plates and tighten bolts.




PROCEDURE: REPAIR OF DECAYED STRINGER ENDS




1 Foreman 1 Power Drill As Required Scabs3 Crew Members As Required Bolts

As Required RingsAs Required OG WashersAs Required Wood

Preservative


.67EA/HR 4 EA/DAY 6 MH/SY




1. Construct temporary bent for jacking.

2. Lift superstructure jacking against steelplate.

3. Remove cross bracing between stringers.

4. Remove existing timber stringer.

5. Cut new stringer as shown.

6. Treat cut and any holes with woodpreservative.

7. Install new stringer using a come-along.

8. Nail cut section to stringer.

9 Fasten cross bracing to new stringer.

10. Fasten deck to new stringers.




PROCEDURE: UNDER THE DECK REPLACEMENT




1 Foreman No Special 1 Replacement2 Crew Members Equipment Stringer

Required As Required Wood PreservativeAs Required CrossbracingAs Required Temporary Bent


.67 EA/HR 4 EA/DAY 6 MH/SY




1. Remove cross bracing between stringers.

2. Cut deck along center lines of stringersadjacent to stringer to be removed.

3. Remove stringer and continuous deck.

4. Install new stringer.

5. Replace deck and nail decking in the samemanner as existing.

6. Fasten cross bracing to new stringers in thesame manner as existing.




PROCEDURE: ABOVE THE DECK REPLACEMENT




1 Foreman No Special 1 Replacement3 Crew Members Equipment Stringer

Required As Required CrossBracing Decking





REFERENCES


Sections 1031 - Timber Structures

Sections 1032 - Timber Stringers



WORK AREA

All timber elements of bridges and theirfasteners between the backs of abutmentbackwalls, including pile caps and bracing bentsbut excluding timber items included under ActivityB744301, Timber Deck (Repair/Replace), andActivity A744601, Timber Stringers,(Repair/Replace).


Repairing or replacing timber elements at anylocation within the work area. The work caninclude, but is not limited to, providing temporarysupports for jacking; jacking all or a portion of thestructure to gain access to the timber elementsbeing repaired or replaced; removing or cuttingfasteners, as required, to facilitate work; removingall or a portion of a deteriorated or damagedmember; prefabricating a replacement element;treating cuts or holes with wood preservative; andrefastening repaired or replaced element.

PROCEDURE DESCRIPTION - shim cap

1. Install U-Clamps and jacks, as shown.

2. Lift span approximately 1/2" higher thanfinal elevation.

3. Cut shims 1/4" less than pile-cap gap andinstall. Use wood preservative.

4. Lower cap.

5. Toe nail shims.

6. Remove U-Clamps and jack.


ACTIVITY TITLE: OTHER TIMBER MEMBERS (REPAIR/REPLACE)

UNIT OF MEASUREMENT: EACH MEMBER

PROCEDURE: OTHER TIMBER MEMBERS (REPAIR/REPLACE)






1 Foreman As Required U-Clamps As Required Shims3 Crew Members As Required Jacks As Required Wood

Preservative





PROCEDURE DESCRIPTIONS

1. Notch existing pile if necessary.

2. Clamp new members as shown.

3. Drill bolt holes and treat with preservative.

4. Place bolts and tighten




PROCEDURE: STRENGTHEN EXISTING CAP




1 Foreman 1 Power Drill As Required Shims3 Crew Members As Required Clamps As Required Rings

As Required BoltsAs Required O.G. WashersAs Required Wood Preservative

PRODUCTION UNITS/HOURS PLANNING UNITS PERFORMANCE STANDARDS





1. Cut through overlay and deck along centerlines of adjacent stringers near pile to bereplaced. Remove sufficient area of deck topermit pile to be driven.

2. Remove cross-bracing as necessary.

3. Drive pile at slight batter so it will be plumbwhen in final position.

4. Install U-Clamps and blocking on pile to bereplaced as shown. Lift cap.

5. Cut new pile and pull into position under cap.

6. Install flashing and lower cap.

7. Remove existing pile and jack.

8. Install cross-bracing, deck, and overlay ifappropriate.




PROCEDURE: REPLACE PILE




1 Foreman 1 Power Saw As Required Timber Pile3 Crew Members 1 Pile Driver As Required Flashing1 Special Crew Member 1 Come Along As Required Crossbracing

(Operator) As Required Jack, U-Clamps As Required DeckingAs Required Blocking As Required Overlay Material

As Required WoodPreservative






1. Install temporary crutch bent near pile to bepartially replaced.

2. Install U-Clamps and jack on pile to bepartially replaced. Lift cap.

3. Shim crutch bent to remove load from andlift span off of pile to be partially replaced.

4. Treat cut area with wood preservative.

5. Install replacement pile section and toe nailor use scabs if appropriate.

6. Remove crutch bent.




PROCEDURE: REPLACE PILE SECTION




1 Foreman 1 Power Saw As Required Temporary 3 Crew Members Jack(s) Bent

U-clamps As Required ShimsAs Required Wood PreservativeAs Required Replacement Pile

Section






1. Remove deteriorated cross-bracing. Plug oldbolt holes with caulk/grout.

2. Temporarily attach bracing to piles withgalvanized nails. Nails should not interferewith bolt installation.

3. Drill and treat holes with wood preservative.

4. Place bolts, washers, and nuts. Tighten.




PROCEDURE: REPLACE CROSS-BRACING




1 Foreman 1 Power Drill As Required Crossbracing3 Crew Members As Required Galvanized Nails

As Required Bolts, Washersand Nuts

As Required Wood PreservativeAs Required Caulk/Grout




Steel: Chapter 20 20-1

Chapter 20: Steel

Table of Contents

7446-01 STRINGER (REPAIR/REPLACE) .......................................................................20 - 3

7446-01 FLOORBEAM (REPAIR/REPLACE) ....................................................................20 - 8

7446-01 GIRDER (REPAIR).........................................................................................20 - 17

7446-01 DIAPHRAGM/LATERAL

BRACING (REPAIR/REPLACE) ..................................................................20 - 22

7446-01 REPAIR PROCEDURE FOR IMPACT AREAS .....................................................20 - 24


20-2 Steel: Chapter 20




REFERENCES


Section1060 - Painting Structural Steel



Based on need as indicated by bridge inspectionsor reports of accidental damage. When damage ordeterioration is so severe that the structuralcapacity of a stringer is impaired, special trafficcontrols may be required on an emergency basis.

WORK AREA

All rolled beam steel stringers; their connectionsto bearings and floor beams which support them;areas of the deck directly adjacent to stringersrequiring repair or replacement; and incidentalitems supported by and connected to stringers,such as diaphragms, cross frames and utilitybrackets.


Repairing and replacing all or portions of steelstringers. The work can include, but is not limitedto, providing temporary supports for jacking;temporarily supporting or reducing loads carried bystringers either by jacking from below or usingneedle beams from above; disconnecting stringersfrom their supports or disconnecting incidentalitems supported by stringers by removing bolts orrivets or using oxyacetylene cutting torches;prefabricating replacement members or elements;drilling and reaming holes; grinding to provide therequired finish or tolerances on steel surfaces;making minor repairs to decks within the workarea; repairing or replacing incidental items withinthe work area; erecting replacement or repairedelements and incidental items, includinginstallation of shear connectors, by welding or hightensile strength bolting; and preparing surfaceswhich have been damaged or left bare by the work,and applying a prime coat of paint. Reportreplacing all or portions of decks or major repairsto decks to appropriate activities such as ActivityD744303, Concrete Deck (Repair), or ActivityC744302, Open Steel Grid Deck (Repair/Replace).



2. Construct temporary bent or install needlebeam under sound portion of superstructure.

3. Lift superstructure.

4. Remove damaged or deteriorated section.

5. Weld new section into place using fullpenetration groove welds.

6. Lower member and check for distress.

7. Remove lifting devices.

8. Sandblast and apply prime coat paint.



ACTIVITY TITLE: STEEL STRINGER (REPAIR/REPLACE)


PROCEDURE: REPLACE SECTION (SUCH AS BEAM END)






1 Foreman As Required Jacks or Carrier As Required Temporary Bent3 Crew Members Beams As Required New Section1 Special Crew Member 1 Sand Blaster As Required Prime Coat Paint

(Certified Welder) 1 Cutting Torch As Required Sand1 Welding Equip.





Low Cost Bridge Repair

Steel Stringer End Connection

Stringer Support BracketPennDOT District 12-0Westmoreland CountyS.R. 993 over Brush CreekSingle span thru truss bridge, stringer endsrepaired by installing steel support bracket.Rehabilitation performed to avoid a weight limitposting.

Design: In-House by District PersonnelConstruction: Westmoreland County

Maintenance CrewDuration of Construction: 1 Week (3 man crew)Maintenance and Protection of Traffic:Lane closure over each stringer being repaired.Cost: $4,000 Material Cost

Stringer Support Bracket

Equipment List:

Temporary Traffic Control DevicesGrinderDrill to install bolts in web of floor beam

Material List:

18 Steel Support Brackets fabricated by Dura-BondSteel (Bid in DGS)A325 Steel BoltsPaint

Stringer Support Bracket

Steel support brackets and MPT designed in-houseby District.

Steel support brackets fabricated by contractor.

Stringer Support BracketLessons Learned:

(1) Original design would repair deficientstringers at 5 locations and reduce the bridge’seffective width. This design did not consider thatthis would prevent access to the bridge from aprivate business with a driveway adjacent to thebridge.

(2) Maintenance forces proposed 4 additionallocations to avoid reducing the bridge width.Additional expense and time was minimal andprovided a reasonable and cost effective solution.



Stringer Support Bracket Plan anddetails by District.

Stringer Support Bracket Plan

Maintenance and Protection of Traffic






3. Disconnect member from structure andremove.

4. Modify structure to accept replacementmember.

5. Install replacement member using high-strength bolts or welds.

6. Remove jacks and check for distress.

7. Clean and paint.

8. Repair deck if necessary.



ACTIVITY TITLE: STEEL STRINGER (REPAIR/REPLACE)


PROCEDURE: REPLACE MEMBER




1 Foreman As Required Welding Torch 1 Temporary Bent3 Crew Members As Required Jacks or Carriers As Required Replacement1 Special Crew Member Beams Members

(Certified Welder) 1 Crane or Lift As Required H.S. BoltsEquip. As Required Prime Coat Paint

As Required Reinforcing SteelAs Required Concrete MixAs Required Formwork





REFERENCES





Based on need as indicated by bridgeinspections. When deterioration is so severe thatthe structural capacity of a floorbeam is impaired,special traffic controls may be required.

WORK AREA

All rolled beam and built-up, riveted or weldedfloorbeams, their connections to girders, chords orbearings; stringer connections to floorbeams; andareas of the deck directly adjacent to floorbeamsrequiring repair or replacement.


Repairing or replacing all or portions of steelfloorbeams. The work can include; but is notlimited to, providing temporary supports forjacking; temporarily supporting the ends offloorbeams or the loads from stringers supportedby floorbeams either by jacking from below orusing needle beams from above; disconnectingfloorbeams from their supports, or stringers fromtheir beams by removing bolts or rivets or usingoxy-acetylene cutting torches; prefabricatingreplacement members or elements; drilling andreaming holes: grinding to provide the requiredfinish or tolerances on steel surfaces; makingminor repairs to decks within the work area;erecting replacement or repaired elements and

incidental items in the work area by welding orhigh tensile strength bolting; and preparingsurfaces which have been damaged or left bare bythe work, and applying a prime coat of paint. Inthose areas where a floorbeam and one or morestringers supported by it are repaired or replacedat the same time, report the work of connectingrepaired or replaced stringers to the floorbeam toActivity A744602, Steel Stringer (Repair/Replace).







6. Lower member and check for distress


8. Clean and apply prime coat paint.

NOTE: Welding details for this repair shouldbe furnished by the District Bridge Office andthe welding should be accomplished bypersonnel certified for the type and theposition of the weld required. Removingversus cleaning decayed area of beam will bedetermined by District Bridge Engineer.


ACTIVITY TITLE: STEEL FLOORBEAM (REPAIR/REPLACE)

UNIT OF MEASUREMENT: EACH FLOORBEAM

PROCEDURE: REPLACE SECTION






1 Foreman As Required Jacks As Required Beam Sections3 Crew Members As Required Carrier Beam As Required Paint1 Special Crew Member As Required Beam

(Certified Welder) 1 Cutting TorchAs Required Welding Equip







2. Disconnect member from structure andremove.

3. Modify structure to accept replacementmember.

4. Install replacement member using high-strength bolts or welds.


6. Clean and paint.

7. Repair deck, if necessary.

NOTE: Welding details for this repair shouldbe furnished by the District Bridge Office andthe welding should be accomplished bypersonnel certified for the type and theposition of the weld required.


ACTIVITY TITLE: STEEL FLOORBEAM (REPAIR/REPLACE)

UNIT OF MEASUREMENT: EACH FLOORBEAM

PROCEDURE: REPLACE MEMBER




1 Foreman 1 Welding Torch 1 Temporary Bent3 Crew Members As Required Jacks or Carrier 1 Replacement1 Special Crew Member Beam Member

(Operator) 1 As Required Prime Coat Paint1 Special Crew Member As Required Reinforcing Steel

(Certified Welder As Required Concrete





Steel Beam Replacement

Steel Stringer End Connection

Steel Beam ReplacementPennDOT District 5-0Schuylkill CountyS.R. 4008 over West Branch of Schuylkill RiverSingle span steel girder bridge with steel grid deck.Replacement of Beam 3 (web deterioration). Repairof steel grid deck.Beam replaced without removing steel grid deck.

Design: In-House by District personnelConstruction: Schuylkill County Bridge CrewDuration of Construction: 6 daysMaintenance and Protection of Traffic: RoadClosure

Equipment List:ExcavatorConcrete FormsConcrete SawCutting torchScaffold

Material List:Steel BeamSteel Reinforcement/DowelsCement Concrete for Backwall

Steel Beam ReplacementRemoval of deteriorated beam (cut in pieces for removal). Removal of approach roadway and backwalladjacent to beam.



