rm A STANDARD SPECIFICATIONS FOR DIRECTORATE GENERAL OF HIGHWAYS MINISTRY OF PUBLIC WORKS REPUBLIC OF INDONESIA BRIDGE CONSTRUCTION VOLUME 2 FEBRUARY 1993 DOCUMENT No. BMS8-M.E° fee PRELIMIN) v1 TABLE OF CONTENTS JARY AND ROADWORKS GENERAL -J-1. Definition -2. Co-operation 3. Programming 4. Review of Progress .5. Site Meetings 6. Materials -7. Construction Plant -8. Working Hours -9. Possession of Site and Commencement of Work -]-10. Contractor's Responsibility for Work -11, Mobilisation -1.12. Notice of Operations -13. Record of Employees and Plant -14, Industrial Matters -15, Safety -16. Adverse Weather Conditions -17, Site Establishment and Contractor's Office -18. Working Area -1.19. Living Quarters, Sheds and Stores 20. Workshop -1.21. Site office, Housing and Vehicles for the Engineer and His Staff, .22. Laboratory -].23. Royalties -24. Work in Private Property -1.25. Care of Site -26. Utility Services .27. Blasting :28. Suppression of Dust -29. Avoidance of Water Pollution .30. Flood Damage 31. Tolerances .32. Load Testing .33. Use and Care of Roads 34. Temporary Roadworks .35. Maintenance and Protection of Traffic -36. Setting out the Work © .}.37. Templates and Straightedges 4.38. Standards 4.39. Units of Measure .40. Work and Material Included in the Contract Prices -1.41. Monthly Statement -42. Daywork -43. Contractor's Supervision 44. Payment HhALOHHOS Vuisaoaa © ooo RSV pats ashen taspsstns ayant certain apenas at BSELSS8S8ssaiIuiaaaarersos BRRe ——— - =Table of Contents 1.2. 1.3. benoor PROVISION FOR TRAFFIC 1.2.1. General 1.2.2. Contractor's Representative 1.2.3. Safety Devices 1.2.4. Traffic Controllers 1.2.5. Plant 1.2.6. Care of Formations 1.2.7. Access to Side Road: 1.2.8. Construction Operations Affecting Traffic 1.2.9. Side-Tracks and Temporary Crossing 1.2.10, Temporary Bridge 1.2.11. Work carried out over 1.2.12. Special Signs and Safety Fences 1.2.13. Height Warning Gauges 1.2.14. Payment CLEARING AND GRUBBING 1.3.1. Description 1.3.2. Removal of Topsoil 1.3.3. Area 1.3.4. Limitations 1.3.5. Disposal 1.3.6. Damage 1.3.7. Payment EARTHWORKS DRAINAGE SUBGRADE, SHOULDERS, SU! SURFACING AND PAVEMENT MISCELLANEOUS PAYMENT 2. FOUNDATIONS 21. 2.2. 2.3. GENERAL, 2.1.1. Contract Levels 2.1.2. Nature of Material COFFER DAMS 2.2.1. General 2.2.2. Construction of Coffer Dams : 2.2.3. Removal of Coffer Dams STRUCTURE EXCAVATION 2.3.1. General 2.3.2. Rock Foundation 2.3.3. Earth Foundation 2.3.4, Removal of Water 2.3.5. Inspection of Foundations 2.3.6. Mass Concrete 2.3.7. Preservation of Channel BACKFILL DISPOSAL OF SURPLUS MATERIAL CAISSONS SHEET PILES FOR TEMPORARY WORKS. MEASUREMENT PAYMENT OOEROBRKYHRYRARALK SSSSSSSSSRBVaRRGaGOSS and Adjacent Property Traffic OBBBBONN BBASE AND BASE BHHHROB BSSRSRSS PON PPE BRD hOOOUNKAS PERE aah RYNRPPD SOOUNHaA Tile of Contant «Stand Spucicatone fr Bridge ConetructonSLOPE PROTECTION AND STABILISATION ‘Table of Contents 3.1 GENERAL 3.2. RIPRAP 3.2.1 General 3.2.2 Materials 3.2.8 Excavation 3.2.4 Placing of Bedding 3.2.5. -Placing of Riprap t 3.2.6 Grouting 3.3 GABIONS AND MATTRESSES : 3.3.1 General 3.3.2 Wire 3.3.8 Manufacture 3.3.4 Tolerances 3.3.5 Fabrication 3.3.6 Placement 3.3.7 Filling “3.4 — Soll CONSERVATION 3.4.1 General a 3.4.2 Methods 3.4.8 Maintenance Watering 3.4.4 Application of Asphalt Emulsion 3.5 GEOTEXTILE DRAINAGE MATERIAL 3.6 MEASUREMENT 3.7 PAYMENT 4, PILES CAST IN PLACE 4.1. GENERAL 4.2, CONTRACT LEVELS 4,3. STEEL CASING 4.3.1. Fabrication 4.3.2. Material Specification Testing of Materials Defective Materials Cutting .3.6. Welding 4.4, SINKING AND EXCAVATION OF CAST IN PLACE PILES 4.4.1. General 2 4.4.2. Driving of Casing. $ 4.4.8. Drilling and Boring £ 4.4.4. Casing Requirements : 4.4.6. Investigation of Found: Q 4.5." CONSTRUCTION SEQUENCE LIMITATIONS, "2 4.6. DIMENSIONAL TOLERANCES - 4.7, PILES WITH ENLARGED BASES, ; a7 Driven Piles 4.7.2. Bored Piles 4.8. CASTING PILES 4.8.1. Reinforcement 4.8.2. Concrete 4.8.8. Withdrawal of Temporary Casing Tats of Conn - Stunde Soars fo Bee ConanTable of Contente 4.9. TEST LOADING 4g 4.9.1. General 49 4.9.2. Procedure 410 4.9.3. Report . an 4.9.4. Acceptance " 4-12 4.10, MEASUREMENT : 412 4.11. PAYMENT 413 PILES DRIVEN 5.1. GENERAL 5-1 5.2, CONTRACT LEVELS 51 5.3. DRIVING SYSTEM 5-1 5.4. DRIVING 5-2 5.4.1. General 5-2 5.4.2. Site Preparation 5-3 5.4.3. Tolerances “ 5-3 5.4.4, Penetration Requirements 5-4 5.4.5. Follower or Dolly a 5-5 5.4.6. Test Piles 5-5 5.4.7. Splicing of Piles 5-6 5.4.8. Jetting, Drilling and Firing and:Pre-boring 5-6 5.4.9. Replacement or Repair of Defective Piles 5-7 5.4.10. Completion of Driving -"" 5-7 5.5. RETESTING 8 5-7 5.6. CAPACITY OF DRIVEN PILES 5-7 5.6.1. Ultimate Capacity based on the DANISH Formula 5-8 5.6.2. Ultimate Capacity based on Wave Equi Methods 5-9 5.7, TEST LOADING 5-9 5.7.1. General 5-9 5.7.2. Procedure 5-10 5.7.3. Report a 5-11 5.7.4. Acceptance 5-11 5.8. PAYMENT res fe Bua Mae 5-12 STEEL PILES " 6.1. GENERAL 64 Description of the Work 6-1 .1.2. Supply of Piles 61 6.2. MATERIALS 23 : 6-2 Specifications £ 6 6-2 Dimensional Tolerances - b 6-2 Testing of Materials + i 6-2 4. Defective Materials 6-3 6.3. FABRICATION 78 63 6.3.1. General : 6-3 6.3.2. Fabrication of Tubular Steel Piles 6-3 Fabrication of Steel Pile Sections 63 Length of Piles = 6-3 Reinforcing Plates for Pile Toes 6-4 Welding 6-4 Tle of Comanta- Standard Spactenona for Badge Consucton6.4, OSION PROTECTION General Tar Epoxy Paint 5! Surface Preparation 6.4.8. Painting 6.5. SPLICING PILES 6.6. HANDLING, STORAGE AND PITCHING OF PILES 6.7. PILE|DRIVING 6.7.1. General 6.8. TRIMMING AND PREPARATION OF THE PILE HEAD. 6.9. TUBULAR STEEL PILES 6.9.1. Backfilling of Pile 6.9.2. Reinforcement 6.9.3. Concreting 6.10. MEASUREMENT 1. PAYMENT * PILES DRIVEN CONCRETE 1. GENERAL JUFACTURE 7.2.1. Supply by Contractor 7.2.2. "Supply by Employer 7.2.8. Dimensions ’ é 7.2.4. Specifications . 7.2.5. Pile Shoes 7.2.6. Marking 7.3. HANDLING, TRANSPORT AND STORAGE 7.3}. General 7.3.2. Handling 7.3.8. Transport 7.3.4. Storage 7.4. DRIVING OF PILES 7.4.1. General 7.4.2. Minimum Age of Piles before Driving 7.4.3. Test Piles Driving Procedure Pile Capacity . Severe Driving Acceptance of Driven Piles (other than Test Piles) ING OFF AND STRIPPING OF PILE HEAD NSIONS OF PILES General Splicing piles by Lapping of Stee! Splicing by Welding of Stee! Splicing with Precast Lengths of Pile Pile Extensions in Reinforced Concrete Pile Extensions which are not Driver’ Pile Extensions of Prestressed Concrete Piles iop OF MEASUREMENT ENT 2 ‘Table of Contents (er snage ConeructonTable of Contents 8. CONCRETE 8.1. GENERAL 8.1.1. Scope 8.2. 8.3. 8.4. 8.6. 8.1.2. Description of Concrete, Mortar and Grout 8.1.3. Classes of Concrete 8.1.4. Strength Requirements ‘SUPPLY AND DELIVERY OF CONCRETE 8.2.1. Mix Design 8.2.2. Materials 8.2.3. Batching 8.2.4. Mixing and Delivery 8.2.5. Acceptance of Concrete CONCRETE IN STRUCTURES 8.3.1. Responsibility of the Contractor 8.3.2. Formwork 8.3.3. Joints 8.3.4. Falsework and Scaffolding 8.3.5. Placing of Concrete 8.3.6. Curing 8.3.7. Quality of Concrete 8.3.8. Surface fi 8.3.9. Tolerances 8.3.10. Miscellaneous ‘STEEL REINFORCEMENT 8.4.1. Scope 8.4.2. Materials 8.4.3. Order Lists 8.4.4. Protection of Materials 8.4.5. Bending 8.4.6. Placing and Fastening 8.4.7. Splicing 8.4.8. Substitution FIBREMESH 8.5.1. General 8.5.2. Material 8.5.3. Use in concrete DEFECTIVE CONCRETE 8.6.1. General 8.6.2. Materials for the Repair of Defective Concrete 8.6.3. Repair of Defective Concrete BACKFILL, ROAD FILLS, AND OPENING TO TRAFFIC METHOD OF MEASUREMENT “8.8.1. Concrete 8.8.2. Reinforcement PAYMENT 8.9.1. Concrete 8.9.2. Reinforcement vi Tutte of Contant «Standard Souscatone for Basse Coneustn‘Table of Contents 9. PRECAST CONCRETE 9.1. GENERAL 91 9.2. FORMWORK a4 9.2/1. General 94 9.2/2. Formwork Materials 9s 9.28. Forms 9-1 9.3. STEEL REINFORCEMENT 92 9.4. PROJECTING REINFORCEMENT 92 9.5. BEARING PLATES 92 9.6. UNIFORMITY OF PROFILE - PRECAST BEAMS 92 9.7. MARKING 9-3 9.8. PREPARATION OF STORAGE AREA AND ACCESS TRACKS 9-3 9.9. DEFECTIVE CONCRETE 93 9.10. GENERAL STORAGE REQUIREMENTS 9-4 9.10.1. Storage And Temporary Supports For Precast Beams 9-4 9.10.2. Storage and Temporary Supports for Piles and Slabs 95 9.11. HANDLING 95 9.12, TRANSPORTING 96 9.13. DAMAGE TO UNITS 96 9.14. ACCEPTANCE 96 9.15. METHOD OF MEASUREMENT o7 9.15.1. Concrete 97 9.19.2. Reinforcement 97 9.16. PAYMENT 97 10. PRESTRESSED CONCRETE 10.1. GENERAL 10-1 10.2. TENDONS 10-1 1. Materials 10-1 .2. Manufacture 10-1 .3. Testing 10-2 .2.4. Handling and Storage 10-2 PRECAUTIONS 10-3 PMENT 10-3 SUREMENT OF TENSIONING FORCE 10-4 IA TO BE RECORDED 10-4 INITIAL PRESTRESS . 