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3/13/2013
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2013 Conaway Conference‐ Structures
Changes from 2010 to 2013 Construction and Materials Specifications in Structures Items
2013 Conaway Conference‐ Structures
Changes to ODOT concrete design requirements reflect the changes to QC/QA contractor owned and designed mixes.
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2013 Conaway Conference‐ StructuresRequirements from Supplemental Specifications 888 (pavements) and 898 (structural concrete) have been brought into • Items 451, 499, 511 ,etc. • new Item 455‐ Quality Control Plan, • new Supplement 1126 ‐ Developing & Submitting a Concrete Mix Design,
• new Supplement 1127 – Pay Factor Determination for Concrete.
2013 Conaway Conference‐ StructuresQC/QA mix requirements• replace Class C Class S, & Class HP with QC1, QC2, QC3 & QC4,
• and modify the Fast Set (FS) & Medium Set (MS) mixes.
Well graded aggregate proportions • help eliminate shrinkage, cracking
• and lower the required amount of cement materials.
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2013 Conaway Conference‐ Structures• Concrete with QC/QA shall be specified for the class of concrete when the total concrete quantity exceeds 150 cubic yards.
• Class QC3 Special Concrete shall be specified when concrete strengths and/or permeability other than the QC1 or QC2 are necessary.
2013 Conaway Conference‐ Structures• 507 BEARING PILES
– 507.03 Materials. Concrete, Class C has been changed to Concrete, Class QC1.
• 517 RAILINGS – 517.03 Materials: Replaced Concrete, Class S or Class HP, with Concrete,
Class QC 2.
• 519 PATCHING CONCRETE STRUCTURES – 519.02 Materials: Replaced Concrete, Class S, with Concrete, Class QC 2.
• 524 DRILLED SHAFTS – 524.02 Materials: Replaced Concrete, Class S, with Concrete, Class QC 2.
• 526 APPROACH SLABS – 526.02 Materials: Replaced Concrete, Class S, HP 3 or HP 4 with
Concrete, Class QC 2.
• 610 CELLULAR RETAINING WALLS – 610.03 Materials (A): Replaced Concrete, Class C with Concrete,
Class QC 1.
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2013 Conaway Conference‐ Structures511.03 – Concrete
• At least 10 days before placing concrete, submit, the Department accepted Job Mix Formula (JMF) to the Engineer.
• The Engineer will review the mix design.
APPENDIX A PCC JMF SUBMITTAL FORM A Supplier Information Accredited Lab Information
Supplier Name Lab Name Location Representative P/S Code Telephone Representative E‐mail Address Telephone E‐mail Address Submittal Date
Design InformationConcrete Class Strength (f'c) @ Age Material Code Overdesign (f'cr) Alt. Usage Req'd Perm.
Mix DesignAGGREGATES Type Size Source Location PS Code Sp. Gr Abs. Design Wt (SSD) Abs. Agg 1 Agg 2 Agg 3 Agg 4
CEMENTITIOUS MATERIALS Total Aggregate Weight
Type / Grade Source Location PS Code Sp. Gr % Design Wt Abs. Cement Cm 1 Cm 2 Cm 3
DESIGN AIR CONTENT Total Cementitious Material
WATER Source: Gal Lbs.
ADMIXTURES W/Cm Ratio: Design Air Volume Type Brand Name Dosage Rate (oz/cwt) oz /yd3 Volume
AGGREGATE GRADATIONS Total % Passing Agg 1 spec Agg 2 spec Agg 3 spec Agg 4 spec Accum % Pass 1.50 in 1.0 in Total Volume 3/4 in Total Weight 1/2 in Unit Weight 3/8 in # 4 # 8 Workability Factor (%) #16 Coarseness Factor (%) # 30 # 50 # 100 # 200 % of Total
Test ResultsMix Design developed by: Using 3‐Point Single Mix Agg Correction Factor
Cm Content Water W/Cm Ratio Avg Strength Permeability Air Slump Yield Mix 1 Mix 2 Mix 3 RESULTS: Perm: 3 Day 7 Day 28 Day Strength:
Office Use OnlyDate Received
By Accepted JMF # Date Reviewed Rejected
2013 Conaway Conference‐ Structures511.04‐Quality Control RequirementsWhen the concrete bid item requires QC/QA, • develop and submit a Quality Control plan (QCP) for the work
• and perform quality control testing of the concrete conforming to Item 455.
