Ohio Department of Transportation

Central Office • 1980 West Broad Street • Columbus, OH 43223

John R. Kasich, Governor • Jerry Wray, Director

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OFFICE OF STRUCTURAL ENGINEERING

Manual of Bridge Inspection Interim Updates

DATE: Effective 1/30/2017

TO: Ohio Bridge Inspectors

CC: Bridge Staff

FROM: Tim Keller, Office of Structural Engineering (OSE)

SUBJECT: Clarification to Item 60-Substructure Summary and Item c13-Expansion Joints

Purpose

This memo provides more detail for bridge inspectors to consistently assign Substructure Summary and

Expansion Joint condition ratings. The language contained herein is meant to be used in conjunction with the

Condition Guide on page 117 of the 2014 Manual and the Material guidance. However, where there are

discrepancies this guidance shall take precedent.

Substructure Summary

The Manual of Bridge Inspection was updated in 2010 and 2014. Although the definitions for the

Substructure Summary did not change between the 2010 and 2014 update, specific guidance was exchanged for

material deficiencies and items such as Pier Seats and Abutment Seats were removed. This change was due to the

introduction of a dual rating system on the individual items (1-4 scale); condition and element level. As a result,

inspector guidance became more ambiguous resulting in some inconsistencies.

Waterproof Joints

In addition to the Substructure Summary clarification, informal research in 2016 investigated the condition

rating of expansion joints statewide. Joints designed to be waterproof but exhibit widespread leaking should be

considered “Poor” whereas the guidelines endorsed a “Fair” condition rating. The condition rating guidance did

not differentiate between waterproof and non-waterproof joints. Also, Polymer Modified Joints (PMJ), also known

as Asphaltic Plug Joints, that have the leveling plate exposed, should be coded “Critical” where the Manual

recommended inspector discretion.

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Item - Expansion Joints

Type -

Waterproof Expansion Joints (Polymer Modified, Strip

Seal, Compression Seal, Modular etc.)

Condition Rating Leaking

(Underneath)

Expansion and

Contraction Opening Armor and Anchorage

1-G

oo

d 9- Excellent No leaking

8-Very Good No leaking

7-Good No leaking Normal Range

2-F

air 6-Satisfactory No leaking

Minor or Surface

Problems

Surface Spalls or minor

cracking in the deck and/or

header may be present

adjacent to the joint.

5-Fair Minor leaking

Surface problems and

very minor structural

problems.

Minor clanking. Loose

armor. Surface gouges.

3-P

oo

r

4-Poor Widespread

Leaking. Gland

pulling out

Structural problems are

not minor. 1”

misalignment.

Deep Gouges in armor.

Slight Clanking under truck

traffic.

3-Serious

Portion of gland

lying on seat.

Free flow of

water.

Major problems. 1-2”

misalignment.

Slight Visible movement or

heavy clanking under car

traffic.

4-C

riti

cal

2-Critical

Steel Plate Exposed for Polymer Modified Joints. Greater than 2”

misalignment (plow catch points exist). Tight on one side and open in the

other. Visible movement and clanking under all traffic loads in all lanes,

major spalls exposing anchorage. Anchorage separation on multiple beams.

Polymer Mod. Joints

Good Poor – When Leaking Underneath

Critical

Critical

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Substructure

Item - Short (~4-Ft) or Stub Abutments

Abut

Wall

Item 60-

Substructure

Summary

Delamination, Efflorescence,

Reinforcing Steel Exposure

Spalling Depth

½ Bridge

Width or

Less

More than ½

Bridge Width

1-G

ood 9- Excellent

8-Very Good Sound

7-Good

Sound. Vertical Cracks with light

efflorescence. A few unsound areas,

some cover missing

2-F

air 6-Satisfactory

Saturation through the wall and

delamination. Exposed reinforcement

possible

Up to 4”

deep

5-Fair

Up to 100% saturation with full width

delamination. Minor section loss to

vertical bars.

Up to 6”

deep

isolated

Up to 4” deep

3-P

oo

r 4-Poor

Advanced Section loss to vertical bars

For example: 4-adjacent bars with

10% loss of section (LOS)

Up to 8”

deep

isolated

Up to 6” deep

3-Serious

Worse than Above with local failures

possible. For example: 5 adjacent

bars with 20% LOS.

Up to 9”

Deep

isolated

Up to 8” deep

4-C

riti

cal

2-Critical

Local failures such as bent or

broken vertical bars. Should close

lane(s) and/or monitor more

frequently.

Backfill

spilling

through

Up to 9” Deep

1-Imminent

Failure/Failed

Worse than above. Immediately close bridge or the bridge is already

closed.