10-5 PAYMENT 10-5 1. PRETENSIQNED PRESTRESSED CONCRETE GENERAL WA STRESSING BED 14 ANCHORAGES WA PLACING OF TENDONS Wt CQVER WwW TENSIONING FORCE 11-2 DEBONDING 11-3 TENSIONING PROCEDURE 113 TENDON FAILURE 113 TRANSFER OF PRESTRESS 14 ‘able of Contants « Stantad Spactitanons tor Bre Construction viiTable of Contents 12. 13, 11.11, PERMISSIBLE PULL-IN OF TENDONS 11-5 11.12, SOLE PLATES AND BEARING RETAINERS 11-5 11.13. PROTECTION OF ENDS 11-5 11.14. PAYMENT 15 POST-TENSIONED PRESTRESSED CONCRETE 12.1. GENERAL 124 12.1.1. Scope 124 12.1.2. _ Prestressing System 124 12.2, DUCTING 124 12.2.1. Supply 12-4 12.2.2, Placing 12-2 12.3, ANCHORAGES 12-3 12.3.1. Supply 12-3 12.3.2. Placing 12:3 12.3.3. Swaging and Button-Heading 12-4 12.4, FALSEWORK 12-4 12.5. CONCRETING 12-4 12.6. TENDONS 12-4 12.6.1. Fabrication 12-4 12.6.2. Placing 126 12.7, REQUIRED STRENGTH AND AGE OF CONCRETE FOR STRESSING 12-5 12.7.1. Strength and Age 125 12.7.2. Post Tensioning Before 28 Days 125 12.8. TENSIONING FORCE REQUIRED 12-6 12.9. STRESSING PROCEDURE 126 12.9.1. General 12-6 12.9.2. Tensioning with Two Jacks 127 12.9.3. Tensioning with One Jack 12-7 12.10, GROUTING 12:8 12.10.1. General 12-8 12.10.2. Grout 128 12.10.3. Mixing and Pumping Equipment 12-9 12.10.4. Grouting 12-9 12.10.5. Precautions After Grouting 12-10 12.11, CONCRETING OF ANCHORAGE RECESSES 1240 12.12. PAYMENT 12-11 POST TENSIONED SEGMENTAL STRUCTURES 13.1. GENERAL 13-1 13.2, MANUFACTURE AND HANDLING OF SEGMENTS 13-1 13.2.1. Permissible Tolerances for Segments 13-4 13.3. ASSEMBLY OF PRECAST SEGMENTS 13-2 13.4, STRESSING 13-2 13.5. GROUTING 13-3 viii ‘Tate of Conon «Standard Spucentone fr Bdge CansctionTable of Comante 13.6. UOINT CONCRETE 13-3 13.6.1. General 13-3 . 13.6.2. Cement Content 13-3 13.6.3. Maximum Aggregate Size 13-3 13.6.4. Strength 13-3 13.6.5. Colour 13-3 3.6.6. Formwork 13-3 3.6.7. Placing of Concrete 13-4 13.7. CONCRETING OF ANCHORAGE RECESSES 13-4 13.8. DAMAGE TO UNITS 13-4 13.9. HANDLING AND PLACING ASSEMBLED MEMBERS 13-5 13.10. PAYMENT 13-5 14. HANDLING AND ERECTION OF PRECAST CONCRETE UNITS 14.1. GENERAL 14-1 14.2. BUPPLY OF UNITS BY EMPLOYER 141 14.3. HANDLING 14-2 "14.4. BECURING DEVICES, ANCHOR POINTS AND BEARINGS 14-2 14.5, TRANSPORT OF PRECAST CONCRETE UNITS. 14-2 14.6. TRANSPORT TIME RESTRICTIONS 14-3 14.7, WEATHER AND ACCESS CONDITIONS 14-3 14.8. DAMAGE TO UNITS 14-3 14.9. _ ERECTION OF PRECAST CONCRETE UNITS. 14-3 4.9.1. General 143 4.9.2. Erection of Precast Concrete Beams 14-4 4.9.3. Erection of Precast Concrete Slabs 14.5 14.10. MEASUREMENT 14-6 14.11. PAYMENT 14-6 15. INSTALLATION OF PRECAST CONCRETE CULVERTS 15.1. GENERAL 15-1 15. UPPLY OF CULVERT UNITS TO CONTRACTOR BY THE MPLOYER 15-1 15.3, HANDLING OF CULVERT UNITS 15-1 15. RANSPORT OF PRECAST CONCRETE UNITS 15-2 15.5. PREPARATION OF STORAGE AREA AND ACCESS RACKS 15-2 AMAGE TO UNITS 15-2 ENERAL STORAGE REQUIREMENTS 15-2 ‘OLERANCES 15-2 VERSION AND DISPOSAL OF WATER 15-3 XCAVATION 15-3 EDDING 15-3 ESTING OF BEDDING AND STRUCTURAL FILLING JATERIALS 15-4 15.13. CAST-IN-PLACE CONCRETE 15-4 15.14. PLACING PIPE CULVERTS 15-4 15.15. PLACING PRECAST CULVERT UNITS 15-4 15.16. STRUCTURAL FILLING 15-5 “able of Contant Stan Spatcaons fr Brite Conmucten ixTable of Contents 16. kA 15.17. CONSTRUCTION LOADING ON CULVERTS 15.17.1. General 15.17.2. Crown Unit or similar Culverts 15.17.3. Concrete Pipe Culverts 15.18. MEASUREMENT 15.19. PAYMENT CONCRETE REPAIRS 16.1. GENERAL 16.2. IDENTIFICATION OF DEFECTS. 16.3. REPLACEMENT OF CONCRETE 16.3.1. Removal of Concrete 16.3.2. Reinforcement 16.3.3. Concrete 16.4. | REPAIRS TO CONCRETE 16.4.1. Non-Injection Crack Repair 16.4.2. Structural Crack Repairs by Epoxy Injection 16.4.3. Resurfacing of Aggregate Exposed Surface 16.4.4. Repair of Spalled Concrete 16.5. SPRAYED CONCRETE REPAIR 16.5.1. General 16.5.2. Materials 16.5.3. Preparation 16.5.4. Application 16.6. MEASUREMENT 16.6.1. Removal and Replacement of Concrete 16.6.2. Epoxy Repairs 16.6.3. Sprayed Concrete 16.6.4. Reinforcement 16.7. PAYMENT FALSEWORK AND SCAFFOLDING 17.1, GENERAL 17.2. FALSEWORK PROPOSALS 17.3. DESIGN 17.4. ERECTION AND USE 17.4.1. General 17.4.2. Provision for Adjustment 17.4.3, Provision for Longitudinal and Lateral Movements 17.4.4, Bracing 17.4.5. Foundations 17.4.6. Falsework at abutment batters 17.4.7. Test Loading 17.4.8. Drainage 17.4.9. Access Through Falsework 17.4.10. Settlement of Falsework REMOVAL OF FALSEWORK PAYMENT aS bin 15-6 15-6 15-6 15-6 15-7 15-7 16-1 16-1 16-1 16-1 16-2 16-2 16-2 16-2 16-3 16-4 16-4 16-4 16-4 16-5 16-5 16-5 16-6 16-6 16-6 16-6 16-6 16-6 17-41 17-41 17-41 17-3 17-3 17-3 17-3 17-3 17-3 17-4 175 175 17-5 175 17-5 17-6 “Tabi of Contant - Sanda Seeticatons for Bios CandrctionTable of Contents 18. EPOXY RESINS 18.1. 18-1 18.2. 18-1 18.3. MATERIALS 18-1 General 18-1 Definitions 18-1 Physical Requirements 18-2 Sampling and Testing 18-2 Information to be Provided by the Contractor 18-2 Rejection and Replacement 18-3 Test Methods 18-3 Properties Prior to Curing 18-4 Properties in the Cured State 18-4 . Supply 18-4 . Safety Precautions 18-4 Storage 18-5 18.4. SURFACE PREPARATION 18-5 . 18.4.1, Method ‘A’ Solvent Cleaning 185 18.4.2. Method ‘B’ Abrasive Blast Cleaning 18-6 18.4.3. Method ‘C’ Ferric Chloride Etching 18-6 18.4.4. Method ‘D’ Chromic Acid Etching 18-6 18.4.5. Method ‘E’ Hydrochloric Acid Cleaning 18-7 18.4.6. Method ‘F’ Preparation of Rubber Surfaces 18-7 18.4.7. Method ‘G’ Preparation of Timber Surfaces 18-7 18.4.8. Method ‘H’ Preparation of Bridge Decks 18-7 18.5. MIXING 18-8 18.5.1. Mixing Equipment 18-8 18.5.2. Mixing 18-8 18.6. METHODS OF APPLICATION 18-9 6.1. General 18-9 6.2. Bonding 18-9 6.3. Repair of Damaged Concrete 18-9 6.4. Data To Be Recorded 18-9 6.5. Environmental Restrictions 18-10 6.6. Temperature 18-10 6.7. Clean-up 18-10 18.7. PAYMENT - 18-11 19. FABRICATION OF WELDED STEEL STRUCTURES 19-1 19.1. GENERAL 19-1 .1.1. Scope 19-1 .1.2. Definitions and Symbols 19-1 .1.3. Shop Drawings 19-1 .1.4. Variations From Drawings 19-1 : .1.5. Responsibility of Contractor 19-2 19.2, MATERIALS 19-2 19.2.1. Specifications 19-2 18.2.2. Materials Supplied by the Employer 19-2 19.2.3. Materials Supplied by the Contractor 19-3 18.2.4. Testing Materials 19-3 19.2.5. Defective Materials 19-3 19.2.6. Handling and Storage of Mater 19-4 “Tobi of Contre» Sunes Spefcatons for Bodge Conscton xiTable of Contents, 19.3. FABRICATION 19-4 19.3.1. Fabrication Programme 19-4 19.3.2. Dimensional Tolerances 19-4 19.3.3. Straightening Material 19-6 19.3.4. Plates and Flats 19-6 19.3.5. Cutting 19-7 19.3.6. Treatment of Edges 19-7 19.3.7. Hot Bending 19-8 19.3.8. Splices 19-8 19.3.9. Web Stiffeners 19-8 19.3.10. Bearings 19-8 19.3.1. Shear Connectors 19-9 19.3.12. Stud Welded Shear Connectors 19-9 19.3.13. Cambering 19-13 19.3.14. Holes for Bolting 19-13 19.3.15. End Preparation of Girder Segments 19-14 19.3.16. Defective Workmanship 19-15 19.4. WELDING EQUIPMENT, ELECTRODES AND OPERATORS —19-15 @ 19.4.1. General 19-15 19.4.2. Arc Welding Equipment 19-15 19.4.3. Electrodes for Manual Welding 19-15 19.4.4. Electrodes and Flux for Submerged Arc Welding «19-16 19.4.5. Electrodes for Metal Inert Gas (MIG) Welding 19-17 19.4.6. Gas Cutting Equipment 19-17 19.4.7. Safety Precautions 19-17 19.4.8. Qualification of Welding Operators 19-17 19.4.9. Procedure Qualifications for Butt and Fillet Welds 19-18 19.5. WELDING 19-19 19.5.1. Preparation of Material for Welding 19-19 19.5.2. Assembly 19-20 19.5.3. Control of Distortion and Shrinkage Stresses 19-21 19.5.4. Weather Conditions 19-21 19.5.5. Preheat Temperatures 19-22 19.5.6. Welding Technique 19-23 19.5.7. Appearance and Finish of Welds 19-26 e@ 19.5.8. Non-destructive Inspection 19-27 19.5.9. Quality of Welds 19-28 19.5.10. Corrections . 