Steel Beam ReplacementInstallation of new beam and deck connections



Steel Beam ReplacementRepair backwall.Patch approach roadway.



Steel Beam Repair

PennDOT District 2-0Mifflin CountyS.R. 1002 over Tributary to Honey CreekSingle span steel girder bridge with timber plankdeck and bituminous overlay.

Plated beams to repair:• Deteriorated webs at ends of beams• Deteriorated flanges at midspan

Design: In-House by District personnel

Construction: Mifflin County Bridge Crew

Duration of Construction: 2 week s (May 2009)

Maintenance and Protection of Traffic: Nonerequired.

Cost: $28,100

Equipment List:Low profile magnetic drill

Material List:Fabricated steel and hardware



REFERENCES





Based on need as indicated by bridge inspectionsor reports of accidental damage. If damage ordeterioration is sufficiently severe so that thestructural capacity of a girder is impaired specialtraffic controls may be required on an emergencybasis.

WORK AREA

All built-up girders, riveted or welded; theirconnections to floor beams, incidental items suchas cross frames and bearings; and areas of thedeck directly adjacent to girders requiring repair.


Repairing built-up steel girders by restoring orreplacing damaged or deteriorated elements. Thework can include, but is not limited to, providingtemporary supports for jacking; modifying girdersto accept jacking loads; temporarily supporting orreducing loads carried by girders by either jackingfrom below or using needle beams from above;disconnecting or removing elements from girdersby removing bolts or rivets or using oxy-acetylenetorches; repairing or prefabricating replacementelements; drilling and reaming holes; grinding toprovide required finish or tolerances on steelsurfaces; making minor repairs to decks within thework area; erecting repaired or replaced elementsand incidental items by welding or high tensilestrength bolting; and preparing surfaces damagedor left bare by the work and applying a prime coatof paint.







6. Lower member and check for distress.





ACTIVITY TITLE: STEEL GIRDER (REPAIR)

UNIT OF MEASUREMENT: EACH GIRDER

PROCEDURE: REPLACE SECTION






1 Foreman As Required Jacks or Carrier As Required Temporary Bent3 Crew Members As Required Beams 1 New Section1 Special Crew Member 1 Welding Equip As Required Prime Coat Paint

(Certified Welder)





Girder In-Fill

PennDOT District 1-0Crawford CountyS.R. 408 over Oil Creek (Hydetown, PA)Single span steel thru girder bridge (fracturecritical) with deteriorated and non-functional rocker nest. Replaced with laminated neoprene bearing pad.Infill of steel thru beams to protect against impactforces (preventive).

Design: In-House by District personnelConstruction: Crawford County Bridge CrewDuration of Construction: 6 weeksMaintenance and Protection of Traffic:Half-width construction with temporary signal.

Cost: $25,000

Equipment List:Hydraulic JacksTimber CribbingConcrete FormsScaffoldWelder

Material List:Class AA Cement Concrete

(Lightweight is an option)Steel Reinforcement/DowelsLaminated Neoprene Bearing PadSteel Anchor BoltsSteel Masonry PlateSteel Sole Plate



Girder In-Fill

Steel through-girder with structure mounted guiderail

Significant deterioration of girder web.



Completed In-Fill

Remember:Check additional dead load on girderAvoid transverse welds on fracture critical beamsRemove all rust and paint because you cannotinspect beam after concrete is placed.

If beams cannot support additional dead load,other alternatives are available.



REFERENCES





Based on need as indicated by bridge inspectionsor reports of accidental damage.

WORK AREA

All steel diaphragms, cross frames, lateralbracing, and their connections to beams andgirders.

*Special Measurement Note: Diaphragms areusually composed of a single member such as achannel. In these cases the single member isconsidered as "one - each item" for measurementpurposes. Cross frames are usually composed of atleast four elements consisting of upper and lowermembers and cross members. All of thesemembers together are considered as "one eachitem" for measurement purposes. Lateral systemsmay be composed of one or two members, andthese may be discontinuous on multi-beam orgirder bridges. One element, or two elementsfastened together, spanning between connectionswithout a break is considered "one each item" formeasurement purposes.


Repairing or replacing all or part of the elementsin structural steel diaphragms, cross frames orlateral bracing. The work can include, but is notlimited to, disconnecting or removing elements byremoving bolts or rivets or using oxy-acetylenecutting torches; straightening members by theapplication of heat and mechanical means;prefabricating replacement elements; repairingelements; drilling and reaming holes; erectingrepaired or replaced elements by welding or hightensile strength bolting; and preparing surfacesdamaged or left bare by the work and applying aprime coat of paint.

Cross frames and diaphragms are oftenconnected to beam and girder stiffeners. Reportthe work of any necessary repairs to thesestiffeners to this activity unless the beam or girderis being repaired at the same time. In that case,report the work to an appropriate activity thatreflects the major effort, such as Activity A744602,Steel Stringer (Repair/Replace).




3. Lift superstructure, as necessary.

4. Remove damaged or deteriorated section ormember.

5. Weld new section or member into placeusing full penetration groove welds.

6. Lower member and check for distress





ACTIVITY TITLE: STEEL DIAPHRAGM/LATERAL BRACING (REPAIR/REPLACE)

UNIT OF MEASUREMENT: * EACH ITEM







1 Foreman As Required Jacks As Required Steel Shapes3 Crew Members As Required Beams As Required Paint1 Special Crew Member As Required Blocking As Required Paint

(Certified Welder) As Required Cutting TorchWeldingEquipment





REFERENCES


Section - 1060 - Painting Structural Steel

Section - 1105 - Fabricated Structural Steel


Based on the need as indicated by inspectionreports or reports of accidental damage. If fracturewill occur due to subsequent impact then thiscorrective action will be done immediately.

WORK AREA

The impact are should be flared back to thematerial edge not less than 1 to 10 slope.


Repairing impact damage to steel girdersrequires very careful attention. Unless correctivemeasures are taken, fracture of the beam canoccur due to impact at the original damage locationor at any other point on the beam. The correctivemeasure to prevent fracture is to grind the impactdamage to a smooth surface to eliminate stressriser and must be done prior to Heat-Straightening.


1. Grind impact area to bright metal to removeany irregularities and surface defects. Usinga sanding disc, smooth area and round overedges. Finish grinding should be doneparellel to the stress so this ensures thattransverse grind marks are not present.

2. If the impact is within the proximity of awelded detail, the weld toes should besmoothed with a die grinder to ensure thatno microcracks were introduced during theimpact. Using a sanding disc, smooth thearea and round over edges. Finish grindingshould be done parallel to the stress so thisensures that transverse grind marks are notpresent.

3. The impact are should be faired back to thematerial edge at not less then a 1 to 10slope.

4. The area should be thoroughly inspected,including any weld toes of details within thevicinity of the impact using ultrasonic ormagnetic particle testing as appropriate forthe detail.


ACTIVITY TITLE: REPAIR IMPACT DAMAGE TO STEEL GIRDER

UNIT OF MEASUREMENT: EACH GIRDER

PROCEDURE: GRIND IMPACT AREA






1 Foreman As Required Hand Grinder As Required Grind1 Crew Members As Required Generator 1 Paint

1 As Required Test


.17 SY/HR 1 EA/DAY 24 MH/EA


Concrete Members: Chapter 21 21-1

Chapter 21: Concrete Members

Table of Contents

7446-01 STRINGER (REPAIR/REPLACE) .......................................................................21 - 3

7446-01 DIAPHRAGM (REPAIR/REPLACE) ..................................................................21 - 10

7446-01 OTHER MEMBERS (REPAIR/REPLACE)...........................................................21 - 12


21-2 Concrete Members: Chapter 21




REFERENCES


Section 1001 - Cement Concrete Structures

1003 - Dowel Holes

1080-Prestressed Concrete BridgeSuperstructures

1107 - Prestressed Concrete Bridge Beams



WORK AREA

All reinforced concrete stringers; all prestressedconcrete stringers; areas of deck directly adjacentto reinforced concrete or prestressed concretestringers requiring repair or replacement; anddiaphragms framed into reinforced concrete orprestressed concrete stringers requiring repair orreplacement.


Repairing or replacing reinforced concrete orprestressed concrete stringers. The work caninclude, but is not limited to, providing temporarysupports for jacking; temporarily supporting theloads carried by the stringer either by jacking frombelow or using needle beams from above;temporarily applying loads to prestressedstringers; removing damaged or deterioratedconcrete and reinforcing steel; drilling and groutingdowels of threaded inserts; constructing false workto support forms; constructing forms; installingreinforcing bars; placing concrete; and replacingprefabricated, prestressed stringers. Report thework of making minor repairs to the deck directlyadjacent to a stringer being repaired or replaced,or the work of repairing or replacing diaphragmsthat frame into a stringer being repaired orreplaced to this activity. Report repairs outside ofthe work area to other appropriate activities suchas Activity D744303, Concrete Deck (Repair), orActivity B744603, Rein forced/Prestressed ConcreteDiaphragm (Repair/Replace).


1. Remove all loose concrete from the damagedarea and clean all areas where new concretewill be bonded.

2. Chip all cracks to a 2 inch deep V-Shapedgroove.

3. Clean and repair any exposed reinforcingsteel or prestress tendons.

4. Install forms to repair stringer to its originalcross section.

5. Seal cracks in the stringer with epoxy andcoat the contact surfaces of the existingconcrete to be patched with an epoxy resin.

6. Place the new concrete while the epoxy resinis still wet.

7. Remove forms and finish surfaces.


ACTIVITY TITLE: REINFORCED/PRESTRESSED CONCRETE STRINGER (REPAIR/REPLACE)








1 Foreman 1 Concrete Mixer As Required Concrete3 Crew Members 1 Air Compressor As Required Epoxy Mortar

with HammerAs Required Access Equip.






1. Drill 1-1/2 in. diameter holes through theweb as shown to accommodate reinforcingsteel to tie the new concrete together. Thesereinforcing bars are to be placed and groutedinto the holes. Care must be exercised toavoid drilling through tendons or reinforcingbars.

2. Roughen and clean the surface of theconcrete beams where the new concrete is tobe bonded.

3. Install the post-tensioning ducts, reinforcingsteel and the forming for the new concrete.

4. Cast the contact surfaces with an epoxyresin and place the new concrete while theepoxy is still tacky.

5. After the concrete has attained designstrength, tension the strands to the specifiedload. The strands should be tensioned in asequence to balance the load on each side ofthe flange.

6. Fill the post-tensioning ducts with grout.




PROCEDURE: REPAIR PRESTRESSED STRINGER (POST-TENSIONING)




1 Foreman 1 Concrete Mixer As Required Concrete3 Crew Members 2 Post-tensioning As Required Epoxy bonding

Jacks materialAs Required Access Equip As Required Post tensioning

ductsAs Required Tendons






1. Where required, construct temporary bentfor supporting jacks and blocking.

2. Place jacks and raise entire end of bridge afraction of an inch. The lift should be onlythat required to insert a piece of sheet metalor other thin material used as a bondbreaker for the new concrete.

3. Place the sheet metal bond breaker on thebeam seat at the pier or abutment.

4. Above the deteriorated concrete to providehorizontal bearing surfaces between the newand old concrete.

5. Place new reinforcing steel and secure to theold reinforcing steel by welding. If weldabilityof the two steels is questionable, use lowhydrogen electrodes and preheat thereinforcing bars. As an alternate to welding,the new reinforce ment can be lapped withthe old steel the amount of the developmentlength.

6. Apply epoxy bonding compound to preparethe surfaces of sheared beam end, place thenew concrete. A nonshrink additive shouldbe used in the new concrete.

7. After concrete has reached sufficientstrength, jack all beams simultaneously tothe height needed to allow placement ofelastomeric bearing pads.

8. Uniformly lower the entire end of the bridge.Check for possible distress in the repairedarea.


Refer to: PUB 408, Section 1002




PROCEDURE: REPAIR DISTRESSED AREAS OF CONCRETE BEAM ENDS




1 Foreman 1 Air Compressor w/ As Required Concrete3 Crew Members chipping hammer As Required Epoxy bonding1 Special Crew Member 1 Welding Equip material

(Certified Welder) As Required Jacks As Required Reinforcingsteel








PROCEDURE: REPAIR DISTRESSED AREAS OF CONCRETE BEAM ENDS



REFERENCES



1003 - Dowel Holes

1080 - Prestressed Concrete Bridge Superstructures



WORK AREA

All concrete diaphragms framed into reinforcedconcrete or prestressed concrete beams or girders;areas of the deck directly adjacent to concretediaphragms requiring repair or replacement; areasof reinforced concrete at prestressed concretebeams or girders at and adjacent to diaphragmsrequiring repair or replacement.


Repairing or replacing concrete diaphragmsframed into reinforced concrete or prestressedconcrete beams or girders. The work can include,but is not limited to, removing damaged ordeteriorated concrete and reinforcing steel; drilling,installing adhesive anchors or grouted dowels orthreaded inserts; constructing false work orinstalling temporary hang-ers to support forms;constructing forms; installing reinforcing bars; andplacing concrete. Report the work of making minorrepairs to decks directly adjacent to diaphragmsbeing repaired or replaced, or minor repairs andconnections to stringers at and directly adjacent todiaphragms being repaired or replaced to thisactivity unless the diaphragms are framed intostringers undergoing major repair or replacement.In that case report all work to Activity A744603,Reinforced/Prestressed Concrete Stringer (Repair/Replace).


1. Remove damaged concrete using 15 lb.hammer.

2. Remove any damaged reinforcing steel.

3. If remaining steel reinforcement is too short(less than 18' embedded), adhesive anchorsthreaded inserts or grouted dowels must beused.

4. Drill holes appropriate for either adhesiveanchors, threaded inserts or dowels andgrout.

5. Install reinforcing steel.

6. Construct form work. Form work must besupported either by false work or temporaryhangers.

7. Place concrete. If possible, a one and onehalf inch diameter vent hole verticallythrough the deck will facilitate concreteplacement.