The Engineer will perform Quality Assurance conforming to 455.
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2013 Conaway Conference‐ StructuresMass Concrete Requirements
For concrete components with a minimum dimension of 5‐ft or greater, or for drilled shafts with a dimension of 7‐ft diameter or greater,
develop a concrete mix design QC‐4 for mass concrete according to 499.03.
2013 Conaway Conference‐ StructuresMass Concrete Requirements
Submit a Thermal Control Plan (TCP) along with the approved JMF (s) to the Engineer for acceptance with
• highest maximum internal concrete temperature ≤ 160⁰ F (71⁰ C)
• maximum differential concrete temperature ≤ 36⁰ F (20⁰ C) (not applicable for drilled shafts),
over 28 days from time of placement.
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2013 Conaway Conference‐ StructuresMass Concrete Requirements
• As an alternative, the Contractor may propose maximum differential temperature limits based on strength gain with time.
• TCP for alternative proposal shall include the methods for determining the temperature and supporting data, calculations and design.
2013 Conaway Conference‐ StructuresMass Concrete Requirements• Any in‐place mass concrete that exceeded the temperature limits or cracked, is considered defective.
• Submit a proposed repair plan to the Engineer.
• The Department will determine if the proposed repair methods are acceptable or if removal is required.
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2013 Conaway Conference‐ Structures511.10 Placing Concrete Conform to the following tolerances from plan dimensions:
2012 Conaway Conference 13
Deviation from plumb for exposedsurfaces
± ¾ inch (19 mm)
Vertical alignment (Deviation from aline parallel to the grade line)
± ½ inch in 20 feet (13 mm in 6 m)
Longitudinal alignment (Deviationfrom a line parallel to the centerlineor baseline)
±½ inch in 20 feet (13 mm in 6 m)
Width dimensions of walls forexposed surfaces
±½ inch (13 mm)
Bridge Slab thickness ±¼ inch (6 mm)
Elevations of beam seats ±1/8 inch (3 mm)
Slope, Vertical Deviation from Plane ±0.2%
Slope, Horizontal Deviation fromPlane
±0.4%
2013 Conaway Conference‐ Structures511.08‐Slipform Construction of Bridge Railing
• If the slipforming exhibits defects, stop work and make adjustments to produce a defect free slipformed surface.
• Do not broom finish the surface of the bridge railings.
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2013 Conaway Conference‐ Structures511.14‐ Curing and Loading• Remove falsework and open structures to traffic when concrete has reached strength specified in Table 511.14‐1A for concrete bid items requiring QC/QA.
• Use Table 511.14.1B for concrete items not requiring QC/QA.
• Do not shorten minimum required Method A curing time regardless of strength test results.
2013 Conaway Conference‐ Structures511.14‐ Curing and Loading
TABLE 511.14‐1A LOADING REQUIREMENTS FOR CONCRETE REQUIRING QC/QA
Span[1] Required Strength [2] Removing Falsework
Any Span Compressive Strength ≥ 0.85% f’c orFlexural Strength (Center point)
≥ 650 psi (4.5 Mpa) All pier caps
Traffic [3] Any
[1] Span is defined as the horizontal distance between faces of the supporting elements when measured parallel to the primary reinforcement.
[2] Field cured samples. The maturity curve method may be used for determining the strength according to Supplement 1098 in lieu of field curing samples
[3] When placing concrete for a superstructure between October 15 and March 15, open the deck to traffic no sooner than 30 days after placement.