19-31 19.6. SUPPLY OF BOLTS, NUTS, SCREWS AND WASHERS, 19-32 19.6.1. Screw Threads 19-32 19.6.2. Specification For Manufacture 19-32 "19.6.3. High Strength Steel Bolts With Associated Nuts ‘And Washers 19-33 19.6.4. Precision Bolts And Screws 19-33 19.6.5. Prevailing Torque Locknuts ("Self-Locking” Nuts) 19-33 19.6.6. Washers (Other Than Washers For High Strength Bolts) 19-34 19.6.7. Protective Treatment For Bolts, Nuts, etc. 19-34 xii “Tile of Contant - Stan Spusenont for Bdge ConstructionINSPECTION AND ASSEMBLY 19-35 9.7.1. General 19-35 9.7.2. Shop Assembly 19-35 9.7.3. Rejection 19-37 19.8. DELIVERY 19-37 19.9. PROTECTIVE TREATMENT OF STEELWORK 19-37 19.10. REPAIRS TO STEEL MEMBERS 19-37 19.11. MEASUREMENT AND BASIS OF PAYMENT 19-38 9.11.1. Weight of Materials 19-38 9.11.2. Basis of Payment 19-39 20. ERECTION OF STRUCTURAL STEELWORK 20.1. GENERAL 20-1 20.1.1. Materials Supplied by the Employer 20-1 10.1.2. Marking Diagram 20-1 10.1.3, Methods of Erection and Equipment 20-1 fo. Handling and Storage 20-1 0.1.5. Setting Out 20-2 0.1.6. Positioning of Bearings 20-2 0.1.7. Deck Expansion J 20-2 20.2. ASSEMBLY OF STEELWORK 20-3 0.2.1. Erection Procedure 20-3 10.2.2. Straightening Bent Material 20-3 10.2.3, Assembly 20-3 10.2.4. Welding 20-4 0.2.5. Bolted Connections 20-4 0.2.6. Installation of High-Strength Bolts 20-6 10.2.7. Repair of Damaged Paint and Metallic Coatings 20-9 20.3, REMOVAL OF FALSEWORK 20-10 20.4. MEASUREMENT 20-10 20.5. PAYMENT 20-10 Exh PROTECTIVE TREATMENT OF STEELWORK 21.1. GENERAL 21-1 21.2. SHOP PAINTING 21-1 an Coating Systems 20-1 1.2.2. Surface Preparation 21-2 1.2.3. Primers 213 1.2.4. Finishing Paints 21-4 1.2.5. Material Identification and Quality Control 21-6 21.3. FIELD PAINTING 21-7 General 21-7 Surface Preparation 21-7 Number of Coats and Colours 21-8 Thickness of Paint Film 21-9 Quality of Paints 21-10 Application of Paint 21-12 Controlled Environmental Conditions Under Which Paint May Be Applied 21-13 Defective Painting 21-13 Painting of Corrosion Prone Areas 21-13 Tis of Conta - Sunda Soapcmons for Boge Connucten xiii‘Table of Contents 21.4, METALLIC COATINGS 21-14 21.4.1. Galvanising 21-14 21.4.2. Electroplating 21-16 21.5. REPAIR OF DAMAGED PAINT AND METALLIC COATINGS — 21-16 21.5.1. Damaged Primer Coats 21-16 21.5.2. Damaged Final Coats and Spot Painting 21-16 21.5.3. Damaged Metallic Coatings 20-47 21.6. MEASUREMENT 21-17 21.7. PAYMENT 21-17 22. FABRICATION AND ERECTION OF MINOR METALWORK ITEMS 22.1. GENERAL 22-1 22.2. MATERIALS 22-1 22.2.1. Specifications 22-1 22.2.2. Testing of Materials 22-1 22.2.3. Storage of Materials 22-2 22.3. WELDING 22-2 22.4, STRAIGHTENING MATERIALS 22-2 e 22.5. CUTTING AND SPLICING 22-2 22.6. BEARINGS 22:3 22.7. RAILINGS 22-3 22.8. PROTECTIVE TREATMENT 223 22.9. PACKING AND DELIVERY 22-4 22.9.1. Marking for Final Erection 22-4 22.9.2. Packing and Marking 22-4 22.9.3. Transport and Handling 22-4 22.10. ERECTION OF MINOR METALWORK 22-4 22.10.1. General 22-4 22.10.2. Lamp Standards 22-4 22.10.3. Name Plates 22-4 22.11. QUALITY OF WORKMANSHIP AND INSPECTION 22-5 22.12. MEASUREMENT AND BASIS OF PAYMENT 225 22.12.1. Mass of materials 225 22.12.2. Basis of Payment 225 23. BEARINGS e@ 23.1. GENERAL + 23-4 23.2. UNREINFORCED ELASTOMERIC BEARING PADS AND STRIPS - SUPPLY : 234 23.2.1. General 23-1 23.2.2. Elastomer 23-1 23.2.3. Pads and Strips 234 23.2.4. Test Certificates 23-3 23.3. ELASTOMERIC BEARINGS - LAMINATED - SUPPLY 23-6 23.3.1. General 23-6 23.3.2. Elastomer 23-6 23.3.3. Bearings 23-6 23.3.4. Delivery of Bearings 23-8 23.3.5. Test Centficates 23-8 23.4. ELASTOMERIC BEARINGS - INSTALLATION 23-10 23.4.1, Marking and Delivery of Elastomeric Bearings 23-10 23.4.2. Installation of Elastomeric Bearings 23-10 xiv ‘Tila of Conte Standard Sonieatans for Srge Consbucton“Table of Comente 23.5. STEEL BEARINGS 23-11 3.5.1. General 23-11 3.5.2. Materials 23-11 3.5.3. Pins and Rollers 23-12 3.5.4. Workmanship 23-12 3.5.5. Testing 23-12 3.5.6. Tolerances 23-13 3.5.7. Cleaning 23-14 3.5.8. Workshop Assembly 23-14 3.5.9. Acceptance 23-14 23.6. INSTALLATION OF STEEL BEARINGS 23-14 3.6.1. General 23-14 3.6.2. Placing 23-14 3.6.3. Checking, Cleaning and Lubrication 23-15 3.6.4. Tolerance on Final installation 23-15 23.7. ROT TYPE BEARINGS - SUPPLY 23-16 3.7.1. General 23-16 3.7.2. Information To Be Supplied 23-16 3.7.3. Bearing Proportions and Materials 23-16 3.7.4. Properties of Materials 23-17 3.7.5. Inspection of Bearings 23-17 3.7.6. Testing of Bearings 23-18 3.7.7. Test Certificates 23-19 3.7.8. Protective Treatment 23-19 3.7.9. Marking and Delivery 23-20 23.8. INSTALLATION OF POT BEARING 23-20 23.9. PROPRIETARY BEARINGS 23-20 3.9.1. Responsibility , 23-20 3.9.2. Testing 23-21 3.9.3. Rejection of Bearings 23-22 23.10. MEASUREMENT 23-22 23.11. PAYMENT 23-22 24. EXPANSION JOINTS 24.1. GENERAL 24-1 24.2. $TEEL REINFORCED ELASTOMERIC JOINTS 24-1 4.2.1. Materials 24-1 4.2.2. Placing of Jointing 24-2 24.3. COMPRESSED ELASTOMERIC JOINT SEALS 24-3 4.3.1. Materials 24-3 4.3.2. Fabrication of Joint Steelwork 24-4 4.3.3, Placing of Joint Steelwork 24-4 4.3.4. Placing of Preformed Neoprene Seal 24-5 24.4. PREFORMED EXPANSION JOINT FILLERS 24-6 4.4.1. Bituminous impregnated Fibre 24-6 4.4.2. Sponge Rubber 24-6 4.4.3. Cork and Self-Expanding Cork 24-6 4.4.4, Bitumen Impregnated Foam Strips 24-6 4.4.5. Physical Requirements 24-6 4.4.6. Installation 24-7 24.5. $TEEL PLATE EXPANSION JOINTS 24-8 4.5.1. General 24-8 ‘eee of Conta» Standen Sofetcaons fer Boe Cenmcton ~vTable of Contents 24.5.2. Sliding Plates 24-8 24.5.3. Finger Plates 24-8 24.6. CERTIFICATION AND ACCEPTANCE 24.9 24.7. ALTERNATIVE PROPRIETARY TYPE DECK JOINTS 24-9 24.8. POST INSTALLATION TESTING 24-10 24.9. MEASUREMENT 24-10 24.10. PAYMENT 24-10 28. BRIDGE RAILING 25.1. GENERAL 25-4 25.2. STORAGE OF MATERIALS 25-1 25.3. WELDING 25-1 25.4. PROTECTIVE COATING 25-1 25.5. MATERIALS 25-1 25.6. ERECTION OF RAILINGS 25-2 25.6.1. General 25-2 25.6.2. Steel Pipe Railing 25-2 25.6.3. Steel Grille Railing 25-3 25.6.4. Aluminium Railing 25-3 25.7. GUARD FENCE RAILING 25-4 25.7.1. General 25-4 25.7.2. Materials 25-4 25.7.3. Erection 25-4 25.8. MEASUREMENT 25-5 25.9. PAYMENT 25-5 26. TIMBER BRIDGES 26.1. GENERAL . 26-1 26.1.1. 26-1 26.1.2. 26-1 26.2. ROUND TIMBERS 26-3 26.2.1. Grade Description 26-3 26.2.2. Quality of Timber 26-4 26.2.3. Dimensions 26-4 26.2.4. Tolerances for Round Timber 26-5 26.2.5. Protection 26-6 26.3. SAWN TIMBER 26-6 26.3.1. Species 26-6 26.3.2. Quality 2 26-6 26.3.3. Tolerances for Sawn Timber 26-6 26.4, STACKING OF TIMBER 26-7 26.4.1. General 26-7 26.4.2. Special Requirements for Treated Timber - Handling 26-7 xvi “Te of Contnte- Standard Specteabone tor Sige ConstuctonTable of Contente 26.5. [TIMBER PILES 26-7 6.5.1. Preparation for Driving Timber Piles 26-7 6.5.2. Equipment for Driving Timber Piles 26-8 6.5.3. Pile Bearing Values 26-8 16.5.4. Driving Timber Piles 26-8 16.5.5. Penetration and Set 26-8 6.5.6. Potting 26-9 6.5.7. Silling 26-9 6.5.8. Splicing 26-10 6.5.9. Cutting Off 26-10 6.5.10. Framed Bents 26-10 6.5.11. Tolerances on Finished Pile Positions 26-11 6.5.12. Marking of Piles after Driving 26-11 6.5.13. Protecting Untreated Timber Trestle Piles 26-11 6.5.14. Protecting Treated Timber Trestle Piles 26-12 6.5.15. Protection in Tidal Waters 26-12 6.5.16. Test Piles 26-13 -ARPENTRY, 26-14 26.6.1. General 26-14 6.6.2. Special Methods for Treated Timber 26-14 6.6.3. Holes for Bolts, Dowels, Rods and Lag Screws 26-15. 6.6.4. Bolts and Washers 26-15 26.7. SUBSTRUCTURE 26-15 6.7.1. Abutment Sheeting 26-15 26.7.2. Halfcaps 26-16 26.8. $UPERSTRUCTURE 26-16 6.8.1. Stringers and Corbels 26:16 26.8.2. Special Treatment of Stringers 26-17 6.8.3. Stringers in Skew Bridges 26-17 6.8.4. Dampcourse 26-17 26.9. DECKING 26-18 #3 1, General 26-18 6.9.2. Transverse Deckit 26-18 6.9.3. Longitudinal Decking 26-19 6.9.4, Two Ply Timber Decks 26-19 6.9.5. Kerbs 26-19 6.9.6. Cross Beams 26-20 6.9.7. Bolting Planks 26-20 6.9.8. Cross Pieces 26-20 6.9.9. Nosing Pieces 26-20 6.9.10. Surfacing of Decking 26-20 26.10. CONNECTIONS IRONWORK 26-21 46.101. General 26-21 26.11. TIMBER PRESERVATION 26-21 6.11.1, Petroleum Jelly 26-21 6.11.2. Creosoting 26-22 6.11.3. Special Requirements for Untreated Timber 26-22 6.11.4. Painting 26-22 6.11.5. Protection Against Termites 26-22 26.12. RAILING 26-23 26.13. MEASUREMENT 26-24 ‘aie of Contam «Suns Sooftennens fr 6rdpe Conucton xviiTable of Contents 27. 28. 26.14. PAYMENT 26.14.1. General 26.14.2. Timber Piles STONE MASONRY 27.1. 27.2. 27.3. 27.4. 27.5. GENERAL MATERIALS 27.2.1. Stone 27.2.2. Mortar CONSTRUCTION 27.3.1. Selection and Placing 27.3.2. Beds and Joints 27.3.3. Header 27.3.4. Backing 27.3.5. Pointing 27.3.6. Coping 27.3.7. Weep Holes 27.3.8. Cleaning Exposed Faces 27.3.9. Curing METHOD OF MEASUREMENT PAYMENT GALVANISED CORRUGATED STEEL STRUCTURES 28.1. 28.2. SUPPLY OF MATERIALS 28.1.1. General 28.1.2. Standards 28.1.3. Materials 28.1.4. Testing Materials 28.1.5. Defective Materials 28.1.6. Cutting and Forming Plates 28.1.7. Shop Assembly 28.1.8. Riveted Pipe Length 28.1.9. Thickness and Corrugations DELIVERY OF MATERIALS. 