8. Remove formwork.


ACTIVITY TITLE: REINFORCED/PRESTRESSED CONCRETE DIAPHRAGM (REPAIR/REPLACE)

UNIT OF MEASUREMENT: EACH DIAPHRAGM







1 Foreman 1 Air Hammer As Required Steel Reinforcemt3 Crew Members 1 Concrete Drill As Required Concrete

As Required Threaded InsertAdhesiveAnchors orDowel & Grout


1.7 SY/HR 1 EA/DAY 24 MH/EA



REFERENCES


Section1001- Cement Concrete Structures

1003 -Dowel Holes

1080 -Prestressed Concrete Bridge Superstructures

1107 -Prestressed Concrete Bridge Beams



WORK AREA

All reinforced concrete or prestressed concretesuperstructure members such as girders or floorbeams, which are not included in the definitions ofstringers or diaphragms; areas of the deck directlyadjacent to such members; and connections ofsuch members to stringers or diaphragms.


Repairing or replacing reinforced concrete orprestressed concrete superstructure members thatare neither stringers nor diaphragms. The work caninclude, but is not limited to, removing damaged ordeteriorated concrete and reinforcing steel; drillingand installing adhesive anchors, grouted dowels orthreaded inserts; constructing false work;constructing forms; installing reinforcing steel; andplacing concrete. Report the work of making minorrepairs to decks in the work area and connecting toother members to this activity. Report concreterepairs outside of the work area to otherappropriate activities such as Activity A744303,Concrete Deck (Repair), or Activity A744603,Reinforced/ Prestressed Concrete Stringer (Repair/ Replace).


1. Remove damaged concrete using a 15 lb.hammer.

2. Remove any damaged reinforcing steel.

3. If remaining steel reinforcement is too short,laps cannot be used. Therefore eitherthreaded inserts or grouted dowels must beused.

4. Drill holes, as appropriate, for the adhesiveanchors, threaded inserts or dowels andgrout.

5. Form work support must be provided eitherby false work or temporary hangers.

6. Install reinforcing steel.

7. Construct Form work. Brace Form work.

8. Place concrete.

9. Remove Form work.


ACTIVITY TITLE: REINFORCED/PRESTRESSED CONCRETE MEMBERS OTHER THAN

STRINGER OR DIAPHRAGMS (REPAIR/REPLACE)








1 Foreman 1 Air Hammer As Required Steel Reinforcement3 Crew Members 1 Concrete Drill As Required Concrete

As Required Threaded InsertAs Required Adhesive AnchorsAs Required or Dowels &

Grout




Truss: Chapter 22 22-1

Chapter 22: Truss

Table of Contents

7447-01 MEMBERS (STRAIGHTEN/REPAIR/REPLACE) ..................................................22 - 3

7447-01 PORTAL (MODIFY) ........................................................................................22 - 29

7447-01 MEMBERS (TIGHTEN/FLAMESHORTEN).........................................................22 - 31

NOTE: For all items in this Chapter - the details for all procedures must be furnished by the DistrictBridge Office and will only be accomplished byqualified personnel.


22-2 Truss: Chapter 22




REFERENCES





Based on need as indicated by bridge inspectionsor reports of accidental damage. Special trafficcontrols may be required when accidental damageimpairs the structural capacity of the truss andduring repair or replacement of members.

WORK AREAAll truss members - upper and lower chords,

diagonals, verticals, and end posts; and theirconnections to other elements of a truss bridgesuch as floor beams, lateral bracing, and bearings.

* Special Measurement Note: Truss membersmay be composed of a single rolled shape, two ormore eye-bars, or a combination of shapes, platesand bars. "Each member" is considered to be thecomplete member connecting two panel points,regardless of the number of elements of which it iscomposed.


Strengthening a truss member by adding partssuch as angles or plates, or repairing a trussmember by splicing existing elements and/orreplacing parts, or completely replacing an entiremember. The work can include, but is not limitedto, providing temporary supports and jacking orother means of unloading truss members;removing parts of truss members or entiremembers by removing bolts or rivets or using oxy-acetylene cutting torches; prefabricatingreplacement elements or entire members; grindingto provide the required finish or tolerances on steelsurfaces; drilling and reaming holes; erectingrepaired or replaced members or elements bywelding or high tensile strength bolting; andpreparing surfaces damaged or left bare by the

work, and applying a prime coat of paint.

Report work on connections between trussmembers and members outside of the work area,such as lateral bracing, to this activity only if thework is limited to reconnections. When workinvolving the same connection is also beingreported to another activity, such as ActivityB744602, Steel Floor beam (Repair/Replace),report the connection work to that activity.


1. Position and install anchor connections.

2. Position and install posts.

3. String cable with turnbuckles.

4. Tension cables to desired force andpermanently secure turnbuckle.

5. Clean and paint posts and turn buckles

NOTE: Details of this procedure should befurnished by the District Bridge Office andthe procedure should only be accom plishedby qualified personnel.


ACTIVITY TITLE: STEEL TRUSS MEMBER (STRENGTHEN/REPAIR/REPLACE)

UNIT OF MEASUREMENT: *EACH MEMBER

PROCEDURE: STRENGTHENING BOTTOM CHORD BY POST-TENSIONING






1 Foreman No special equip As Required Posts (Braces)3 Crew Members required As Required Cables

As Required TurnbucklesAs Require Paint


.03 EA/HR .2 EA/DAY 150 MH/EA




1. Fabricate braces to proper length and drillholes in them.

2. Restrict traffic, as necessary, to provide workspace.

3. Drill holes in chord and lower connection tomatch holes in brace.

4. Attach braces with high strength bolts.

5. Clean and paint new members.

NOTE: Details of this procedure should befurnished by the District Bridge Office andthe procedure should only be accomplishedby qualified personnel.




PROCEDURE: STRENGTHENING TOP CHORD




1 Foreman No special equip As Required New Braces2 Crew Members required As Required High Strength

BoltsAs Required Paint


.03 EA/HR .2EA/DAY 150 MH/EA




1. Install anchorage devices adjacent to eachabutment.

2. Suspend cables across channel each side ortruss.

3. Attach cables to anchorage devices and tobeams brackets, or other devices on thespan.

4. Adjust turnbuckles to tighten cable

NOTE: Details of this procedure should befurnished by the District Bridge Office andprocedure should only be accomplished byqualified personnel.




PROCEDURE: STRENGTHEN ENTIRE BRIDGE CABLE SLING SUPPORT SYSTEM




1 Foreman 1 Backhoe As Required Concrete3 Crew Members As Required Anchors1 Special Crew Member As Required Cables

(Operator) As Required AttachmentAssemblies

As Required Turnbuckles






1. Excavate and prepare foundation for tower.

2. Erect tower.

3. Install cable attachment to the bridge.

4. Attach cables to bridge attachments and thetower.

5. Clean and paint tower.

NOTE: Details of this procedure should befurnished by the District Bridge Office andthe procedure should only be accomplishedby qualified personnel. Comply withapplicable permit and proceduralrequirements of the Department ofEnvironmental Resources, Pennsylvania FishCommission and local Conservation Districtsin accomplishing this procedure.




PROCEDURE: STRENGTHEN ENTIRE BRIDGE CABLE-STAYED SUPPORT SYSTEM




1 Foreman 1 Backhoe As Required Concrete (for3 Crew Members 1 Crane footing)1 Special Crew Member As Required Tower

(Operator) As Required CablesAs Required Attachment

AssembliesAs Required TurnbucklesAs Required Paint






1. Excavate and prepare foundation.

2. Erect tower.

3. Modify existing bridge members, as required.

4. Install bearing.

5. Paint bearing.

NOTE: Details of this procedure should befurnished by the District Bridge Office andthe procedure should only be accomplishedby qualified personnel. Comply withapplicable permit and proceduralrequirements of the Department ofEnvironmental Resources, Pennsylvania FishCommission and local Conservation Districtsin accomplishing this procedure.




PROCEDURE: STRENGTHEN ENTIRE BRIDGE SHIFTING SUPPORTS




1 Foreman 1 Backhoe As Required Concrete3 Crew Members 1 Crane As Required Tower1 Special Crew Member As Required Bearings

(Operator As Required Paint






1. Excavate and prepare foundation.

2. Erect tower.

3. Modify existing bridge members, as required.

4. Install bearing.

5. Paint bearing.





PROCEDURE: STRENGTHEN ENTIRE BRIDGE ADDITION OF SUPPORTS




1 Foreman 1 Backhoe As Required Concrete3 Crew Members 1 Crane As Required Tower1 Special Crew Member As Required Bearings

(Operator) As Required Paint






1. Add connections for new members.

2. Add new members.

3. Clean and paint new members.





PROCEDURE: STRENGTHEN ENTIRE BRIDGE METHOD OF SUBDIVISION




1 Foreman 1 Drill Reamer As Required H.S. Bolts3 Crew Members As Required New members

As Required Paint






1. Relieve load, as appropriate.

2. Disconnect members, if necessary, after re-lieving the load. Observe any precautionsregarding leaving one piece of a two elementmember in place while repair is affected.

3. Clean and prepare surfaces for welding oranti-corrosion treatment. Cleaning forwelding can often be at least partiallycompleted in advance.

4. Position and align parts making use ofclamps and pins, as applicable.

5. Weld the connections or fasten as otherwisedesigned ensuring at least the minimumweld is attained.

6. Clean and inspect welds and apply protectivecoating to the area, as required.

7. Apply load to the repair.

8. Remove any lifting or dead load supportingequipment.

NOTE: Details of this procedure should befurnished by the District Bridge Office andthe procedure should only be accom plishedby qualified personnel. Welding details forthis repair should be furnished by the DistrictBridge Office and the welding should beaccomplished by personnel certified for thetype and position of the weld required.




PROCEDURE: STRENGTHEN TRUSS CONNECTIONS AND BRACES




1 Foreman 1 Cold Chisel As Required New Assemblies3 Crew Members 1 Welding As Required Paint1 Special Crew Member 1 Equip Lifting

(Certified Welder)As Required Equip Cable








PROCEDURE: END VERTICAL






PROCEDURE: EYEBAR AT PIN-ALTERNATE 1






PROCEDURE: EYEBAR AT PIN-ALTERNATE 2






PROCEDURE: PIN PLATE






PROCEDURE: LATERAL CONNECTION

3/16” FLARE BEVELGROOVE WELD ALL SIDES

3/16” FLARE BEVELGROOVE WELD 6” EACHSIDE






PROCEDURE: LOWER LATERAL






PROCEDURE: VERICAL CHANNEL AT KNEEBRACE CONNECTION




1. Bolt a side splice plate to the damagedmember. Remove any rivet heads whichinterfere with the splice plate when therepair is near a connection.

2. If necessary, remove old tie plates or lacingbars from the two channels in the area of thecrack to allow placement of the bottom tieplate. Some temporary lateral bracing maybe required prior to completing the repair.

3. Bolt the bottom tie plate to the member.

4. Paint plate.

NOTE: Splice plates have been successfullyattached using welds, but fatigue problemsmay result from welds where the structureexperiences a high traffic volume. A boltedconnection for the splice is preferable.Details of this procedure should be furnishedby the District Bridge Office. The procedureshould only be accomplished by qualifiedpersonnel.




PROCEDURE: REPAIR BY SPICE PLATE




1 Foreman 1 Cold Chisel 2 Side Splice Plates3 Crew Members 1 Power Drill 1 Bottom Plate

As Required Bolts & NutsAs Required Paint








PROCEDURE: REPAIR BY SPICE PLATE




1. Install the wood blocking and WF beam ontop chord to carry the cable sling.

2. Install a cable having the capacity to carrythe maximum load in the vertical memberbeing repaired over the WF beam and woodblocking.

3. Tighten the cable system to eliminate thedead load tensile force in the member beingreplaced.

4. If the member to be replaced is composed ofangles, it can be repaired by first removingand replacing two of the angles, thenremoving and replacing the last two angles.The two angles removed first should be theweaker ones or as otherwise de-termined bythe existing condition of the vertical member.If the member to be replaced is similar to

that shown in Section BB, first one channel isremoved and replaced, then the other. If theentire member can be safely removed, it canbe replaced with other type sections of equalstrength. High strength bolts are used forconnecting the new vertical members.

5. Install the batten plates or lacing bars at thereq-uired intervals along the vertical.Tighten the high strength bolts at allconnections.

6. Paint the new component.7. Remove cableslings and other temporary components andrestore the bridge to normal trafficconditions.





PROCEDURE: REPLACE VERTICAL TENSION MEMBER




1 Foreman 1 Cable 1 WF Beam3 Crew Members 1 Turnbuckle As Required Blocking

As Required Cable Clamps As Required Paints








PROCEDURE: REPLACE VERTICAL TENSION MEMBER




1. Jack the temporary support until the desig-nated load is reached. Place blocks andwedges that could hold the temporarysupport in position in the event of jackfailure.

2. Remove rivets or bolts in gusset plates atbottom chord and top chord if entire memberis to be replaced. If only a portion of amember is to be replaced, remove rivets orbolts in splice, if present, or cut member inpreparation for new splice.

3. If a new splice is to be added, drill holes totemplate from holes in new member.

4. Install new member. Tighten the highstrength bolts at all connections.

5. Remove any temporary blocks or wedges,unload jack, and remove jack and entire jacksupport system.

6. Paint new member.





PROCEDURE: REPLACE VERTICAL COMPRESSION MEMBER




1 Foreman 1 Jack As Required 12"x12" tempoary

3 Crew Members 1 Cutting Torch support member

1 Special Crew Member 1 Lifting Equip As Required Jacking Blocks

(Certified Welder) 1 Replacement

Member

As Required Paint








PROCEDURE: REPLACE VERTICAL COMPRESSION MEMBER




1. Restrict traffic to one lane on the oppositeside of the bridge from the repair.

2. Cut and install the necessary wood blocking.

3. Install a cable having the capacity to carrythe full dead load in the diagonal plus thelive load distributed from the restrictedtraffic.