8-Very Good Sound concrete, staining

through joint. 7-Good Vertical cracking with light efflo.

Moisture from joint.

6-Satisfactory Concrete is sound except 10-Ft

of delam and 6-Ft of spall. Staining from joint above. 5-Fair 4”-Deep spalling and delam at top 5-15” of

abutment full width. Loose concrete removed.

2-Critical

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Substructure

Item - Abutment and Pier Walls & Caps (excluding Stub or shorter 4’ Abutment Walls)

Abut

or

Pier

Wall/

Cap

Item 60-

Substructure

Summary

Area Remaining Under Bearing Devices

Abutment or Pier Supporting More than 3 Beams

(Redundant)

Abutment or Pier

Supporting 3 Beams or

Less (Non-Redundant)

1-G

ood 9- Excellent No problems noted, no section loss

8-Very Good Minor spalling/delamination up to fascia bearings for redundant structure.

7-Good Aesthetic deficiencies, minor spalling, delaminations. Minor loss under fascia

bearings for redundant structure.

2-F

air

6-Satisfactory

Structural Elements Show Some Minor

Deterioration. For example: Spalling or

delaminations up to masonry plate(s) but no

undermining to interior beams. Minor undermining

is possible under a fascia masonry plate.

For example: Minor

spalling, delaminations,

no undermining.

5-Fair

Structural Elements Show Deterioration but are

Sound. For example: Fascia bearing loss up to

50%, interior bearings have spalling or

delaminations under small portions of the masonry

plates.

For example: Spalling or

delaminations up to

masonry plate but no

undermining.

3-P

oo

r 4-Poor

Advanced. For example: One interior bearing may

have up to 50% and the adjacent are sound, at least

two on one substructure unit with up to 20% loss.

For example: Spalling

undermining portions of

masonry plate.

3-Serious

4-Poor and local failures possible. For example:

More than two adjacent interior masonry plates

with more than 20% loss.

For example: Spalling

undermining portions of

masonry plate up to 20%

of area.

4-C

riti

cal

2-Critical

3-Serious. . . AND unless closely monitored may

be necessary to close the bridge until correction

action is taken.

For example: Spalling

undermining portions of

masonry plate more than

20% of area.

4-Poor – undermined

more than 25% of one

interior bearing plate.

Abutment

Wall

Includes

the Seat

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Substructure

Item - Pier Bents

Type –

Steel Bents This includes Cylindrical Bents that Do NOT have reinforcing

cage or Carbon or Glass Fiber Wrap Confinement

Pier

Bent

Item 60-

Substructur

e Summary

Steel Piles

1-G

oo

d

9- Excellent No problems noted, no section loss

8-Very Good No problems noted, no section loss, general isolated surface deterioration

7-Good Some minor problems such as isolated rust and very minor isolated section loss

2-F

air

6-

Satisfactory

Structural Elements Show Some Minor Deterioration. For example: rust

and minor section loss on most piles

5-Fair

Structural Elements Show Deterioration but are Sound. For example: minor

section loss on all piles, small corrosion holes in three non-neighboring bents,

up to 33% loss in one exterior bent, a load rating that takes into account

advanced section loss and has more than 150% remaining capacity for legal

loads.

3-P

oo

r 4-Poor

Advanced Section Loss. For example: Small corrosion holes in three bents in

one pier, 15% loss of section on three neighboring bents, or advanced loss 33%

in two non-adjacent interior bents.

3-Serious 4-Poor. . . AND Local Failures Possible. For example: Large corrosion holes

in multiple bents, 33% loss of area in three bents in one pier.

4-C

riti

cal

2-Critical

3-Serious. . . AND unless closely monitored may be necessary to close the

bridge until correction action is taken. For example: minor buckling or

misalignment that is a change since previous inspection, flange & web crack,

missing steel sheath over portions of neighboring piles.

Find the worst, or thinnest, horizontal cross section anywhere on the bent. Most often this occurs at the

wet-dry water line or mud-line. Access may require wading in low water or performing a dive inspection.

Write in the notes what bents are in water and whether or not they are protected. Structurally the steel

cross section is important near the middle of the unbraced length between the cap and often below the

mudline. The cross sectional shape will be a W-Shape or a cylinder. Shrinking or reducing the average

area of remaining steel or cross section will reduce the bents ability to carry traffic. For comparison

purposes each ½ flange is roughly 17% of the total area on a W-shape.

4-Poor – exterior bent with

more than 40% loss of area

1-Imminent

Failure

Fluted Cylinder with

no internal Cage

Cylinder with no

internal Cage

4-Poor exposed concrete

due to LOS to cylinder