28.2.1. Assembly Drawings 28.2.2. Marking 28.2.3. Supply of Bolts 28.2.4. Supply of Coupling Bands 28.2.5. Handling and Storage 26-24 26-24 26-25 27-1 27-1 27-1 27-1 27-1 27-1 27-2 27-2 27-2 27-3 27-3 27-3 27-3 27-3 27-3 27-4 28-1 28-1 28-1 28-1 28-1 28-1 28-2 28-2 28-2 28-2 28-2 28-2 28-3 28-3 28-3 28-3 xvi ‘Tila of Contr - Standard Spacicnona for Bisge Consbuctono of Contente 28.3. INSTALLATION OF CORRUGATED STEEL STRUCTURES 28-4 28.8.1. General 28-4 28.8.2. Diversion of Water 28-4 28.8.3. Excavation for Corrugated Steel Pipe and Pipe Arches 28-4 28.8.4. Excavation for Corrugated Steel Arches 28-5 28.8.5. Stream Excavation 28-5 28.8.6. Bedding of Corrugated Structures 28-6 28.8.7. Testing of Materials 28-6 28.8.8. Assembly of Corrugated Steel Pipes and Pipe Arches 28-7 28.8.9. Assembly of Helical Lock-Seam Corrugated Steel Pipes © 28-7 28.8.10. Assembly of Corrugated Steel Plate Arches 28-7 28.8.11. Strutting 28-7 288.12. Backfilling 28-8 28.4. PROTECTIVE COATING 28-8 284.1. General 28-8 28/42, Motorials 28-9 28.4.3. Application of Protective Coatings 28-9 28.5. INVERT PAVEMENT 28-10 28.6. MEASUREMENT 28-10 28.7. PAYMENT 28-10 29. DEMOLITION OF EXISTING STRUCTURES 29.1. GENERAL 29-1 29.2. METHOD OF DEMOLITION 29-1 2912.1. General 29-1 2912.2. Removal of Substructure 29-1 29/2.3. Public Utility Services 29-1 23/2.4. Use of Explosives 29-2 29.3. DISPOSAL OF DEMOLISHED MATERIALS 29-2 29.4. UNDERWATER INSPECTION 29-3 29.5. CLEANING UP 29-3 29.6. MEASUREMENT 29-3 29.7. PAYMENT 29-3 30. TEMPORARY BRIDGING . 30.1. GENERAL 30-1 30.2. METHODS OF ERECTION 30-1 30.3. MATERIALS 30-1 30\3.1. General 30-1 30|3.2. Materials Supplied by the Employer 30-1 30|3.3. Materials supplied by the Contractor 30-3 3013.4. Replacement of Missing or Severely Damaged Components 30-3 30|3.5. Repair of Materials supplied by the Employer 30-3 30|3.6. Handling and Storage 30-4 30.4. TRAFFIC CONTROL 30-4 Ti of Contant Staaa Soect ston fr Brage Comicon xixTable of Contente 30.5. CONSTRUCTION 30.5.1. General 30.5.2. Civil works 30.5.3. Demolition of Existing Structure 30.5.4. Area for Temporary Works 30.5.5. Setting Out 30.5.6. Assembly of Components 30.5.7. Installation of Bridge Bearings 30.5.8. Erection MAINTENANCE OF BRIDGE METHOD OF MEASUREMENT 30.7.1. Erection of Temporary Bridge Structures 30.7.2. Transportation and Delivery of Materials 30.7.3. Timber Decking 30.8. PAYMENT 31. CRIB WALLS 31.1. GENERAL 31.2. CLEARING AND GRUBBING 31.3. EXCAVATION 31.4, AGRICULTURAL DRAINS 31.5. SUPPLY OF MATERIALS 31.5.1. Units Supplied by Contractor 31.5.2. Units Supplied by Employer 31.6. DIMENSIONAL TOLERANCES 31.7. HANDLING AND STORAGE OF CRIB WALL UNITS. 31.8. PLACING CRIB WALL UNITS IN POSITION 31.9. CRIB WALL FILLING 31.10. EARTH FILL 31.11, CONCRETE CAPPING 31.12. DAMAGE TO UNITS 31.13. TESTING 31.14, MEASUREMENT 31.15, PAYMENT 32. REINFORCED EARTH RETAINING WALLS 32.1, GENERAL 32.2. MATERIALS 32.3. HANDLING AND STORAGE OF CONCRETE FASCIA PANELS 32.4. DAMAGE TO CONCRETE FASCIA PANELS OR OTHER COMPONENTS SUPPLIED BY THE EMPLOYER 32.5. LEVELLING FOOTINGS 32.6. ERECTION OF FASCIA PANELS 32.7. ARRANGEMENT OF REINFORCING STRIPS 32.8. BOLTING OF REINFORCING STRIPS TO CONCRETE FASCIA PANELS 32.9. TOLERANCES 32.10. PLACEMENT OF FILL FOR REINFORCED EARTH x Tle of Contin - Sundré Speteaton for Brits Conerucion32.11. 32.12. 32.13. 32.14. 33. SUPPLY 33.1. 33.2, 33.3. 33.4. Table of Contents ILL FOR REINFORCED EARTH 2.11.1. General 2.11.2. Physical Properties 2.11.3. Chemical and Electrochemical Properties CCEPTANCE EASUREMENT PAYMENT |AND INSTALLATION OF ROCK ANCHORS ROCK ANCHOR SYSTEMS }OCK ANCHOR COMPONENTS 3.2.1. Materials for Tendons 3.2.2. Sheathing 3.2.3. Anchorages 3.2.4. Button-Heading of Wire 3.2.5. Handling and Treatment of Tendons OCK ANCHOR ASSEMBLY 3.3.1. Spacers 3.3.2. Grout Feeder Tubes 33.3.3. Bond Length 3.3.4. Anchorage of Tendons REPARATION FOR INSTALLATION 3.4.1. Drilling 3.4.2. Waterproofing of Holes INSTALLATION GROUTING STRESSING OPERATIONS 3.7.1. General 3.7.2. Required Strength and Age of Grout for Stressing 3.7.3. Tensioning Force Required 3.7.4. Stressing 3.7.5. Data to be Recorded 33.8. CUTTING OFF STRAND TYPE TENDONS 33.9. PAYMENT 34, CONCRETE FOR INCIDENTAL CONSTRUCTION 34.1, GENERAL 4.1.1. Description of Concrete, Mortar and Grout 34.2. MATERIALS 4.2.1. Concrete Materials 4.2.2. Reinforcement 34.3: STRENGTH 34.4. FONSISTENCY 34. ‘ORMS 34.6. PLACING OF REINFORCEMENT 32-7 32-7 32-7 32-7 32-8 32-8 32-8 33-1 33-1 33-1 33-2 33-2 33-3 33-3 33-4 33-4 33-4 33-4 33-4 33-5 33-5 33-5 33-6 33-6 33-7 33-7 33-7 33-7 33-8 33-10 33-10 33-10 34-1 34-1 34-2 34-2 34-2 34-2 34-3 34-3 34-4 xxi‘Table of Contante 34.8. 34.9. 34.10. 34.11. 34.12. 34.13. 34.14. 34.15. 34.16. 34.17. APPENDIX APPENDIX A MIXING OF CONCRETE 34.7.1. General 34.7.2. Equipment 34.7.3. Mixing at Site or at a Central Mixing Plant 34.7.4. Mixing in Transit 34.7.5. Delivery by Road Vehicles of Agitation or Truck Mixer Type PLACING OF CONCRETE SPALLS COMPACTION OF CONCRETE CONSTRUCTION JOINTS CURING REMOVAL OF FORMS SURFACE FINISH 34.14.1. Class 1 Finish 34.14.2. Class 2 Finish DEFECTIVE CONCRETE MEASUREMENT 34.16.1. Concrete 34.16.2. Reinforcement PAYMENT 34.17.1. Concrete 34.17.2. Reinforcement TEST METHODS 34-5 34-5 34-5 34-5 34-6 34-6 34-7 34-7 34-8 34-8 34-9 34-9 34-9 34-9 34-9 34-10 34-10 34-10 34-11 34-11 34-11 34-12 xxii Tle of Contant Standard Spucientene fr Bdge Canttuction~* Au STA FOR PROTECTIVE TREATMENT OF STEELWORK DIRECTORATE GENERAL OF HIGHWAYS MINISTRY OF PUBLIC WORKS REPUBLIC OF INDONESIA DARD SPECIFICATIONS RIDGE CONSTRUCTION SECTION 271 JANUARY 1993 DOCUMENT No. BMS8-S.ETABLE OF CONTENTS 21. PROTECTIVE TREATMENT OF STEELWORK 21.4, 21.2. 21.4, GENERAL SHDP PAINTING 21{2.1. Coating Systems 21|2.2. Surface Preparation 2112.3. Primers 21]2.4, Finishing Paints 2112.5. Material Identification and Quality Control FIELD PAINTING 2113.1. General 2113.2. Surface Preparation 2113.3. Number of Coats and Colours 2113.4. Thickness of Paint Film 2113.5. Quality of Paints 2113.6. Application of Paint 2113.7. Controlled Environmental Conditions Under Which Paint May Be Applied 2118.8. Defective Painting 2118.9. Painting of Corrosion Prone Areas METALLIC COATINGS 2114.1. Galvanising 2144.2. Electroplating . RERAIR OF DAMAGED PAINT AND METALLIC COATINGS 2115.1, Damaged Primer Coats 2116.2. Damaged Final Coats and Spot Painting 21/5.3._ Damaged Metallic Coatings MEASUREMENT 7. PAYMENT 211 21-41 21-1 21-2 21-3 21-4 21-6 21-7 21-7 21-7 21-8 21-9 21-10 21-12 21-13 21-13 21-13 21-14 21-14 21-16 21-16 21-16 21-16 21-17 21-17 21-17 Tobie of Cantante «Stra Soscfceban for Be Censtucton21. PROTECTIVE TREATMENT OF STEELWORK 21.1. GENERAI This Section covers t} systems specified her} The coatings shall be to rain or frost before where moisture will c| Unless carried out ing coating work will on| atmospheric pollution In cases where more shall be tinted to give| Where, because of I surface of intermediat ie application of protective treatment of steelwork by the coating ein pplied to dry surfaces and the coated surfaces shall not be exposed hey are dry. Also, coating shall not be carried out under conditions ndense on the surfaces before they are dry. Joors or under a satisfactory cover, abrasive blast cleaning and ly be permitted when outdoor conditions (viz., moisture, wind, land temperatures) are, in the opinion of the Engineer, suitable. han one coat of the same colour is to be applied, alternate coats contrast between coats. ycal conditions, it is not possible to prevent contamination of the le coatings, the surface shall be cleaned down between coats. All marks and stamps for field assembly shall be carefully preserved and/or reproduced after cleaning and co ting. 21.2. SHOP PAINTING 21.2.1. Coating Systems The general coating connectors, the inner ystem, which shall be applied to all surfaces excluding shear urfaces of fully sealed hollow sections and excluding bolts, nuts, washers, screws andlitems for which other treatment is specified, shall consist of : i. abragive blast cleaning ii, app inor iii, appl isc iv. appl whit belo The coatings shall be ing one coat of an approved two-pack solvent borne self-curing Janic zinc silicate primer coating ing two coats of an approved epoxy polyamide cured coating which patible with the primer, ‘to the interior surface of the box girders ing two coats of an approved chlorinated rubber finishing paint h is compatible with the primer to all other surfaces except as noted }f a type as shown on the Drawings or in the Special Specifications. This method of painting will not normally be specified or permitted for painting to be carried out after erection or f repainting. The surfaces which will be in contact with concrete in the finished work shall not receive the finishing coats spe ‘cified in (ii) and iv) above. BMSO-SE «Sten Soectcsnone Ip Brge Conewuctan «26 Janay 198 21121. PROTECTIVE TREATMENT OF STEELWORK All surfaces within 75 mm of field welding shall not be primed until after the completion and approval of the field welding. These surfaces shall be masked to prevent coating with primer during the initial priming operations. Protection angles, footway cover plates and corrugated steel guardrail components shall be treated as follows : * abrasive blast cleaning or pickling + hot-dip galvanising No finishing paints will be applied to the surfaces of these items All bolts, and associated washers shall receive protective treatment as shown on the Drawings and as specified herein. Contact surfaces between parts fixed together by welding or high strength friction grip bolting shall not be painted but shall be cleaned to the satisfaction of the Engineer. Other contact surfaces shall. be given one coat of priming paint Surfaces of galvanised or electroplated components which will subsequently be coated with the finishing paint shall be de-greased and wash primed prior to the application of the finishing paint The inner surfaces of fully sealed hollow sections shall receive no protective treatment. 