4. Tighten the cable system.

5. When the member to be replaced iscomposed of angles, Sec. AA, followingsheet, it should be repaired by first removingand replacing two of the angles; thenremoving and replacing the last two angles.The two angles removed first should be theweaker ones or as otherwise determined by

the existing condition of the diagonalmember. When the member is composed ofchannels, Sec. BB, following sheet, first onechannel is removed and replaced, then theother. High strength bolts are used forconnecting the new diagonal members.

6. Install the batten plates or lacing bars at therequired intervals along the diagonal.Tighten the high strength bolts at allconnections.

7. Paint the new components.

8. Remove cable slings and other temporarycomponents and restore the bridge tonormal traffic conditions.




PROCEDURE: REPLACEMENT OF A TENSION DIAGONAL IN A RIGIDLY CONNECTED TRUSS




1 Foreman 1 Cutting Roch As Required Wood Blocking3 Crew Members As Required Cables1 Sprecial Crew Member As Required Bolts & Nuts

(Certified Welder) 1 ReplacementMember

As Required Paint








PROCEDURE: REPLACEMENT OF A TENSION IN A RIGIDLY CONNECTED TRUSS






PROCEDURE: KNEEBRACE REPLACEMENT



REFERENCES





Based on need as indicated by bridgeinspections. Reports of accidental damage to aportal or to the portal of another truss bridge in thesame vicinity, which has a similar underclearance,should be considered as an indication that portalmodification may be appropriate. WORKAREAPortals, their connections to end posts, andportions of other end posts affected by portalmodifications.


Modifying portals of steel through truss Bridgesto increase underclearance and/or to reduce thepotential for damage to such bridges from overheight loads. The work can include, but is notlimited to, removing all or portions of the portal byremoving bolts or rivets or using oxy-acetylenecutting torches; prefabricating parts or an entirelynew portal; grinding to provide the required finishor tolerances on steel surfaces; drilling or reamingholes; erecting replacement or modified elementsby welding or high tensile strength bolting; andpreparing surfaces which have been damaged orleft bare by the work, and applying a prime coat ofpaint. Minor modifications or repairs to end postswill usually be required as a result of makingmodifications to portals. Report such work withthat reported under this activity. A separate reportis not required.


Technique A

FRemove knee braces

Technique B

FRemove lower horizontal member and cutdiagonals to new length.

FReplace horizontal member in new positionand add no diagonals.

Technique C

FRemove all portal bracing and installreplacement members, which must befabricated to fit between end posts

NOTE: The dimensions, locations, and instal-lation or removal procedure for componentsshall be provided by the District BridgeEngineer. Welding details for this repair shouldbe furnished by the District Bridge Office andthe welding should be accomplished bypersonnel certified for the type and position ofthe weld required


ACTIVITY TITLE: STEEL TRUSS PORTAL (MODIFY)

UNIT OF MEASUREMENT: STEEL TRUSS PORTAL (MODIFY)







1 Foreman 1 Cutting Torch As Required New Members3 Crew Members 1 Power Drill As Required HS Bolts & Nuts1 Special Crew Member As Required Access Equip As Required Paint

(Certified Welder)



EXAMPLES OF PORTAL MODIFICATIONS



REFERENCES





Based on need as indicated by bridge inspectionsand the observation of tension members during thepassage of live loads. Special traffic controls forboth loadings and speed are required during thework of flame shortening.

WORK AREA

All eye-bar and rod truss tension members.

* Special Measurement Note: Truss tensionmembers composed of eye-bars or rods usuallyconsist of one or two elements but can be made upof more elements. "Each Member" is considered tobe the complete member connecting two panelpoints regardless of the number of memberelements which are tightened or flame shortened.


Tightening rod-turn buckle type tensionmembers by adjusting turnbuckles, and flameshortening eye-bar type tension members by theapplication of controlled heat and mechanical force,to equalize stresses between tension members oftwo trusses or elements of single tensionmembers. The work can include, but is not limitedto, turning existing turnbuckles; removing paint;installing clamps; applying controlled heat usingoxy-acetylene heating torches; applyingmechanical force using clamps; measuring theincrement of shortening; measuring the frequencyof oscillation of paired members to insure that theyare essentially equal; and preparing surfaces whichhave been damaged or left bare by the work, andapplying a prime coat of paint.


1. Remove paint from the eye-bar in the areato be heated. Attach the upsetting clampwhile supporting inclined eye-bars asnecessary to remove sags.

2. Restrict traffic as necessary to control liveloads on the span.

3. Heat the eye-bar to the proper temperatureand shorten the bar by upsetting it withforce applied by turning the screws of theupsetting clamp assembly.

4. Water quench the bar after it has sufficientlyair cooled.

5. Determine the proper tension in the bar bymeas-uring the vibration frequency.

6. Restore traffic on completion of theprocedure.7. Repaint as necessary.

NOTE: Details of this procedure should befurnished by the district bridge office and theprocedure should only be accomplished byqualified personnel.


ACTIVITY TITLE: STEEL TRUSS MEMBER (TIGHTEN/FLAME SHORTEN)




Abutments, Wings, Piers: Chapter 23 23-1

Chapter 23: Abutments, Wings, Piers

Table of Contents

7448-01 BACKWALL (REPAIR/REPLACE) .....................................................................23 - 3

7448-02 ABUTMENTS (REPAIR)...................................................................................23 - 7

7448-02 WING (REPAIR/REPLACE) .............................................................................23 - 13

7448-02 PIER (REPAIR) ..............................................................................................23 - 24

7448-03 FOOTING (UNDERPIN)...................................................................................23 - 33

7450-01 MASONRY (REPOINT) ....................................................................................23 - 40

7451-01 ABUTMENT SLOPEWALL (REPAIR/REPLACE) .................................................23 - 42

7451-01 ABUTMENT SLOPEWALL (CONSTRUCT NEW)..................................................23 - 46

7332-01 INSTALLING WEEP HOLES IN EXISTING MSE WALLS.....................................23 - 48


23-2 Abutments, Wings, Piers: Chapter 23




REFERENCES




1003 - Dowel Holes

1017 - Pressure Mortar Painting andSurfacing



WORK AREA

Abutment backwalls for the full width of thestructure between abutment parapets, and to adepth sufficiently below the bridge seat elevationto permit the installation of dowels and/or theproper lapping of reinforcement bars. If moreextensive repairs are required or if both backwallsand pedestals/seats are involved, report all work toActivity B744802, Abutments (Repair).

* Special Measurement Note: Cubic yards ofconcrete or masonry placed, not the deterioratedmaterial removed.


Repairing or replacing all or portions of concretemasonry backwalls. The work can include, but isnot limited to, installing sheeting, if necessary, andexcavating pavement and other roadway materialbehind backwalls to gain access to them; removingdeteriorated or damaged concrete. reinforcingsteel; or masonry; drilling and installing adhesiveanchored or grouted dowels; installing reinforcingsteel; constructing forms; placing concrete;replacing and pointing masonry elements; pressuregrouting masonry; epoxy pressure grouting; andrestoring all pavement and other roadway materialbehind the backwalls. In some instances removal ofconcrete in a backwall is primarily for the purposeof gaining access to anchorages for armored ormodular dams, or making minor repairs to concrete

associated with deck joints and is within thedefined work area for an activity involving deckjoints. In these cases report all work to theappropriate activity, such as Activity D744102,Steel Dam Deck Joints (Repair/Rehabilitate), orActivity B744102, Compression Seal Deck Joints(Repair/ Rehabilitate).


1. Temporarily tack weld the abutment side ofsteel armored joints, plate expansion dams,or toothed expansion dams to the deck sideof the joint assembly.

2. Cut and excavate the approach slab orpavement to allow access to the backwall.

3. Remove deteriorated concrete or masonryand/or reinforcing bars from the backwall.

4. Place replacement reinforcing bars by tyingthem into existing bars in the abutment orby grouting dowel bars into the abutment.

5. Place forms for concrete.

6. Place and cure concrete. Insure concrete isplaced beneath existing joints.

7. Remove forms and temporary tack welds onjoints or dams.

8. Backfill and compact subgrade under theapproach slab or pavement.

9. Patch the approach slab or pavement.

NOTE: Welding details for this repair shouldbe furnished by the District Bridge Office andthe welding should be accomplished bypersonnel certified for the type and positionthe weld required.


ACTIVITY TITLE: ABUTMENT BACKWALLS (REPAIR/REPLACE)

UNIT OF MEASUREMENT: *CUBIC YARDS OF CONCRETE OR MASONRY







1 Foreman 1 Welding Equip As Required Reinforcing Steel3 Crew Members 1 Concrete Mixer 1 C.Y. Concrete1 Special Crew Member 1 Backhoe or Gradall

(Certified Welder) 1 Roller or Tamper1 Special Crew Member

(Operator)


.17 CY/HR 1 CY/DAY 36 MH/CY



TYPICAL JOINT DETAILS



CROSS SECTIONS OF ABUTMENTS WITH BACKWALLS



REFERENCES




1003 - Dowel Holes

1017 - Pressure Mortar Pointing andSurfacing



WORK AREA

The breastwall and other portions of bridgeabutments, except for wingwalls when only thewingwalls are involved. The wingwalls are includedin the work area when both breastwalls and wingsare being repaired at the same time.

* Special Measurement Note: Cubic yards ofconcrete or masonry placed, not deterioratedmaterial removed.


Repairing all or portions of concrete or masonryabutments. The work can include, but is not limitedto, installing sheeting when necessary andexcavating material retained by or protecting theabutment; temporarily modifying superstructuresto accept jacking loads; providing temporarysupports for jacking; removing loads fromabutments either by jacking from below or usingneedle beams from above; removing deterioratedor damaged concrete, reinforcing steel or masonry;drilling and installing dowels; installing reinforcingsteel; constructing forms; placing concrete;replacing and pointing masonry elements; pressuregrouting masonry; epoxy pressure grouting; andreplacing excavated material.

When only the backwall or bridge pedestal/seatsare involved, the work should not be reportedunder this activity. It should be reported under

appropriate activities for the work. When protectivematerial such as riprap is excavated to gain accessto the work, it should be replaced in conformancewith work descriptions in appropriate activities,such as Activity B745301, Rock Protection.However, a separate report is not required, and thework should be reported under this activity.


1. Remove backfill or materials protecting orbeing retained by the abutment to gainaccess to the repair area.

2. Provide temporary supports for jacking orset up needle beams to remove loads fromthe abutment as required.

3. Remove loads from the abutment by jackingor using needle beams or removing portionsor the entire span as necessary.

4. Remove deteriorated concrete or masonryand additional material as required toestablish vertical and horizontal surfaces.

5. Place dowel bars, reinforcing steel andforms.

6. Apply bonding agent, place and cureconcrete and remove forms.

7. Reload the abutment by removing jacks orneedle beam or replacing the span.

8. Place and compact backfill and rockprotection as required.


ACTIVITY TITLE: ABUTMENTS (REPAIR)








1 Foreman 1 Gradall or 1 C.Y. Concrete Mixer3 Crew Members Excavator As Required. Reinforcing Steel1 Special Crew Member Concrete Mixer

(Certified Welder) 1 Staging, needle1 Special Crew Member beam, jacks or

(Operator) other equip toremove the load

1 Tamper or roller1 Welding Equip






1. Remove deteriorated concrete and laitancesby chipping and blast cleaning.

2. Drill and set tyscrus and lagstuds.

3. Set reinforcing steel and forms.

4. Just prior to placing concrete, apply epoxybonding agent.

5. Place cement concrete, cure, remove forms,and provide erosion control.




PROCEDURE: JACKET CONCRETE




1 Foreman 1 Air Compressor 1 C.Y. Concrete Mixer3 Crew Members 1 Concrete Mixer As Required Reinforcing Steel


..08 CY/HR .5 CY/DAY 60 MH/CY

TYPICAL SECTIONJACKET ABUTMENT8 WINGS–FULL DEPTH

6” MIN. NEW CONCRETE

COFFERDAM

WATER LINE




1. Construct sandbag cofferdam and excavatefor footing to sound material.

2. Clean existing stone that is to come incontact with new concrete.

3. Set dowels with non-shrink grout orapproved adhesive in existing open stonejoint at 24 in. horizontally and vertically with1 ft-3 in. embedment length.

4. Set concrete forms and place concrete asrequired against existing stone abutment.Prior to placing concrete, apply epoxybonding compound to stone that is to comein contact with new concrete.

5. Place forms, reinforcing steel, and concretefor new abutment footing.

6. Place forms, reinforcing steel, and concretefor new abutment wall.

7. Remove loads from the existing abutment byjacking or using needle beams as necessary.

8. Install new bearings or move old bearings asnecessary. Reload the newly jacketedabutment.

9. Remove formwork and the cofferdam.




PROCEDURE: L-SHAPED ABUTMENT JACKET (REPAIR) FOR STONE ABUTMENTS




1 Foreman 1 Concrete Mixer 1 C.Y. Concrete3 Crew Members As Required Reinforcing Steel

As Required Sandbags


.08 CY/HR .5 CY/DAY 60 MH/CY



REFERENCES


Section626 - Gabions

675 - Random Stone Slope Wall

735 - Geotextiles



1003 - Dowel Holes

1017 - Pressure Mortar Pointing andSurface



WORK AREA

The full length and depth of abutment wingwallsfrom, and including, the abutments parapets to theend of the wingwalls.



Repairing all or portions of concrete or masonryabutments. The work can include, but is not limitedto, installing sheeting when necessary andexcavating material retained by or protecting thewingwall; removing deteriorated or damagedconcrete, reinforcing steel or masonry; drilling andinstalling dowels; installing reinforcing steel;constructing forms; placing concrete; replacing andpointing masonry elements; pressure groutingmasonry; epoxy pressure grouting; and replacingexcavated material.