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2013 Conaway Conference‐ Structures511.14‐ Curing and Loading
TABLE 511.14‐1BLOADING REQUIREMENTS FOR CONCRETE NOT REQUIRING QC/QA
Span[1] Age of Concrete in Days No Beam Beam Test [2]
Removing Falsework
Over 10 feet (3 m) 14 5 10 feet (3 m) or less and all pier caps
7 3
Traffic [3] Any 14 7 [1] Span is defined as the horizontal distance between faces of the supporting
elements when measured parallel to the primary reinforcement. [2] Applicable only when the average modulus of rupture for two tests is not less
than 650 psi (4.5 MPa). [3] When placing concrete for a superstructure between October 15 and March
15, open the deck to traffic no sooner than 30 days after placement.
2013 Conaway Conference‐ Structures511.17‐ Bridge Deck GroovingSaw longitudinal grooves, in a continuous pattern, parallel to the centerline, • after water curing the concrete and • either before or some period after applying curing compound and
• before opening the bridge to traffic.
Reapply the curing compound after removing standing water, • within 12 hours after sawing grooves in the deck,
• if the grooves were sawed after applying the curing compound and
• the concrete deck is less than 30 days old.
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2013 Conaway Conference‐ Structures511.17‐ Bridge Deck Grooving• Do not saw 9 to 12 inches from any devices in a bridge deck, such as scuppers or expansion joints.
• Do not saw a minimum of 2 inches to a maximum of 24 inches from skewed expansion joints.
• Maintain a clearance of 2 inches to 4 inches from the grooves to longitudinal joints in the deck.
2013 Conaway Conference‐ Structures511.17‐ Bridge Deck Grooving• Maintain a clearance of a minimum of 9 inches to a maximum of 30 inches from the grooves to the curbs or parapets.
• No un‐grooved portions of deck beyond edge line and into the temporary or permanent travelled lanes.
• Saw grooves in a uniform pattern spaced at 3/4 inch,
• approximately 0.15 inches deep and • 0.10 inches wide.
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2013 Conaway Conference‐ Structures511.20‐ Compressive StrengthSample and test concrete strength according to 511.04.
Concrete Requiring QC/QA• Evaluate QC compressive test sublotresults per Supplement 1127.
• Reevaluate if compressive strength test result for a sublot of concrete < 88% f’c, by nondestructive testing or cores.
2013 Conaway Conference‐ Structures511.20‐ Compressive StrengthConcrete Requiring QC/QA• If non destructive testing is used, original cylinder results will be used for calculating the compressive strength pay factor (PFc).
• Or core results will be used in place of original cylinder results for pay factor determination.
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2013 Conaway Conference‐ Structures511.20‐ Compressive StrengthConcrete Requiring QC/QAIf core results indicate that the compressive strength is < 88% f’c,
• submit a plan for corrective action to the Engineer.
• If the corrective plan is not approved, the Engineer will require the Contractor to:
2013 Conaway Conference‐ Structures511.20‐ Compressive StrengthConcrete Requiring QC/QA
1. Remove and replace the unacceptable sublot and retest the new sublot at no cost to the Department or
2. Leave the unacceptable material in place and pay for the sublot with a pay factor of 0.75.
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2013 Conaway Conference‐ Structures• 511.20‐ Compressive Strength• Concrete Not Requiring QC/QA• The Engineer evaluates the strength results according to Table 511.22‐2.
• If single compressive strength test result is < f’c, the material will be considered unacceptable material,
• Department will determine acceptance per Item 106.07.
• If three or more compressive strength test results are < f’c , investigate reasons for the low strengths.
2013 Conaway Conference‐ Structures511.21‐ Air ContentConcrete Requiring QC/QA• Test the air content according to Item 455.
• Air results outside the requirements of Table 499‐03‐1 is unacceptable material per Item 106.07, whether the concrete requires QC/QA or not.
• The amount of unacceptable material will be represented by the test result.