21.2.2. Surface Preparation a. Abrasive Blast Cleaning Before painting, regardless of any precleaning of steelwork which may have been carried out prior to or during fabrication, all surfaces of the steel shall be thoroughly cleaned by abrasive blast cleaning to white metal. The surface finish shall be in accordance with AS 1627 ‘Metal Finishing - Preparation and Pretreatment of Surfaces’ Part 4 (Abrasive Blast Cleaning of Stee! Surfaces) Class 3 and shall have a surface roughness or ‘maximum profile height’ of between 0.015 mm and 0.060 mm. A dry blast process shall be employed. The abrasive may be either metallic or non-metallic but shall be of an approved type to produce the surface roughness specified. The use of coarse steel angular grit, copper slag or any other material which will give a high surface profile or could contaminate the surface is not permitted. All compressed air used in blast cleaning and blowing down after cleaning shall be free from oil and moisture. b. Pickling All weld areas are to be abrasive blast cleaned to the standard of AS 1627 Part 4 Class 3 before pickling. Pickling shall be carried out in accordance with AS 1627 Part § (Pickling Steel Surfaces) 21-2 BMS8.5.E Sinan Spreieaane far Badge Conaucton «26 Janay 199921.2.3. Primers a. Approved The primer coating st coating which compli for 2 Class 4 primer Partially hydrolysed er} weight of metallic zin to 1 when the zinc cor of Tests for Paints’ 5 The primer coating sh to by the Engineer s surfaces b. Applicati Before any deteriorati hours after grit blasti 21, PROTECTIVE TREATMENT OF STEELWORK Primers jail be a two-pack solvent borne self-curing inorganic zinc silicate 'S with the requirements of AS 2105 ‘Inorganic Zinc Silicate Paint’ It must consist substantially of finely divided metallic zinc and I silicate solution. The formulation must be such that the ratio by to all other non-volatile compounds in the product shall exceed 4 tent is determined by the method of analysis in AS 1580 ‘Methods 4.1 ‘Metallic Zinc Content’ Ibe tinted a distinctive green or such other colour as consented as to be readily visually distinguishable from the prepared steel in of Primer n of the blast cleaned surface is visible, and in any case within four 1g. all surfaces of steelwork, as specified in Clause 21.2.1, shall receive one coat of the approved primer. Any surface showin: Contractor's expense All surfaces within 75 Masking of shear con be taken during the connectors. The primer shall be ap| or brushed into all cor blemishes will not be removed by abrasive The primer manutactur Where necessary the 4 artificial means to ens| c. Curing The primer coat shall by applying a chemic: The primer shall be tho} solution. deterioration before being primed shall be recleaned at the mm of field welds shall be masked to prevent coating with primer. lectors to prevent overspray is not necessary. However, care shall ‘ating of the girder to prevent build up of primer on the shear lied so as to produce a smooth, even coating and shall be sprayed lers and crevices. Wrinkling, blistering, air holes, lumps or other plowed, and, where the Engineer so directs, the primer shall be last cleaning and replaced at the Contractor's expense. er’s directions for mixing and application shall be adhered to strictly. felative humidity in the vicinity of the spraying shall be increased by sre proper curing of the coating. le cured by either air curing ( where a self curing coating is used) or curing solution to the dried coating. oughly cured within one half an hour of the application of the curing Besge Consvveven - 26 January 1998 21-321. PROTECTIVE TREATMENT OF STEELWORK d. Coating Thickness The minimum dry film thickness of primer shall be as follows : . surfaces which will not be subsequently 100 micrometres coated with finishing paint . surfaces which will be subsequently 75 micrometres Coated with finishing paint . surfaces which will subsequently in 30 micrometres direct contact with concrete (except shear connectors) . shear connectors nil The dry film thickness of paint shall be measured by the Engineer's Representative with a calibrated magnetic film thickness gauge. The manufacturer's specification will be used to determined the number of readings to be taken to ensure an accurate measurement of the paint thickness. e. Adhesion Test The primer shall fulfil the requirements of the following test of adhesion. Using a straight edge and a hardened steel scriber which has been ground to a sharp 30 degree point, two parallel lines shall be scribed at a distance apart equal to ten times the average coating thickness. In scribing the two lines, enough pressure shall be applied on each occasion to cut through the coating to the base metal in a single stroke. If at the second cut any part of the coating between the lines breaks away from the base metal, the coating shall be deemed to have failed the test. 21.2.4. Finishing Paints a Approved Finishing Paints i. General 5 The finishing paint shall be compatible with the primer coat systems used and shall be supplied by the same supplier as for the priming coat. The coating used shall be subject to the Engineer's ‘consent. The colour required for the final coats for steelwork shall be as shown on the Drawings. ii. Interior Surfaces of Box or Trough Girders The finishing paint shall be a high-build heavy duty epoxy polyamide catalyst cured coating, white in colour and with a semi-gloss finish. The paint shall contain 55% (+ 5%) volume of solids as consented to by the Engineer. The paint shall be suitable for application directly to the solvent borne zinc silicate primer paint 21-4 USES - Standard Sonscuons for Bdge Constucton «26 January 1883The finishing paint Plasticised stabilised to allow a high build ¢| a gloss finish. b. Preparati Prey Not more than eight washed with fresh cl or other contaminant suitable solvents shall areas concerned rew: ii. Prey The heads of all bolts| be painted shall be c} AS 1627 Part 1 (Degt then given one coat 21, PROTECTIVE TREATMENT OF STEELWORK Exterior Surfaces of Girders and Other Surfaces hall be a chlorinated rubber based coating, based in unmodified hlorinated rubber. Intermediate coats may contain thickening agents ‘ating to be applied in one application. The finishing coat shall have n for Finishing Paint aration of Primer Coated Surfaces {8) hours prior to application of the finish coat the surface shall be in water to remove any silt, salt, sand, dust, grit, grease, cement from the surface and allowed to dry thoroughly. If necessary, be used to remove contaminants that are not water soluble and the shed with water. paration of Metallic Coated Surfaces nuts and washers and other components which subsequently will refully de-greased using an approved solvent in accordance with feasing of Metal Surfaces using Solvent or Alkaline Solutions) and of an approved wash primer of a type compatible with zinc or cadmium, depending on the metal plating used, in accordance with AS 1627 Part 8 (Wash Primer Pretrea c. Applicati iment of Metal Surfaces). in of Finishing Paint The finishing paint shell be applied to the prepared surface by spray so as to produce a smooth even coating The paint shall be appl specified. Paint shall ind shall be sprayed or hand brushed into all corners and crevices. lied evenly in two coats having the total minimum dry film thickness not be applied in wet, foggy, damp or dusty weather or in other unsuitable weather cohditions unless precautions are taken to exclude the effects of such weather, from the wor The paint manufactur k, 1's directions for mixing and application shell be adhered to strictly. Immediately before the paint is actually used, it shall be stirred vigorously to ensure that there is no settlement the pot of paint shall of ingredients at the bottom of the paint container. While in use, e regularly stirred to avoid settlement of components. d. Coating Thickness The minimum dry film attention shall be pail bolts. The Contractor is to thickness is achieved hickness of the finishing paint shall be 100 micrometres. Particular to achieving this film thickness on all corners, edges, rivets and |monitor wet film thickness to ensure that the minimum dry film BEMS.S.E- Stncers Sprctenons for Brope Conmrucron «26 Janay 1983 21-521. PROTECTIVE TREATMENT OF STEELWORK The conversion of dry film thickness to wet film thickness = Dry film build (um) x 100 % Volume solids The dry film thickness of paint shall be measured by the Engineer's Representative with a calibrated magnetic film thickness gauge. The manufacturer's specification will be used to determined the number of readings to be taken to ensure an accurate measurement of the paint thickness. 