When protective material such as riprap isexcavated to gain access to the work, it should bereplaced in conformance with work descriptions inappropriate activities, such as Activity B745301,Rock Protection. However, a separate report is notrequired, and the work should be reported under

this activity. When wingwalls are being repaired atthe same time as breastwalls, a separate reportunder this activity is not required, and all workshould be reported under Activity C744802.


1. Excavate and remove all unsuitable materialbelow the wingwall extension.

2. As required, replace unsuitable material withacceptable granular material and thoroughlycompact the entire foundation to a firm,even surface.

3. Place specified geotextile fabric or placecement concrete pad.

4. Assemble, bind, join, and place gabions.

5. Fill Type A gabions by hand or small powerequipment, with specified aggregate.

6. As specified, secure lid to sides, ends, anddiaphragms using connecting wire.

NOTE: Comply with all applicable permit andprocedural requirements of the Departmentof Environmental Resources, PennsylvaniaFish Commission and local Conservationdistricts in accomplishing this procedure.


ACTIVITY TITLE: ABUTMENTS WINGWALLS (REPAIR/REPLACE)


PROCEDURE: EXTEND WINGWALLS WITH GABIONS






1 Foreman 1 Gradall or 1 C.Y. Stone for gabions3 Crew Members Backhoe As Required Gabion basket1 Special Crew member 1 Concrete Mixer and ties

(Operator) (for concrete As Required Geotextile fabric(pad) (for granular bed)

1 Tamper or Roller As Required Aggregate for1 Sweeper base

As Required Water





WINGWALL CROSS-SECTION




1. Remove existing wingwalls and excavate tosound material.

2. Clean all concrete that is to come in contactwith new concrete. Chip and clean existingconcrete to remove any unsound materialand laitances.

3. Drill and set dowels.

4. Set forms, reinforcing steel and placeconcrete. Just prior to placing concrete,

apply epoxy bonding compound to allexisting cleaned concrete that is to come incontact with fresh new concrete.

5. Prior to placing concrete, provide foradequately reinforced weep holes.

6. Backfill adequately cured concrete wing-walls. Suitable filter shall be provided forweep holes.

7. Provide scour protection.




PROCEDURE: REPLACE CONCRETE WINGWALLS




1 Foreman 1 Gradall or 1 C.Y. Concrete3 Crew Members Backhoe As Required Reinforcing Steel1 Special Crew member 1 Concrete Mixer 1 C.Y. Stone for scour

(Operator) protections





NOTE: Exact dimensions, rebar size, and rebar spacing to be furnished by District Bridge Office.



ROCK SLOPE PROTECTION




1. Excavate as required to set dowels andforms.

2. Remove all fractured or deterioratedconcrete to sound concrete by chipping , andblast to remove laitances.

3. Drill and set form anchor bolts and dowels.Dowels are to be placed a minimum of 9 in.Into sound concrete and set with non-shrinkgrout or approved adhesive, 18 in. on center,front and back.

4. Cross-lace reinforcing bars as shown and setforms.

5. Just prior to placing concrete, apply epoxybonding agent to all existing concrete that isto come into contact with new concrete.

6. Cure concrete until concrete has developedsufficient strength to resist the imposedlateral pressures before backfilling withgranular material.

7. Backfill and provide erosion protection asnecessary.




PROCEDURE: REPAIR BROKEN OR DETERIORATED CONCRETE WINGWALLS




1 Foreman 1 Concrete Mixer 1 C.Y. Concrete Mixer2 Crew Members 1 Gradall or As Required Reinforcing Steel1 Special Crew member Backhoe

(Operator)








PROCEDURE: REPAIR BROKEN OR DETERIORATED CONCRETE WINGWALLS




1. Excavate and remove all unsuitable materialbelow the face of wingwall to be retained orstabilized.

2. As required, replace unsuitable material withacceptable granular material and thoroughlycompact the entire foundation to a firm,even surface.



5. Fill Type A gabions by hand, and Type Bgabions by hand or small power equipment,with specified aggregate.


7. Place specified large rock buttress at a one-to-one slope.

NOTE: Comply with all applicable permitand procedural requirements of theDepartment of Environmental Resources,Pennsylvania Fish Commission and localConservation districts in accomplishing thisprocedure.




PROCEDURE: STABILIZE EXISTING WINGWALLS WITH GABIONS OR PRECAST

CONCRETE BLOCK




1 Foreman 1 Gradall or 1 C.Y. Stone for gabions

2 Crew Members backhoe As Required Gabion basket

1 Special Crew member 1 Concrete Mixer and ties

(Operator) As Required Geotextile fabric

(for granular bed)

As Required Aggregate for base





OR PRECASTCONCRETE BLOCK



REFERENCES




1003 - Dowel Holes




WORK AREA

All portions of all types of concrete or masonrypiers. Work on timber piles or bents is not includedwithin this work area and should be reported toActivity B744601, Other Timber Members (Re-pair/Replace).



Repairing all or portions of concrete or masonrypiers. The work can include, but is not limited to,installing sheeting when necessary and excavatingmaterial temporarily modifying superstructures toaccept jacking loads, providing temporary supportsfor jacking; removing loads from piers either byjacking from below or using needle beams fromabove; removing dowels; installing reinforcingsteel; constructing forms; placing concrete;replacing and pointing masonry elements; pressuregrouting masonry; epoxy pressure grouting; andreplacing excavated material.

When only the bridge pedestals/seats areinvolved, the work should not be reported underthis activity, but should be reported under ActivityD744503, Bearing Pedestal/Seat (Reconstruct).When protective material such as riprap isexcavated to gain access to the work, it should bereplaced in conformance with work descriptions inappropriate activities, the work should be reportedunder this activity.


1. Saw cut the boundaries of the deterioratedconcrete to be removed to a depth of 3/4".

2. Remove deteriorated concrete by chippingwith light power tools.

3. Blast clean exposed reinforcing bars of allrust and foreign materials. Replacedeteriorated bar sections as necessary.

4. Place reinforcing mesh as necessary.

5. Blast clean the existing concrete to bepatched to remove loose concrete chips andlaitances.

6. Place forms, coat existing concrete surfacedwith epoxy bonding agent, and placeconcrete.

7. Remove forms and finish surfaces afterconcrete has cured.



ACTIVITY TITLE: PIERS (REPAIR)








1 Foreman 1 Concrete Mixer 1 Concrete3 Crew Members 1 Welding Equip As Required Reinforcing Steel1 Special Crew member 1 Scaffolding or

(Certified Welder) lifting equip






1. Remove deteriorated concrete from existingpiles.

2. Clean existing reinforcing steel and replaceany steel as required.

3. Install new mesh reinforcing cage aroundpile. Use spacers to keep the form in theproper position.

4. Place forming jacket around pile and seal thebottom of form against pile surface.

5. Pump concrete into the form through theopening at the top. Finish the concrete atthe top of the form.





PROCEDURE: REPAIR DETERIORATED CONCRETE PILE




1 Foreman 1 Concrete Mixer 1 C.Y. Concrete2 Crew Members welding As Required Reinforcing Steel1 Special Crew member 1 Equipment and steel mesh

(Certified Welder) 1 Access Equip 1 Each Forming jacket






1. Clean crack of all loose concrete andlaitances.

2. Seal crack with epoxy grout.

3. Drill holes perpendicular to the crack place.

4. Inject epoxy grout into the drill holes underlow pressure.

5. Place the rebars into the drill holes.

6. Clean any excess grout.





PROCEDURE: EPOXY GROUTED REINFORCEMENT FOR REPAIR OF CRACKED HAMMER

HEAD PIERS




1 Foreman 1 Injection equip As Required Epoxy Grout3 Crew Members 1 Concrete Drill As Required No. 4 Reinforcing

As Required Access Equip Steel






1. Erect all intermediate supports andanchorage assembly at one end of pier cap.Locate existing stirrups and horizontal steelin pier cap prior to installing expansion boltsfor the supports.

2. Insert corrugated pipes with pre-groutedthread-bars inside to the intermediatesupports or the pier cap.

3. Erect the smooth PVC pipes with threadbarsinside to the intermediate supports or thepier cap.

4. Erect anchorage assembly at other end ofpier cap.

5. Add anchor plates with steel tubes to bothassemblies, pack tubes with plastic corrosioninhibitor and add anchor units on both ends.

6. Initially post-tension all threadbars to 10kips in order to seat the post-tensioningsystem on the pier cap.

7. Epoxy inject all cracks in the pier cap.

8. After the injected epoxy has hardened, post-tension the system to the required load perbar.

9. Install sealing caps with plastic corrosioninhibitor and plastic nuts.




PROCEDURE: POST TENSIONING OF CRACKED HAMMER HEAD PIERS




1 Foreman 1 Jack C.Y. Epoxy Grout3 Crew Members 1 Epoxy Injecting As Required Post-Tensioning

Equip Bars as FittingsAs Required Access Equip





REFERENCES




1003 - Dowel Holes


Based on need as indicated by bridge inspectionsor special inspections conducted because of rapidrun-off resulting from unusually high water.

WORK AREA

All footings on all substructures units;abutments, wingwalls, piers, and sufficient areaadjacent to them to allow for any necessaryexcavation and the placing of water controldevices.


Underpinning concrete or masonry footing withconcrete or pumped grout. The work can include,but its not limited to, excavating material;installing sheeting or other water control devicessuch as bagged concrete riprap or nylon tubesfilled with pumped grout; erecting temporarysupports to permit the removal of unsatisfactorymaterial; constructing forms; drilling and groutingdowels; placing reinforcing steel; placing concreteor pumping grout; and replacing excavatedmaterial. When protective material such as riprapis excavated to gain access to the work area, itshould be replaced in conformance with workdescription in appropriate activities, such asActivity B745301, Rock protection. However, aseparate report is not required, and the workshould be reported under this activity.


1. Construct sandbag cofferdam to an elevationabove the water level or divert stream usingtemporary pipes.

2. Clean all exposed concrete of marine growthand remove loose or deteriorated concrete.

3. Excavate as required to sound material.

4. Drill required dowel holes, set and installdowels, set additional reinforcing, and placeforms.

5. Place form work 6” higher than the bottomof the foundation to ensure the cementconcrete fills the scour area and supports thefoundations properly.

6. Remove forms and protect against continuedstream bed erosion with gabions or stoneriprap.



ACTIVITY TITLE: FOOTING (UNDERPIN)








1 Foreman 1 Concrete Mixer 1 C.Y. Concrete3 Crew Members 1 Gradall or1 Special Crew Member backhoe

(Operator)





Underpinning

PennDOT District 5-0Monroe CountyS.R. 3018 over Kettle CreekSingle span reinforced concrete slab bridge withundermining at far abutment

UnderpinningDesign: In-House by District personnelConstruction: Monroe County Bridge CrewDuration of Construction: 1 weeksMaintenance and Protection of Traffic: RoadClosureCost: $29,585

Equipment List:• Concrete Forms• Excavator• Pumps/E&S Control Measures

Material List:• HDPE Pipes• Steel Reinforcement/Dowels• Cement Concrete



Underpinning

Diversion of stream flow utilized through HDPE Pipes. Installation of other E&S Control measures.

Installation of steel dowels, Concrete Forms, and Placement of new Concrete.

Lessons Learned:1) Dewatering was biggest challenge.2) Scour problem was larger than anticipated.

Be prepared to make field adjustments.




1. Clean all exposed concrete of marine growthand remove loose or deteriorated concrete.

2.. Excavate as required to sound material.

3. Place concrete riprap bags around scourarea. Where the scoured-out material is fine-grained, a filter should be placed prior toplacing the riprap.

4.. Pump or tremie concrete into damaged area.

5. Protect against continued stream bed erosionas required by rebuilding stream bed withproperly designed riprap or by paving thestream bed.



ACTIVITY TITLE: FOOTING (UNDERPIN)


PROCEDURE: UNDERPIN USING TREMIE CONCRETE




1 Foreman 1 Concrete Mixer 1 Concrete2 Crew Members 1 Gradall or1 Special Crew Member backhoe

(Operator)





REFERENCES


Section1017 -Pressure Mortar Pointing andSurfacing


Based on need as indicated by bridgeinspections. Work should not be scheduled whenthere is any possibility of freezing temperatures.

WORK AREA

All masonry substructure units; abutments,wingwalls and piers, and sufficient area adjacent tothem to allow for any necessary excavation and theplacing of water control devices.


Pointing and repointing masonry elements issubstructure units with mortar. The work caninclude, but is not limited to, excavating materials;installing sheeting or other water control devicessuch as bagged concrete riprap; removal ofdeteriorated concrete with hand or power tools;cleaning surfaces to be mortared with highpressure water, air-blasting or sand-blasting, asappropriate and necessary; mixing mortar andmortaring prepared joints.

When protective material such as riprap isexcavated to gain access to the work, it should bereplaced in conformance with work descriptions inappropriate activities, such as Activity B745301,Rock Protection. However, a separate report is notrequired, and the work should be reported underthis activity.


1. Thoroughly clean masonry joints of all looseand unsound mortar and foreign material.

2. Saturate the joint surfaces with clean waterbefore applying mortar.

3. Fill all the voids with mortar, making thesurface flush with the adjacent face of thestructure.

4.. Cure all new mortar with wet burlap or clearcuring compound.

5. Clean the face of the masonry.

SAP ASSEMBLY NUMBER: 711-7448-04 BMS2 Flex-Action: F744804

ACTIVITY TITLE: MASONRY (REPOINT)

UNIT OF MEASUREMENT: CUBIC YARDS OF MASONRY







1 Foreman 1 Pressure Grouting As Required Mortar3 Crew Members Equip


CU/HR CU/DAY CU/CY



REFERENCES


Section673 -Precast Cement Concrete BlockSlopewall, Cast-in-Place CementConcrete Slab Slopewall

674 -Stone Slopewalls

675 -Random Stone Slopewall

1001 -Cement Concrete Structures


Based on need as indicated by bridgeinspections. If the bridge is a water crossing, thework can usually be done most conveniently duringthe middle to late summer season when waterlevels are normally low.

WORK AREA

The entire area of existing slopewalls andsufficient additional area to permit any necessaryexcavation and installation of cutoff or toe walls.