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2013 Conaway Conference‐ Structures511.21‐ Air Content
For Air Content outside the requirements of 499.03‐1, • Concrete Requiring QC/QA,
Contractor hires an independent laboratory to perform the testing.
• Concrete Not Requiring QC/QA,the Department will perform the testing.
TABLE 499.03‐1 CONCRETE MIX DESIGN REQUIREMENTS Quantities per Cubic Yard
Provide Concrete with 6±2% Air Content Class Design Strength
psi (MPa) Permeability [1]
Maximum (Coulombs)
Cementitious Content [2]
Minimum. lbs (kg)
Aggregate Requirements
QC 1 4,000 (28.0) at 28 days 2,000 520 (236) Well‐Graded QC 2 4,500 (31.0) at 28 days 1,500 520 (236) Well‐Graded QC 3 Special As per plan
1,500 or as per plan
520 (236) or as per plan Well‐Graded
QC 4 Mass Concrete As per plan [3] 2,000 or as per plan 470 (213) [4] [5]
or as per plan Well‐Graded
QC MS [7] See Supplement 1126 N/A 800 [7] (475) 1 inch nominal maximum size
QC FS [7] See Supplement 1126 N/A 900 [7] (534) 1 inch nominal maximum size
QC Misc [6] 4,000 (28.0) at 28 days 1 inch nominal maximum size
[1] AASHTO T277 Modified [2] Cementitious Content includes cement and pozzolan materials, denoted as Cm [3] Strength for Mass Concrete (QC 4) may be tested at either 28 or 56 days. [4] Do not use Type III cement or accelerating admixtures in mass concrete. [5] The maximum fly ash or GGBF slag content may be increased up to 50%. [6] For QC Misc mixes only –Water/Cementitious ratio limited to 0.50 maximum [7] Cement Only – No pozzolan materials
2013 Conaway Conference‐ Structures511.21‐ Air ContentCore the unacceptable concrete. Patch the core hole with approved material.
• High air content concrete, test core for compressive strength.
• Concrete with a minimum strength of f’cmay be left in place.
• Low air content concrete, test core for the in‐place hardened air content, specific surface and spacing factor according to ASTM C 457.
• Remove and replace unacceptable materials .
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2013 Conaway Conference‐ Structures511.22‐ Pay FactorsConcrete Requiring QC/QA
• Final adjusted price calculated with pay factors based on the percent within limits (PWL).
• PWL established per lot(s) accepted in the QCP for each bid item quantity of concrete.
• PWL calculated per to Supplement 1127 using either the Contractor’s verified QC compressive test results or core results.
PWLI =
QI – QL+ PWLLQH – QL
2013 Conaway Conference‐ Structures511.22‐ Pay FactorsConcrete Requiring QC/QA• Compressive strength pay factor (PFC) from Table 511.22‐1 applied to each bid item represented in the lot.
• Approach slab and deck concrete test results will be will combined in the same lot to determine final pay factors.
TABLE 511.22‐1PAY FACTORS FOR CONCRETE
REQUIRING QC/QAPWL PFC
85 % – 100 % 1.0084% 0.99583% 0.99082% 0.98581% 0.98080% 0.97579% 0.97078% 0.96577% 0.96076% 0.95575% 0.950
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2013 Conaway Conference‐ Structures511.22‐ Pay FactorsConcrete Requiring QC/QAIf PWL value for lot of concrete is
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2013 Conaway Conference‐ Structures501.04‐ Shop DrawingsA. Contractor Acceptance of Shop
Drawings for Items 513 and 515• Two Ohio Registered Engineers seal and sign each drawing.
• ODOT’s Office of Materials Management is not rating shop drawings for Structural Steel (Supplement 1078) and Pre‐stressed Concrete (Supplement 1079) fabricators.
2013 Conaway Conference‐ StructuresPSID‐1‐12 Prestressed Concrete I‐Beam Bridge Details• “Indiana Hybrid” I‐beam. • The sections are available in heights beginning at 36‐inches and increasing in 6‐inch increments up to 72‐inches.