21.2.5. Material Identification and Quality Control All paints to be supplied by the Contractor for use on the works in this Contract shall be approved by the Engineer in writing prior to their use All paints supplied by the Contractor for this contract shall be from the same manufacturer and shall be submitted, together with the appropriate product data sheet issued by the manufacturer, to the Engineer for his consent prior to application. The Engineer may at his discretion require that the Contractor submit to him from the manufacturer in advance a 1 litre sample certified by the manufacturer to be completely representative of the product to be supplied under this Contract. In the case of two pack formulations the sample is to be submitted in two separate containers clearly identified as to their contents. The sample, shall also be accompanied by a written statement from the manufacturer setting out the following : . the product Identification code specific to the formulation of the product . the generic name of the binder or binders in sufficient details to specify the product * the pigment type generally and the specific content of the critical component * the pigment to binder ratio by weight * the volume/solids content. The sample may be subject to investigation by testing by the Employer to determine * the comparison of the properties of the sample with those listed on the manufacturers’ product data sheet and the manufacturer's written statement * the identification of the binder by its infra red spectrum as determined on a Beckman IR20 Spectrograph . the content of any specified or critical component of the formulation 21-6 MSE. «Stance Spucietons for Bdge Centucton = 26 January 1999. the In addition to the ad\ 500 millilitre samples 21. PROTECTIVE TREATMENT OF STEELWORK fatio of the pigment, binder and solvent in the formulation. ance sample the Engineer may, at his discretion arrange to take ifrom the paints as delivered to the work and submit these samples to such tests as deemed by him to be necessary to prove their reliability and conformity with the manufactut manufacturers’ produ The Contractor shall of and containers for If, in the opinion of thi of inferior quality to thy all paint delivered to Rejected materials sh 21.3. FIELD PA} 21.3.1. General This section covers tI repainting of existing carried out all steelw the site. This Clause shall be re Steel against Exterior Where repainting of a shall be ascertained bj and details submitted painting system to be| The repair of small al treatment to small are| 21.5 of this Specifica| fer's advance sample above and to the details given in the +t data sheets and written statement ‘ake available at his own cost all facilities necessary for the taking he above mentioned sampling. Engineer, the samples taken from paint delivered to the work are ie sample submitted in advance of the work, the Engineer may reject ithe work which, in his opinion, are represented by the sample. ll be replaced by the Contractor at his expense. INTING 1@ painting of steel members under field conditions, including the tructures. Where field painting of steel for new structures is to be rk shall be primed as specified in this Clause before transporting to \d in conjunction with AS 2312 ‘Guide to the Protection of Iron and Atmospheric Corrosion’ existing structure is to be carried out the existing coating system(s) the Contractor prior to the commencement of painting operations to the Engineer. The Engineer will advise the Contractor of the used in each location. {eas of protective treatment, as well as application of protective 's following erection shall be carried out in accordance with Clause ion 21.3.2. Surface Preparation All parts of the bridge to be repainted shall be washed down using high pressure water sprays. The water sj 20 000 kPa (2 000 ki moisture and debris. If the high pressure w: shall be used to ensur The surface of all met as grade Sa 2 in AS Preparation standards| ray equipment shall be capable of generating pressures of up to iem*). Particular attention shalll be given to areas which trap iter spray does not remove all the dirt and debris, trowels or brushes that the surface of all metalwork is clean prior to painting. Iwork to be repainted shall be blast cleaned to a standard described 627 Part 4 and as depicted in AS 1627 Part 9 (Pictorial Surface for painting steel surfaces) MSS. Strid Soe 2 Brcpe Constuctan = 26 Jeary 1999 21-721. PROTECTIVE TREATMENT OF STEELWORK The Contractor shall ensure that no deep scratching on the steel surface due to prolonged use of needle guns in the one location occurs. Flame cleaners shall be used so that the paint surface is only softened or begins to peel and not so that the steel is heated to such a temperature that it begins to glow. Prior to abrasive blasting treatment, any dirt or grease shall be cleaned off and heavy layers of rust shall be removed by chipping Metalwork which has previously been galvanised may be cleaned by wire brushing to @ grade Sa 1 finish if the depth of pitting is not greater than 5 mm. if the depth of pitting exceeds 5 mm and/or the extent of rust is, in the opinion of the Engineer, sufficiently large then the metalwork shall be blast cleaned as described above. ‘Sand or any substance containing free silica shall not be used as an abrasive in any blasting operation without the approval of the Engineer. Representative ilmenite or copper slag may be used as a blasting agent. The use of other blasting agents may be consented by the Engineer The operator of blasting equipment shall wear an air supply helmet and appropriate oil filters shall be fitted to the air lines. All compressed air used in blast cleaning and blowing down after cleaning shall be free from oil and moisture. Blast cleaning shall be discontinued by the Contractor when the wind direction is such as to cause a dust nuisance to any nearby residents or road users. ‘The surface shall be cleaned of any traces of blast products on the surface and in pockets, pits and corners by brushing with clean brushes, blowing with compressed air or vacuum cleaning All areas of steel damaged by rust, paint chippers, needle guns, grit blasting, accidents, etc and with jagged peaks projecting as a result, shall be suitably prepared by filing or grinding etc. before painting so that a profile height of 50 ym is not exceeded. The priming coat shall be applied to the steel surface within four (4) hours of the surface being cleaned. If a cleaned surface is allowed to remain unpainted longer, it shall be recleaned before priming, 21.3.3. Number of Coats and Colours All metalwork to be repainted (other than small areas requiring touching up only) shall be coated by the system shown on the Drawings or in the Special Specifications. The paint systems and the dry film thickness of each coat are described in the table below: snd Spacicnans fr Bdge Con21. PROTECTIVE TREATMENT OF STEELWORK System Coat Type Thickness (mmi 1 Primer Alkyd based zinc chromate 40 Undet Coat - : Finish Coat Alkyd based enamel 50 2 Primer Epoxy Zinc Rich 75 Unde} Coat Epoxy 100 Finist{ Coat Polyurethane 30 3 Primer Epoxy Zine Rich 75 Undet Coat Epoxy 100 Finist{ Coat Epoxy Finish 50 4 Primer Epoxy Zine Rich 75 Undet Coat Chlorinated Rubber 30 Finist{ Coat Chlorinated Rubber 30 5 Primer Aluminium Epoxy Mastic 120 Undet Coat Aluminium Epoxy Mastic 120 Finist| Coat Polyurethane 30 Succeeding coats of ppint shall be of such shade as to contrast sharply with the coat being covered, 21.3.4. Thickness of Paint Film The dry film thicknesq of each coat shall be as set out in the Table above. Particular attention shall be paid to achieving this film thickness on all corners, edges, rivets and bolts. The Contractor shall monitor wet film thickness to ensure that the minimum dry film thickness is achieved The paint colours shall be as shown on the Drawings and the Contractor shall use the following the conversion dry film thickness to wet film thickness: Wet film thickness # | Dry film build (ym) x 100 % Volume solids OMS6.5E -Straae Jos Badge Constucten «26 Janaay 1993 21-921. PROTECTIVE TREATMENT OF STEELWORK The dry film thickness of paint shall be measured by the Engineer's Representative with a calibrated magnetic film thickness gauge. The manufacturer's specification will be used to determined the number of readings to be taken to ensure an accurate measurement of the paint thickness. 