*Special Measurement Note: Square yards ofslopewall surface repaired or replaced, notremoved.


Repairing or replacing portions of an existingslopewall, composed of the same materials. Thework can include, but is not limited to, installingsheeting or other water control devices; excavatingmaterial; removing deteriorated or damagedconcrete masonry units; constructing forms;grading surfaces and install-ing aggregate and/orgeotextiles; placing reinforcing steel; placingconcrete; laying concrete blocks or stones; andmortaring joints. If an entire slopewall is removedand replaced with a slopewall composed of adifferent material, all work should be reportedunder Activity A745102, Abutment Slopewall

(Construct New).


1. Excavate for a new end wall around toe ofslope to extend to below scour line or tosolid rock.

2. Set up forms for end wall and placeconcrete.

3.. Fill voids in existing sound slope protectionby removing sections of protection and fillingvoids with crushed store.

4. Grade and place bedding for slope wallextension.

5. Replace damaged sections, sections removedto fill voids with concrete, and placeextension.

6. Fill voids in embankment and protect slopesadjacent to stone protection with large stoneriprap.


ACTIVITY TITLE: ABUTMENT SLOPEWALL (REPAIR/REPLACE)

UNIT OF MEASUREMENT: *SQUARE YARDS OF ABUTMENTS SLOPEWALL







1 Foreman 1 Gradall or .012 CY Concrete and/or2 Crew Members backhoe concrete blocks1 Special Crew Member 1 Air compressor As Required Joint sealing

(Operator) and Jack materialHammer As Required Sand and fine

1 Concrete Mixer aggregate` As Required Large aggregate

stone for riprapAs Required Reinforcing Steel

1SY Geotextiles





PROFILE

SECTION B-B



REFERENCES


Section673 - Precast Cement Concrete BlockSlopewall, Cast-in-Place CementConcrete Slab Slopewall

674 -Stone Slopewalls

675 - Random Stone Slopewall

1001 -Cement Concrete Structures


Based on need as indicated by bridgeinspections. If the bridge is a water crossing, thework can usually be done most conveniently duringthe middle to late summer season when waterlevels are normally low.

WORK AREA

The filled area in front of a stub or semi-stubabutment extending from a line drawnperpendicular to the centerline of the bridge fromthe end of one wing to a similar line drawn fromthe other wing between the abutment structure atthe top and the stream bed or shoulder dependingupon whether the structure is a water crossing oran overpass at the bottom (see sketch).


Constructing new precast cement concrete block,cast-in-place cement concrete slab, stone orrandom stone abutment slope walls within the workarea. The work can include, but is not limited to,installing sheeting or other water control devices;excavating material; removing deteriorated ordamaged concrete masonry units; constructingforms; grading surfaces and installing aggregateand/or geotextiles; placing reinforcing steel;placing concrete; laying concrete blocks or stones;and mortaring joints.

Similar work on the bridge approaches back ofthe described work area should not be reportedunder this activity, but should be reported toappropriate highway maintenance activities.


1. Remove existing deteriorated abutmentslopewall.

2.. Regrade slope and place sand andgeotextiles as required for precast cementconcrete blocks or stone.

3. Place forms and concrete, precast concreteblocks, or stones.

4.. Construct cut-off and toe walls.

5. Seal joints as required.


ACTIVITY TITLE: ABUTMENT SLOPEWALL (CONSTRUCT NEW)

UNIT OF MEASUREMENT: *SQUARE YARDS OF ABUTMENTS SLOPEWALL







1 Foreman 1 Gradall or 1 CY Concrete2 Crew Members backhoe As Required Concrete blocks1 Special Crew Member 1 Concrete Mixer As Required Reinforcing Steel

(Operator) 1 Jack Hammer As Required GeotextilesAs Required Aggregate


4 SY/HR 25 SY/DAY 1 MH/SY



REFERENCES


Section 1060 – Painting Structural Steel

1105 – Fabricated Structural Steel


The following conditions of MSE walls shoulddetermine the priority in scheduling work: a) MSEwall slightly bulging or in distress, b) Anticipatedhigher probability of water accumulation behind theMSE wall

WORK AREA

Drill weep holes in existing MSE walls, except incases where bridge and approaches (for at least500 feet at each end) are entirely in fill sections.Where MSE wall slightly bulging or in distress andor anticipated higher probability of wateraccumulation behind the MSE wall.


Locate anchors/inserts to avoid drilling intothem. Drill weep holes spaced 5 to 10 feet apart indistressed areas. Install casing and secure it.


1) Drill weep holes in existing MSE walls, exceptin cases where bridge and approaches (for atleast 500 feet) are entirely in fill condition,as follows:

a) Location of horizontal and verticalreinforcements on each panel.

b) Location of anchorages or connector insertson each panel. VSL walls have two sets wiremesh connector inserts on each panel.Reinforced Earth RE walls could have two toten tie strips per panel, depending on panelsize.

c) Weep holes (2” diameter minimum or 4”diameter maximum) are to be installed at 5’to 10’ horizontal intervals and in areas ofobvious distress, bulge and water stains inthe existing MSE wall panels 1’-0 minimumabove the finished ground line. Wider weep

hole spacing may be used if deemedappropriate. Note that the closer spacing isprescribed due the presence of 15% fine(passing the No. 200 sieve) aggregates

d) Holes may be drilled through the panel joint.The joint at the selected drilling locationshould first be filled with a fast-settingcement patching material (such as set-45).Then carbide-faced drill bit can be used tomake weep hole.

e) For holes not in joints, use a pachometer toverify and locate the steel bars andanchor/connector inserts in the panel. Thedrilled hole should be a minimum of 2” awayfrom any horizontal or vertical reinforcingbars and 6” away from anyanchorage/connector location.

2) Drill through the panels with a heavy dutyelectrically operated rotary/impact drill, suchas TE-72 Hilti drill set in the rotary andimpact mode. Use a 3” carbide tipped bit (for2” well casing) or a 5” carbide bit (for a 4”well casing). In a 7” to 8” thick wall panel,the desired hole will have to be drilledincrementally, using a 1/2 “ cold chisel tochip away the complete portion of thedesired hole.

3) Upon completion of the desired hole, use a19” and/or 27” hilti flat chisel, with drill inimpact mode to loosen structure backfill todesired depth. Clean out loose material asnecessary with a clean-out hole fabricated tofit into hole. Collect backfill samples andplace in waterproof containers for laboratorytesting, as required.

4) View inside cavity and measure for requiredlength of wall casing so it is flush with panelface. Drill a near vertical hole in the panel forplacement of a nail to secure casing in theflush position with the wall panel. Wrap andtape a piece of geotextile to the deep end ofthe well casing, Insert the well casing andplace plastic nail through the drilled hole inwell casing matching the hole in the panel.Caulk annular space between well casing andthe drilled hole in panel.

SAP ASSEMBLY NUMBER: 711-7332-01 BMS2 Flex-Action: RTWALLR

ACTIVITY TITLE: INSTALL WEEP HOLES IN EXISTING MSE WALLS

UNIT OF MEASUREMENT: EACH WEEP HOLE

PROCEDURE: DRILL WEEP HOLES IN EXISTING MSE WALLS



Equipment Needed Hand Tools and Accessories

1- Hilti TE-72 Electrically operated Drill or equivalent Plastic electricians tape

1- Hilti 3" (F-BK 318-12) or (G-BK 5-17) carbidetipped single piece core bit Geotextile

1- 19" flat chisel - Hilti 2 lb Hammer

1- 27" flat chisel - Hilti 1/2" cold chisel for chipping out cored wall sectionsof panel (2" at a time)

1- 1/4" or 3/8" carbide tipped bit Hilti Duct tape

1- Generator with extension cords as required Cut steel nails or round grooved masonry nails

1- Power drill for 1/4" bit (hammer type) Caullking gun w/ caulk cartridges

1- Pachometer for locating steel in the panels Ball of heavy duty twine or rope

5 foot lengths on 2" or 4" well casing with 0.02 slits(Acker drill Co.) plastic bucket, for lowering supplies

1- Clean-out rod (Hoe) for removing loosened wallbackfill

plastic pint containers and lids for samples or heavyduty plastic bags

Tape measure or ruler

Flashlight or trouble light

Crayon makers


Culverts: Chapter 24 24-1

Chapter 24: Culverts

Table of Contents

7452-01 HEADWALL/WINGS (REPAIR/REPLACE) .........................................................24 - 3

7452-01 APRON/CUTOFF WALL (REPAIR/REPLACE) .....................................................24 - 6

7452-01 BARREL (REPAIR) ...........................................................................................24 - 8


24-2 Culverts: Chapter 24




REFERENCES




1003 - Dowel Holes



WORK AREA

The full length and depth of masonry andconcrete headwalls and wingwalls of culvertsidentified by the Department as having theminimum dimensions to qualify as beingconsidered a bridge as per the Bridge ManagementSystem. These are identified as having the last twodigits of 31 or 32 in the structure type code(6A29).

* Work Measurement Note: Square yards ofeither the front face or back face repaired orreplaced, or both in those cases where a singlereplacement or repair involves both faces.


Repairing or replacing all or portions of concreteor masonry headwalls or wingwalls. The work caninclude, but is not limited to , installing sheeting,when necessary, and excavating material retainedby or protecting the headwall or wingwall,removing deteriorated or damaged concrete,reinforcing steel; constructing forms, placingconcrete, replacing and pointing masonryelements, pressure grouting masonry, epoxypressure grouting, and replacing excavatedmaterial.

When roadway embankment or protectivematerial such as riprap is excavated to gain accessto the work, it should be replaced in conformancewith standard highway maintenance procedures orwith work descriptions in appropriate activities,such as Activity B745301, Rock Protection, as

applicable. However, separate reports are notrequired, and all the work should be reportedunder this activity.


1. Install siltation devices.

2. Excavate as required to set dowels andforms.

3. Remove all fractured or deterioratedconcrete to sound concrete by chipping, andblast clean to remove laitances.

4. Drill and set form anchor bolts and dowels.Dowels are to be placed a minimum of 9inches. Into sound concrete and set withnon-shrink grout, or approved adhesive, 18 in. on center, front and back.

5. Cross-lace bars and set forms.

6. Just prior to placing concrete, apply epoxybonding agent to all existing concrete that isto come into contact with new concrete.

7. Cure concrete until concrete has developedsufficient strength to resist the imposedlateral pressures before backfilling withgranular material.

8. Remove siltation devices.



ACTIVITY TITLE: CULVERT HEADWALL/WINGS (REPAIR/REPLACE)

UNIT OF MEASUREMENT: *SQUARE YARDS OF CULVERT HEADWALLS OR WINGWALLS

PROCEDURE: REPAIR






1 Foreman 1 Concrete Mixer As Required Concrete Mix3 Crew Members 1 Gradall or Backhoe As Required Reinforcing Steel1 1 Special Crew Member As Required Formwork

(Operator) As Required Siltation Devices







2. Install sluices or other water diversiondevices.

3. Remove existing wingwalls and/or headwalland excavate to sound material.

4. Clean all concrete that will be in contact withnew concrete. Chip and blast-clean existingconcrete to remove any unsound materialand laitance.

5. Drill holes and set dowels with non-shrinkgrout or approved adhesive.

6. Prior to placing concrete, provide foradequately reinforced weep holes.

7. Set forms and reinforcing steel and placeconcrete. Just prior to placing concrete,apply epoxy bonding compound to allexisting cleaned concrete that is to come incontact with fresh new concrete.

8. Backfill adequately cured concrete,wingwalls. Suitable filter shall be providedfor weep holes.

9. Provide scour protection for wings.

10.Remove siltation devices.

11.Remove sluices or other water diversiondevices.



ACTIVITY TITLE: CULVERT HEADWALL/WINGS (REPAIR/REPLACE)

UNIT OF MEASUREMENT: *SQUARE YARDS OF CULVERT HEADWALLS OR WINGWALLS

PROCEDURE: REPLACE




1 Foreman 1 Concrete Mixer As Required Concrete Mix3 Crew Members 1 Gradall or Backhoe As Required Reinforcing Steel1 1 Special Crew Member As Required Riprap

(Operator) As Required Siltation Devices





REFERENCES




1003 - Dowel Holes


Based on need as indicated by bridgeinspections. Work can be most efficientlyperformed during periods of low water which aremost likely to occur during late summer or earlyfall.

WORK AREA

The entire width and length of existing masonryand concrete aprons and cutoff walls of culvertsidentified by the Department as having theminimum dimensions to qualify as beingconsidered a bridge identified in the BridgeManagement System. These are identified ashaving the last two digits of 31 or 32 in thestructure type code, (6A29).

* Special Measurement Note: Square yardsmeasured horizontally for aprons and vertically forcutoff walls.


Repairing and replacing all or portions of existingculvert cement concrete or masonry aprons andcutoff walls. The work can include, but is notlimited to, constructing sluices or providing othermeans to conduct water through the structure andto protect the work and freshly placed concretefrom flowing water; driving sheeting; removingdeteriorated masonry units, mortar concrete, andreinforcing steel; excavating material to therequired dimensions; placing and compactingsuitable base material; drilling and install-ingdowels; constructing forms; placing and tyingreinforcing steel; placing concrete; placing and

pointing masonry units; and backfilling.



2. Construct sluices or other devices to divertstream.

3. Remove deteriorated masonry.

4. Excavate unsuitable material.

5. Place and compact base material.


7. Construct formwork.

8. Place reinforcing steel.

9. Place concrete. Just prior to placingconcrete, apply epoxy bonding agent to allexisting concrete that is come into contactwith new concrete.

10.Remove formwork.

11.Remove sluices and siltation devices.

12.Grade Streambed.



ACTIVITY TITLE: CULVERT APRON/CUTOFF WALL (REPAIR/REPLACE)

UNIT OF MEASUREMENT: *SQUARE YARDS OF APRON CUTOFF WALL

PROCEDURE: GENERAL REPLACEMENT






1 Foreman 1 Backhoe As Required Concrete 3 Crew Members 1 Drill As Required Reinforcing Steel1 Special Crew Member As Required Epoxy

(Operator) As Required DowelsAs Required Base MaterialAs Required BackfillAs Required Sluice MaterialAs Required Siltation Devices





REFERENCES




1003 - Dowel Holes



Based on need as indicated by bridgeinspections. Work can be most efficientlyperformed during periods of low water which aremost likely to occur during late summer or earlyfall.

WORK AREA

The full length and width of masonry andconcrete culvert barrels of culverts identified by theDepartment as having the minimum dimensions toqualify as being considered a bridge identified inthe Bridge Management System. These areidentified as having the last two digit of 31 or 32 inthe structure type code, (6A29). In addition anyarea required to install flow control devices whichare needed to facilitate the work.

* Work Measurement Note: Square yards ofeither the inside face or outside face repaired, orboth in those cases where a single repair involvesboth faces.


Repairing all or portions of concrete or masonryculvert barrel. The work can include, but is notlimited to, constructing sluices or providing othermeans to control water flow through the culvert sothe work can be accomplished; driving sheeting;excavating material; removing deterioratedconcrete, reinforcing steel or masonry; epoxypressure grouting; and replacing excavatedmaterial.

When roadway embankment or pavement isexcavated to gain access to the work, it should bereplaced in conformance with standard highwaymaintenance procedures. Separate reports are notrequired, however, and all work should be reportedunder this activity.



2. Construct sluices or other devices to divertstream.

3. Remove deteriorated masonry.


5. Construct formwork.

6. Place reinforcing steel.

7. Place concrete. Just prior to placingconcrete, apply epoxy bonding agent to allexisting concrete that is to come in contactwith new concrete.

8. Replace, repair and point masonry elements.

9. Pressure inject any cracks with epoxycement.

10.Remove sluices.


12.Backfill, if necessary.



ACTIVITY TITLE: CULVERT BARREL (REPAIR)

UNIT OF MEASUREMENT: *SQUARE YARDS OF CULVERT BARREL







1 Foreman 1 Backhoe As Required Concrete 3 Crew Members 1 Drill As Required Reinforcing Steel1 Special Crew Member 1 Pressure Injection As Required Epoxy Cement

(Operator) Equip As Required DowelsAs Required BackfillAs Required Sluice MaterialAs Required Siltation DevicesAs Required Grout




Erosion Control: Chapter 25 251

Chapter 25: Erosion Control

Table of Contents

7453-01 STREAMBED PAVING (REPAIR/CONSTRUCT)...................................................25 - 3

7453-01 PAVING METAL BOTTOM PIPES, ARCHES,

AND CULVERTS ...............................................................................................25 - 5

7453-01 ROCK PROTECTION - DUMPED RIP RAP...........................................................25 - 7

7453-01 ROCK PROTECTION - GABION BASKETS ..........................................................25 - 9

7453-01 STREAM DEFLECTOR (REPAIR/CONSTRUCT) .................................................25 - 10

7453-02 SCOUR HOLE (BACKFILL) ..............................................................................25 - 12

7453-03 VEGETATION/DEBRIS (REMOVE) ..................................................................25 - 14

7453-03 DEPOSITION (REMOVE) ................................................................................25 - 16


25-2 Erosion Control: Chapter 25



Erosion Control: Chapter 25 25-3

REFERENCES


Section667 -Cement Concrete Paving forStreambed

1003 -Dowel Holes BD 632M (For fish passage baffles)

SCHEDULING CONSIDERATIONSBased on need as indicated by bridge inspections

and/or changes in stream flow or conditions thatincrease the potential for scour problems. Work canbe most efficiently performed during periods of lowwater, which are likely to occur during latersummer and early fall. Be aware of any seasonalenvironmental restrictions.

WORK AREAThe entire width and breath of existing paved

streambed areas or areas indicated on plans fornew streambed paving, plus sufficient additionalspace to allow for required excavation and for theconstruction of sluices or other means to conductwater through the structure during the pavingoperation.

* SPECIAL MEASUREMENT NOTE: Cubic yardsof concrete placed (not removed or repaired).

ACTIVITY DESCRIPTIONRepairing existing areas of cement concrete

streambed paving or constructing new cementconcrete streambed paving in accordance withplans prepared for the work. The work can include,but is not limited to, constructing sluices orinstalling sheeting or providing other means toconduct water through the structure and to protectthe work area and freshly placed concrete fromflowing water; removing deteriorated concrete,reinforcing steel and unsuitable material below thebottom of the paving; excavating material to therequired dimensions to depress the culvert floor 1foot below stream bed; placing and compactingsuitable base material; drilling and groutingdowels; constructing forms; placing and tyingreinforcing steel; placing concrete and concrete fishpassage baffles; saw cutting concrete; and placingpreformed joint filler.



1. Obtain necessary permits / clearances fromenvironmental agencies

2. Divert upstream flow with a sump or damand pump water via conduit to the other sideof the culvert. This dewatering scheme willbe part of the overall E & S approval. Referto PUB 464.

3. Clean out debris and silt as required.

4. Construct reinforced paving to a depth of12", as needed, and place riprap at theoutlet end as needed. Do not finish offconcrete, leave the surface rough to allowturbulent flows and depositions.

5. Allow concrete to harden (enough to walkon), install concrete fish passage baffles inaccordance with BD-632M or as perPFBC/DEP direction, flush concrete withstream water and pump upland until pH levelis below 9. Measure pH with a calibratedmeter and not pH paper. Upland dischargewill preclude any reentry of water into thestream and any erosion effects.

6. Remove sump or dams and restore streamflow. Seed and mulch as required following,approved E & S Controls.


ACTIVITY TITLE: STREAMBED PAVING (REPAIR/CONSTRUCT)

UNIT OF MEASUREMENT: *CUBIC YARDS OF CONCRETE STREAMBED PAVING







1 Foreman 1 Excavation Equip 1 CY Concrete3 Crew Members 1 Drill As Required Siltation Devices1 Special Crew Member Concrete Saw As Required Backfill

(Operator) As Required DowelsAs Required Reinforcing SteelAs Required Joint Filler

Material


1 CY/HR 6 CY/DAY 5 MH/CY



REFERENCES


Section667 -Cement Concrete Paving forStreambeds

1003 - Dowel Holes

BD 632M


Based on need as indicated by bridge inspectionsand/or changes in stream flow or conditions thatincrease the potential for scour problems. Work canbe most efficiently performed during periods of lowwater, which are likely to occur during latersummer and early fall. Be aware of any seasonalenvironmental restrictions.

WORK AREA

The entire width and breath of existing pavedstreambed areas or areas indicated on plans fornew streambed paving, plus sufficient additionalspace to allow for required excavation and for theconstruction of sluices or other means to conductwater through the structure during the pavingoperation.

* SPECIAL MEASUREMENT NOTE: Cubic yardsof concrete placed (not removed or repaired).


Repairing existing areas of cement concretestreambed paving or constructing new cementconcrete streambed paving in accordance withplans prepared for the work. The work can include,but is not limited to, constructing sluices orinstalling sheeting or providing other means toconduct water through the structure and to protectthe work area and freshly placed concrete fromflowing water; removing deteriorated concrete,reinforcing steel and unsuitable material below thebottom of the paving; excavating material to therequired dimensions; to depress the culvert floor 1foot below streambed; placing and compactingsuitable base material; drilling and groutingdowels; constructing forms; placing and tyingreinforcing steel; placing concrete; concrete fishpassage baffles; saw cutting concrete; and placing

preformed joint filler.



1. Obtain necessary permits / clearances fromenvironmental agencies

2. Divert upstream flow with a sump or damand pump water via conduit to the other sideof the culvert. This dewatering scheme willbe part of the overall E & S approval. Referto PUB 464.

3. Clean out debris and silt as required.

4. Construct reinforced paving to a depth of 6"to 8", as needed, and place riprap at theoutlet end as needed. Do not finish offconcrete, leave the surface rough to allowturbulent flows and depositions.

5. Install concrete fish passage baffles inaccordance with BD-632M or as perPFBC/DEP direction.

6. Allow concrete to harden (enough to walkon), flush concrete with stream water andpump upland until pH level is below 9.Measure pH with a calibrated meter and notpH paper. Upland discharge will preclude anyreentry of water into the stream and anyerosion effects.

7. Remove sump or dams and restore streamflow. Seed and mulch as required, followingapproved E & S Controls.


ACTIVITY TITLE: PAVING METAL BOTTOM PIPES, ARCHES, AND CULVERTS

UNIT OF MEASUREMENT: *CUBIC YARDS OF CONCRETE PAVING







1 Foreman 1 Excavation Equip 1 CY Concrete3 Crew Members 1 Drill As Required Siltation Devices1 Special Crew Member 1 Concrete Saw As Required Backfill

(Operator) As Required DowelsAs Required Reinforcing SteelAs Required Joint Filler

Material





REFERENCES


Section626 - Gabions

674 - Stone Slope Walls

850 - Rock Lining

DM 4 Chapter 7


Based on need as indicated by bridge inspectionsand/or changes in stream flow or conditions thatincrease the potential for scour problems. Be awareof any seasonal environmental restrictions.

WORK AREA

All areas at and adjacent to bridge substructureunits that are subject to scour and require rockprotection.


Restoring existing rock protection by relocatingexisting rock and placing additional rock as re-quired, or placing new rock protection at andadjacent to bridge substructure units. The workcan include, but is not limited to, removingdislocated existing rock; preparing surface byexcavating unsuitable material, backfilling, placingmaterial, and grading surface; placing geotextiles;placing gabion baskets; and placing rock eitherdirectly on geotextiles and prepared; choking thetops of Riprap placed in a streambed withstreambed material.

The minimum size of stone in rock protectionshould be based on a maximum anticipatedvelocity of water per DM 4 Chapter 7 section PP7.2.5.


1. Obtain necessary permits / clearances fromenvironmental agencies.


3. Prepare foundation by removing unsuitablebase material if required.

4. Backfill with suitable base material ifrequired.

5. Place geotextiles if appropriate.

6. Place Riprap of the size specified by dumpingto depth specified.

7. Choke with streambed material if required.



ACTIVITY TITLE: ROCK PROTECTION

UNIT OF MEASUREMENT: *CUBIC YARDS OF ROCK PROTECTION

PROCEDURE: DUMPED RIPRAP






1 Foreman 1 Excavation Equip 1 CY Riprap3 Crew Members1 Special Crew Member 2 Rock Stick

(Operator)








3. Excavate and remove all unsuitable materialbelow the face of the wingwall to be retainedor stabilized.

4. As required, replace unsuitable material withan acceptable granular material andthoroughly compact the entire foundation toa firm, even surface.



7. Fill Type A gabions by hand, or with smallpower equipment, using specified aggregate.


9. Place the specified large rock buttress at aone-to-one slope.



ACTIVITY TITLE: ROCK PROTECTION

UNIT OF MEASUREMENT: *CUBIC YARDS OF ROCK PROTECTION

PROCEDURE: GABION BASKETS




1 Foreman 1 Excavation Equip 1 CY Aggregates or3 Crew Members Large Rocks1 Special Crew Member As Required Siltation Screens

(Operator) As Required BackfillAs Required GabionsAs Required Geotextile

Fabric






ACTIVITY TITLE: STREAM DEFLECTOR (REPAIR/CONSTRUCT)

UNIT OF MEASUREMENT: CUBIC YARDS


REFERENCES


Section206 - Embankment

626 - Gabions

850 - Rock Lining


Based on need as indicated by bridge inspectionsand/or hydraulic evaluations. Work can be mostefficiently performed during periods of low waterwhich are most likely to occur during later summeror early fall. Be aware of any seasonalenvironmental restrictions.

WORK AREA

Areas of stream banks adjacent to bridges atexisting stream deflectors or as shown on the planfor new stream deflectors.


Repairing existing or constructing new streamdeflectors. The work can include, but is not limitedto, removing displaced existing embankmentprotection material; excavating unsuitablematerial; driving sheet piling; and placingembankment protection materials.

When appropriate portions of the work shall beperformed in accordance with other pertinentactivities such as Activity B745301, RockProtection, or Activity ECREMDP, Deposition(remove), but separate activity reports are notrequired and all work should be reported under thisactivity.




3. Remove displaced existing embankmentprotection material and dispose of properly.

4. Excavate unsuitable material and dispose ofproperly.

5. Drive piling as shown on plans.

6. Place and compact suitable material.

7. Place geotechnical fabric.

8. Place embankment protection material.







1 Foreman 1 Excavation Equip 1 CY Embankment Pro-3 Crew Members 1 Pile Driver tection Material2 Special Crew Members 1 Crane As Required Sheeting

(Operators) As Required Geotextile Fabric






ACTIVITY TITLE: SCOUR HOLE

UNIT OF MEASUREMENT: *CUBIC YARDS OF BACKFILL

PROCEDURE: EXCAVATE AND FILL

REFERENCES


Section703 - Aggregates

(PUB 23 and PUB 238)


Based on need as indicated by bridgeinspections. Inspections in addition to regularlyscheduled inspections may be appropriate followingunusually high water, particularly in areas wherescourable material is present and where scourholes previously occurred. Be aware of anyseasonal environmental restrictions.

WORK AREA

All areas of stream beds at and adjacent tosubstructure units where scour holes are presentand cause potential hazard to a bridge.

*SPECIAL MEASUREMENT NOTE: Cubic yardsof material placed, not excavated.


Filling scour holes at and adjacent tosubstructure units with scour resistant material,typically large riprap. The work can include, but isnot limited to, excavation of silt or other highlyscourable material naturally deposited in scourholes.

Allied work such as the removal of debris that isa contributing cause to the formation of a scourhole and the placing of heavy rock around a pier toprevent a scour hole from becoming a hazard to apier should be reported under appropriate activitiessuch as Activity B745301, Rock Protection, and

Activity ECREMVG, Vegeta tion/Debris (Remove).