21.3.5. Quality of Paints a General All ingredients used in the manufacturer of the paints specified shall comply with the requirements of the applicable current ASTM or Australian Standard Specifications for such materials. No paint shall be used in the work without the prior consent of the Engineer. The use of red lead type paints will not be permitted. b. Alkyd Based Zinc Chromate Paint Alkyd based zinc chromate paint, of a type as shown on the Drawings or in the Special Specifications, shall be supplied in a ready mixed condition and shall comply with the requirements of Australian Standard K 211 'Zinc Chromate Primers for Structural Steel’. Aluminium Epoxy Mastic Aluminium Epoxy Mastics, of a type as shown on the Drawings or directed by the Engineer, shall contain ninety percent (90%) solids by volume and have a Volatile Organic content of 93 grams per litre. They shall be able to withstand a maximum continuous temperature of 82 degrees Celsius. The Contractor shall demonstrate that the mastic is compatible with the existing paint system that it is to cover. Any use of compatible thinners shall be as set out in the manufacturer's instructions for use. d Polyurethane Epoxy The polyurethane epoxy shall be a single component system containing 49 + 2 percent of solids and shall be able to withstand a maximum continuous temperature of 82 degrees Celsius Any use of compatible thinners shall be as set out in the manufacturer's instructions for use. e Epoxy Zinc Rich Primer Epoxy zinc rich primer, of a type as shown on the Drawings or directed by the Engineer, shall be supplied in a suitable two part pack and shall comply with the requirements of Australian Standard AS 2674 ‘Paints for Steel Structures - Epoxy Primer (two parts)’ 21-10 258.5 «Staal Soecticeuons for Beage Constucten «26 Jenumy 1983,21. PROTECTIVE TREATMENT OF STEELWORK f. Chlorinated Rubber Chlorinated rubber, high build paint, of a type as shown on the Drawings or directed by the Engineer, shall be suipplied in a ready mixed condition and shall comply with the requirements of Austfalian Standard. AS 2672 Paints for Steel Structures - Chlorinated Rubber, high build g. Alkyd Based Enamel Alkyd based enamel paint, of a type as shown on the Drawings or directed by the Engineer, shall be supplied in already mixed condition and shall comply with the requirements of Australian Standard. AS 2673 Paints for Stee! Structures - alkyd/micaceous iron oxide. h, Epoxy Pajnt Epoxy paint, of @ typp as shown on the Drawings or directed by the Engineer, shall be supplied in a suitable {wo part pack and shall comply with the requirements of Australian e Standard. AS 2603 Pints for Steel Structures - Full gloss (two pack). i. Zinc Rich| Cold Galvanising Paint Zinc rich cold galvanising paint, of a type as shown on the Drawings or directed by the Engineer, shall be supplied in @ ready mixed condition and shall comply with the : fequirements of a tye 2 primer as set out in Australian Standard AS 2204 ‘Zinc Rich Organic Priming Paint Manufacturer's Certificates Before any consignment of paint or paint material is used in the work the Contractor shall furnish to the Engines Manufacturer's Certificates for such consignment, certifying that the paint or paint material complies with the relevant specification and, in addition giving: escription of material e vendor's reference number batch number quantity in batch date| of manufacture : k. Storing and Sampling of Paint Paint shall be suppliet in a ready mixed condition and shall be purchased as soon as practicable before application. Drums in which paint|is stored shall be kept in a cool place and turned top to bottom at least once each week| Paint older than 6 months shall not be used in the work and shall be immediately removed from the work site BRS. - Stance Sonctcavon fo Budge Consnucion + 26 Janry 1993, 21-1121, PROTECTIVE TREATMENT OF STEELWORK At any time during the progress of the work, the Engineer may take samples of paints in use in the work for testing. If any doubt exists as to the quality of any consignment of paint, such paint shall not be used until it has been tested and proved satisfactory. 21.3.6. Application of Paint The paint shall be applied so as to produce a smooth, uniform even coating in close contact with the metal, or with previously applied paint, and shall be worked into all corners and crevices. The application of zinc chromate paint by spray will not be allowed. Zinc chromate paint may be applied by brush or roller. Use of the roller is restricted to flat areas where a uniform coating can be achieved. Application of iron oxide top coats by spray painting is permissible. Application of silica paint, if consented to by the Engineer (refer Clause 21.3.9) will not be permitted by spray unless the operator is equipped with a respirator or an air supply helmet. Silica paint for this Specification is classified as a paint having a free silica content by weight of two percent (2%) or greater. The epoxy zinc rich primer and the zinc rich cold galvanising paint may be applied by either brushing, rolling or spraying. The aluminium epoxy mastic and the polyurethane may be applied by either brushing, rolling or spraying. All paint shall be thoroughly mixed before application and shall be kept thoroughly stirred during application to ensure that the pigment is kept in uniform suspension. Unless stipulated by the manufacturer, no thinners, driers, extenders or any other admixture shall be added to any paint. All painting shall be performed during daylight hours. Paint shall not be applied under the following conditions . when the relative humidity is greater than 85% . where weather conditions indicate that work is likely to be interrupted by rain, fog or mist or if there is a forecast of these occurring within the next 24 hours . when the temperature of the surface is less than 3 degrees Celsius above dew point, or when conditions do not comply with Fig. 21.1. These conditions are to ensure that condensation does not occur. . when high wind conditions exist, especially when spray techniques are being employed. Loss of atomised particles of paint and possible contamination by dust and foreign particles is to be avoided 21-12 MSHS Stnaia Spue. whi pain} 21. PROTECTIVE TREATMENT OF STEELWORK re the surface is hot enough to cause blistering and produce a porous film . when a surface is wet, damp or dusty. At least 48 hours sha| coat which is not thor I elapse between coats. Paint shall not be applied over a previous loughly dry. 21.3.7. Controlled Environmental Conditions Under Which Paint May Be Applied The Engineer may apy rove the use of waterproof sheeting over light framing to keep the Painting area dry and/or to the use of other means to provide suitable conditions for Painting, 21.3.8. Defective Any painting found ur or application or from then be thoroughly c| Specification. 21.3.9. Painting On areas of steel stru Painting satisfactory by the Engineer due to faulty paints, improper cleaning ny Cause whatsoever, shall be removed to bare metal which must leaned and repainted in accordance with the requirement of this f Corrosion Prone Areas tures (cross girders, etc) which are subject to severe corrosion one of the painting systems below may be used in addition to that set out in Clause 21.3.3 as shown on the Drawin, . one pes after appr . two steel The The type of epoxy coal !$ or directed by the Engineer: epoxy top coat of 150 ym minimum dry film thickness over the ified oil based paint system. The epoxy coat can be applied only the initial oil based paint has dried sufficiently, that is after ximately one (1) month (2) epoxy coats, each of 150 ym minimum dry film thickness, over cleaned to grade Sa 2% as described in AS 1627 Part 9. wo coats are : epoxy priming coat epoxy top coat fone (1) epoxy priming coat of 150 ym thickness over the specified oil based system (if any). One or two coats of chlorinated rubber, each of 100 ym to 125 ym minimum dry film thickness. 