3. Excavate highly scourable material anddispose of properly.

4. Place scour resistant material, choke withstreambed material if required.







1 Foreman 1 Excavation Equip 1 CY Scour Resistant3 Crew Members 1 Rock Stick Material2 Special Crew Member As Required Siltation Devices

(Operators)


2 CY/HR 12 CY/DAY 2.5 MH/CY



SAP ASSEMBLY NUMBER: 711-7453-03 BMS2 Flex-Action: ECREMVG

ACTIVITY TITLE: VEGETATION/DEBRIS (REMOVE)

UNIT OF MEASUREMENT: CUBIC YARDS OF VEGETATION OR DEBRIS REMOVED


REFERENCES

None


Based on need as indicated by bridge inspectionsor as reported by bridge maintenance personnel.Debris is likely to collect at substructure unitsduring a period of high water to help reduce scourproblems. Be aware of any seasonal environmentalrestrictions.

WORK AREA

Areas around substructure units where debrishas collected, and areas of stream beds and banksadjacent to the structure under State control wherestanding vegetation impedes stream flow or mightbecome dislodged and cause hazardous conditionsin the future.


Removing and disposing of vegetation and debriswhich is growing or has collected in the work area.The work can include, but is not limited to,removing debris collected around substructureunits by manual and/or mechanically assistedmeans; cutting down and removing growingvegetation; loading material in truck; anddisposing of material at an approved dumpinglocation.



2. Remove debris collected aroundsubstructure.

3. Remove vegetation from stream banks andthe streambed as permitted.

4. Dispose of debris and vegetation properly.






1 Foreman 1 Chain Saw (None)3 Crew Members As Required Bush Ax1 Special Crew Member 1 Excavation Equip

(Operators) 1 Winch or PullingEquip


3.3 CY/HR 20 CY/DAY 1.5 MH/CY



SAP ASSEMBLY NUMBER: 711-7453-03 BMS2 Flex-Action: ECREMDP

ACTIVITY TITLE: DEPOSITION (REMOVE)

UNIT OF MEASUREMENT: CUBIC YARDS OF DEPOSITED MATERIAL REMOVED


REFERENCES

None


Based on need as indicated by bridge inspectionsor as reported by bridge maintenance personnel.Material deposited during periods of high waterespecially if the material is deposited in a mannerthat will change the direction or velocity of the flowincreasing the possibility of scour. Be aware of anyseasonal environmental restrictions.

WORK AREA

Streambeds and banks at and adjacent to bridgesubstructure units where excess material has beendeposited that reduces the hydraulic efficiency ofthe structure.


Excavating and disposing of soil, clay silt, sand,gravel or rock that has been deposited instreambeds and on stream banks at and adjacentto bridge substructure units. The work can include,but is not limited to, excavating depositedmaterial; grading streambeds and banks; loadingmaterial in trucks; and disposing of material atapproved dumping locations.

If the deposition of material has been initiatedbecause of a collection of debris or vegetation, thedebris and vegetation should be removed inaccordance with Activity ECREMVG,Vegetation/Debris (Remove), but separate activityreports are not necessary. All required work is tobe reported under this activity.




3. Excavate deposition as permitted anddispose of properly.

4. Grade streambed and banks, if required.







1 Foreman As req’d Excavation As Required Silt Barrier2 Crew Members Equip2 Special Crew Member

(Operators)


4 CY/HR 24 CY/DAY 1.25 MH/CY


Construct Temporary: Chapter 26 26-1

Chapter 26: Construct Temporary

Table of Contents

7454-01 SUPPORT BENT ...............................................................................................26 - 3

7454-01 PIPES............................................................................................................26 - 11

7454-01 BRIDGE.........................................................................................................26 - 13


26-2 Construct Temporary: Chapter 26




REFERENCES



1005 - Piles

1031 - Timber Structures


Based on need as indicated by evaluations ofbridge inspection reports and other pertinent databy the Review Engineer.

WORK AREA

All areas shown on plans as required forinstallation of temporary support bents, placing ofequipment, access to the work, and portions ofexisting superstructures or substructures at endadjacent to the bents.


Constructing temporary bents to supportsuperstructures or substructures as indicated onthe plans provided by the Department for thework. The work can include, but is not limited to,driving piles; excavating material; installingstructural steel; cutting, drilling and erectingtimber members; and modifying existingsuperstructures or substructures to acceptattachments to the bents or loads imposed bythem.

Work under this activity is intended to tempo-rarily support or strengthen structures to eliminateor raise posting limits, to allow the passage ofoverweight permit vehicles, to protect the bridgeand the public using it pending structurerehabilitation or replacement, or for a similarspecific primary purpose. Work to providetemporary supports or jacking platforms so that amaintenance activity such as Activity D744802,Piers (repair), can be performed should be reportedto that activity and not to this activity.


1. Obtain necessary permits

2. Modify structure to accept new loaddistribution if necessary.

3. Prepare foundation for temporary bent ordrive piles depending on bent type selected.

4. Construct bent.

5. Jack superstructure (depending o type ofsupport being installed).

6. Block and shim as necessary.



ACTIVITY TITLE: CONSTRUCT TEMPORARY SUPPORT BENT








1 Foreman 1 Crane 1 Each Temporary Bent3 Crew Members 1 Pile Driver As Required Blocking1 Special Crew Member with Jack As Required Shims

(Operator)


.03 BEA/HR 30 EA/DAY .6 MH/EA

ALTERNATE NO. 1



ALTERNATE NO. 2



ALTERNATE NO. 3



ALTERNATE NO. 4

ALTERNATE NO. 5



ALTERNATE NO. 6



ALTERNATE NO. 7



ALTERNATE NO. 8

Exising Pier Cap



REFERENCES


Section 601 - Pipe Culverts

603 - Metal Plate Culverts


Based on need as indicated by evaluation ofbridge inspection reports and other pertinent databy the Review Engineer. Pipes can be installedmost conveniently during periods of low waterwhich are likely to occur during later summer andearly fall. Be aware of an seasonal environmentalrestrictions.

WORK AREA

All areas shown on plans as necessary for theinstallation of pipes and the embankments in whichthey are placed.


Placing of temporary pipes in temporaryembankments to divert traffic from an existingstructure (so-called _go-arounds_) or placing oftemporary pipes in an existing embankment todivert water from an existing structure. The workcan include, but is not limited to, excavatingmaterial; placing pipe; bolting structural plate pipesections together; installing bands, or other meansto connect pipe sections; placing and compactingembankment material; placing embankmentprotection material; and installing guide rail.

Any necessary earthwork and other associatedwork should be done in accordance with therequirements of the appropriate highwaymaintenance activities, but should be charged tothis activity. Work under this activity is intended toraise posting limits, to protect a bridge and thepublic using it pending structure rehabilitation orreplacement, or for a similar primary purpose. If amaintenance activity such as Activity E744803,Footing (Underpin), is being performed and a pipeis used to temporarily contain or direct the flow ofwater under the bridge, the work should bereported to that activity rather than to this new one.




3. Construct approach fills.

4. Excavate, if necessary.

5. Prepare the bedding material.

6. Install Pipe.

7. Backfill.

8. Place pavement.

9. Install Guiderail.


ACTIVITY TITLE: CONSTRUCT TEMPORARY PIPES








1 Foreman 1 Excavation Equip As Required Fill Material2 Crew Members Bedding Material2 Special Crew Member Bridge / Pipe

(Operators) 1 Paver Components1 Post Driver As Required Pavements1 Crane As Required Guardrail


.08 BR/HR 5 BR/DAY 60 MH



REFERENCES


Section903 - Temporary Bridge and Approaches

1001- Cement Concrete Structures


Based on need as indicated by evaluation ofbridge inspection reports and other pertinent databy the Review Engineer. Be aware of any seasonalenvironmental restrictions.

WORK AREA

All areas shown on plans as necessary for theerection of a temporary bridge and its approaches.


Constructing temporary bridges and approachesin accordance with plans furnished by theDepartment. The work can include, but is notlimited to, excavating material; driving piles;installing sheeting or other devices to control theflow of water; constructing forms; placingreinforcing steel; placing concrete; cutting, drillingand erecting timber members; erecting structuralsteel members; and placing embankments andperforming associated work. Any necessaryearthwork and other associated work should bedone in accordance with the requirements of theappropriate highway maintenance activities, butshould be charged to this activity.




3. Construct approach fills.

4. Excavate, drive piles, place caps, installbulkheads, set beams, place deck, andattach rails as necessary to constructtemporary bridge.

5. Backfill and finish grading approaches.

6. Place pavement.

7. Install Guiderail


ACTIVITY TITLE: CONSTRUCT TEMPORARY BRIDGE








1 Foreman 1 Concrete Mixer As Required Reinforced Steel3 Crew Members As Required Concrete


2.3 EA/HR 14 EA/DAY 2.2 MH/EA


Miscellaneous Bridge Activities: Chapter 27 27-1

Chapter 27: Miscellaneous Bridge Activities

Table of Contents

7459-01 BRIDGE MAINTENANCE ...........................................................................27 - 3

7459-01 PROTECTIVE COATINGS

DECK/PARAPET/SIDEWALK ....................................................................27 - 4

7459-01 PROTECTIVE COATINGS STRUCTURES .....................................................27 - 6


27-2 Miscellaneous Bridge Activities: Chapter 27




REFERENCES


Section504 Pavement Relief Joint

511 Pressure Relief Joint (4")

1000 Structures

Standards for Roadway Construction (PUB 72)

RC – 24 Pavement Relief Joint

SCHEDULING CONSIDERATIONS:

Based on need as indicated by bridgeinspections. Work is limited to those areas ofbridges and structures classified as non-structuralactivities.

WORK AREA:

Entire Structure including approaches. IncludesPavement Relief Joints, Pressure Relief Joints,Covered Bridge Roof, Covered Bridge Siding andany other non-structural element activity notcovered by a specific activity code.


Repair or replacement of any nonstructuralelement of a bridge or bridge approach. Activitywill vary based on need. Bridge Maintenance, Otheris not a catch-all and is only intended for thosenon-structural activities not covered under anyother specific activity title


Repair or replacement of any nonstructuralelement of a bridge of bridge approach elements asdirected by the County Manager or District BridgeEngineer. All work should be in accordance with(pub. 408).

NOTE: Obtain approval from thePennsylvania State museum commissionprior to beginning work on any coveredbridge and/or Historical Structure. Refer toBMS2 5E04.

SAP ASSEMBLY NUMBER: 711-7459-01 BMS2 Flex-Action: None

ACTIVITY TITLE: BRIDGE MAINTENANCE






1 Foreman As Required To be determined As Required To be determinedAs Required Crew Members based on need based on need


VARIES VARIES VARIES



REFERENCES


Section 503 - Protective Coating for Cement Concrete Pavement

1019 - Protective Coating for Reinforced Concrete Surfaces


Requirement for application determined byDistrict Bridge Engineer based on conditions orcircumstances at specific structures, establishedcycles for reapplication, and/or absorption tests.Temperature and moisture restrictions arerelatively rigid for applying concrete coatingmaterials and work schedules should take theseinto account.

WORK AREA

Bridge deck, parapets and sidewalks, and otherportions of the bridge super structure designatedby the Review Engineer for the application ofprotective coatings. Cleaning, reported underActivity B743101, Clean/Flush Scupper/Down -spouting or C743102, Clean/Flush Bearing/BearingSeat as applicable.


Applying a two-component epoxy-resin systemor other protective coating as approved anddesignate for such use by the Department toelements in the work area. The work can include,but is not limited to, thoroughly cleaning thesurfaces to be coated to eliminate potential bond-inhibiting matter by sweeping, flushing, drying, andetching and/or sand blasting; and applying thecoating by brush, roller or spray.


1. Clean surface to be coated of all grease,laitances, and all foreign material by waterblasting and scrubbing with a stiff bristlebrush. Surfaces judged to be unsound shallbe removed to a depth judged sound bysand blasting and water blasting.

2. Surface shall be completely dry prior tocoating. Temperature shall be above 50OF.

3. Apply coating according to manufacturer’sspecifications.

4. Successive coats shall not be applied untilpreceding coats have become dry to thetouch.


ACTIVITY TITLE: APPLY PROTECTIVE COATING DECK/PARAPETS/SIDEWALKS








1 Foreman 1 Water-Blaster As Required Coating3 Crew Members 1 Sand Blaster

brushes





REFERENCES


Section1019 - Protective Coating for ReinforcedConcrete Surfaces


Requirement for application determined byDistrict Bridge Engineer based on conditions orcircumstances at specific structures. Temperatureand moisture restrictions are relatively rigid forapplying concrete coating materials and workschedules should take these into account.

WORK AREA

Abutments, pier caps, endwalls and otherunsubmerged portions of bridge substructuresdesig-nated by the Review Engineer for theapplication of protective coatings. Cleaning,reported under Activity B743101, Clean/FlushScupper/ Downspouting or C743102, Clean/FlushBearing/ Bearing Seat as applicable.


Applying a two-component epoxy-resin systemor other protective coating as approved anddesignate for such use by the Department tosubstructure elements in the work area. The workcan include, but is not limited to, thoroughlycleaning the surfaces to be coated to eliminatepotential bond-inhibiting matter by sweeping,flushing, drying, and etching and/or sand blasting;and applying the coating by brush, roller or spray.


1. Clean surface to be coated of all grease,laitances, and all foreign material by waterblasting and scrubbing with a stiff bristlebrush. Surfaces judged to be unsound shallbe removed to a depth judged sound bysand blasting and water blasting.

2. Surface shall be completely dry prior tocoating. Temperature shall be above 50OF.

3. Apply coating according to manufacturer'sspecifications.

4. Successive coats shall not be applied untilpreceding coats have become dry to thetouch.


ACTIVITY TITLE: APPLY PROTECTIVE COATING SUBSTRUCTURE








1 Foreman 1 Water-Blaster As Required Coating3 Crew Members 1 Sand-Blaster

2 Brushes


50 SY/HR 300 SY/DAY 08 MH/SY

bridge maintenance manual

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