's shall be as shown on the Drawings or as directed by the Engineer. fo Broae Consnucton «26 Janay 1983, 21-1321. PROTECTIVE TREATMENT OF STEELWORK 21.4, METALLIC COATINGS 21.4.1. Galvanising All galvanizing specified on the Drawings shall be by the hot dip galvanizing process in accordance with the requirements of AASHTO M 111 (ASTM A 123) ‘Zinc (Hot Galvanized) Coatings’, AASHTO M 232 (ASTM A 153} ‘Zinc Coating (Hot-Dip) on Iron and ‘Steel Hardware’ and this Clause. Surface Preparation Steelwork shall be precleaned in accordance with the requirements of AS 1627 Part 1 followed by acid pickling in accordance with the requirements of AS 1627 Part 5. Abrasive blast cleaning to Class 2 finish in accordance with the requirements of AS 1627 Part 4may be used. Surface contaminants and coatings which cannot be removed by the normal chemical cleaning process in the galvanizing operation shall be removed by abrasive blast cleaning ‘or some other suitable method b. Galvanizing All articles to be galvanized shall be handled in such a manner as to avoid any mechanical damage and to minimize distortion. Galvanising parameters such as galvanizing temperature, time of immersion and withdrawal speed shall be chosen to suit the requirements of the article being galvanised. The composition of the zinc in the galvanising bath shall be not less than 98.0% zinc. Coating Requirements i. Thickness The thickness of the galvanized coating shall conform with the table below: Minimum average coating on any individual tests area Products Coating Mass | Equivalent Thickness Gram/sq.m Micron Steel 5 mm thick and over 600 84 Steel under 5 mm thick but not 450 63 less than 2 mm Steel less than 2 mm thick 350 49 Centrifuged work 300 42 21-14 []MSO‘SE - Straud Sonotcnons fer ge Consucton «26 January 1883The thickness of the below: 21. PROTECTIVE TREATMENT OF STEELWORK jalvanized coatings of threaded fasteners shall conform with the table Minimum Average Minimum Individual Coating Mass |/ Equivalent Thickness | Coating Mass Equivalent Gram/Sq.M Micron Gram/Sq.M_ | Thickness Micron 375 52 300 42 Actual thicknesses sI arise, as to the qual AASHTO T 65 ‘Test: Articles or ASTM E 3} (Electromagnetic Test ‘The galvanized coatin| possible, and free fro article. On silicon kill sound and continuou: The integrity of the c measurements. Where slip factors ar these shall be obtain surfaces. Where a paint finish i and all edges shall be| all be measured by an suitable thickness meter. Should any doubt lity of galvanizing, tests shall be carried out in accordance with for Weight of Coating on Zinc-Coated (Galvanised) Iron or Steel ‘6 ‘Measuring Coating Thickness by Magnetic Field or Eddy Current Methods’ Surface Finish W shall be continuous, adherent, as smooth and evenly distributed as any defect that is detrimental to the stated end use of the coated d steels, the coating may be dull grey, provided that the coating is jating shall be determined by visual inspection and coating thickness required to enable high strength friction grip bolting where shown, }d after galvanizing by suitable mechanical treatment of the mating to be applied to the galvanized coating, all spikes shall be removed free from lumps and runs. iii. | Adhesion The galvanized coatin| transport and erecti AASHTO M 111 (AS iv. Pa: Galvanized reinforcin« solution applied by thy d. Transpor Galvanized componen} ventilated conditions shall be sufficiently adherent to withstand normal handling during In. The Engineer may test the adhesion in accordance with M A 123) ‘sivation bars and ferrules shall be passivated in a 2% sodium dichromate e galvanizer. and Storage 's shall, wherever possible, be transported and stored under dry, well (0 prevent the formation of wet storage staining. for tnage Consiacton = 26 Janamy 1982 21-1521. PROTECTIVE TREATMENT OF STEELWORK A chromate passivation treatment after galvanizing may be used to minimise the wet storage staining which may occur on articles unable to be stored in dry, well ventilated conditions. Any wet storage staining shall be removed by the galvanizer if formed prior to leaving the galvanizer's plant. Provided that the coating thickness complies with the requirements of AASHTO M 111 (ASTM A 123), no further remedial action shall be required to the stained areas. 21.4.2. Electroplating All parts which are to be electroplated with zinc or cadmium, shall be plated in accordance with AS 1789 ‘Electroplated coatings - Zinc on iron or steel’, Fe/Zn 12c Type C, or in accordance with Australian Standard AS 1790 ‘Electroplated coatings - Cadmium on iron or steel’, Fe/Cd 12c Type C. 21.5. | REPAIR OF DAMAGED PAINT AND METALLIC COATINGS 21.5.1. Damaged Primer Coats Scratched and slightly damaged areas of the primer coat shall be touched up to the satisfaction of the Engineer, using an appropriate cleaning process and an approved primer and minimum dry film thickness identical to that used for the original priming operation. Badly damaged areas of primer coat shall be abrasive blast cleaned and re-coated with the approved primer in accordance with the requirements for these processes. 21.5.2. Damaged Final Coats and Spot Painting Field welds, the heads of bolts and all areas where the shop paint has been damaged or has been omitted for field connections shall be cleaned to base metal with wire brushes or other approved methods. Two coats of priming paint shall then be applied. This paint shall be brushed out evenly so as to produce a uniform coating of the specific film thickness. Ample time for drying shall be allowed between successive application of paint. After obtaining the consent of the Engineer to the repairs of the primer, application of an approved primer to the minimum coating thickness specified shall be applied. Painted areas which, in the opinion of the Engineer, have been badly damaged shall be cleaned and re-coated with the approved paints in accordance with the requirements of this Section, 21-16 MSE. - Stent Soestcetont for Bndge Canstucton «26 Janumy 188321.5.3. Damaged Scratched and slight! touched up in accord} Galvanised Coatings’ zine-rich coating to th Badly damaged galva 21.6. MEASURI Unless stated otherwik painting of steelwork the paint system spec Items which are to b the cost of such coati in Section 19 of this Measurement, for pay! ‘of the Contractor shal repairs be carried out, 21.7. PAYMENT Unless expressly stat will be made the cost 21. PROTECTIVE TREATMENT OF STEELWORK Metallic Coatings damaged areas of galvanised and electroplated coatings shall be jance with ASTM A 780 ‘Practice for Repair of Damaged Hot-Dip sing an suitable cleaning process and an approved two-pack epoxy le minimum coating thickness specified. ised and electroplated surfaces will not be accepted EMENT e in the Special Specifications, measurement, for payment, of the hall be made on the surface area which is prepared and coated with ified and accepted by the Engineer. galvanised or electroplated will not be measured for payment and 1g shall be deemed to be included in the fabrication costs as set out specification. \ent, of repairs to coatings required to be carried out due to no fault I be made on the surface area on which the Engineer directs that }d that separate payment for painting, galvanising or electroplating furnishing, preparing and applying all materials which are required for the cleaning, painting or coating operations, including all labour, tools and equipment, shall be included in thi and installing the vari Where separate paymé rates bid in the priced Bid Schedule for installing and for furnishing us items, nt for protective treatment is to be made, the item for payment will include full payment for providing all labour, materials (except materials specified to be supplied by the Emplo: and painting or coatin Payment for the item of steelwork and paint of this Specification a Repairs to surface tre: Employer's expense All materials, tools an the completed work: otherwise. Any work in addition t be paid for in accorda er}, tools, equipment and any other work incidental to the cleaning of the various items of steelwork. ill include provision, erection and removal of scaffolding, cleaning Ing oF Coating of steelwork all in accordance with the requirements \d no separate payment will be made for any of these. tment which are directed to be carried out by the Engineer at the ill be paid for as a separate item. equipment supplied by the Contractor which do not form part of shall remain the property of the Contractor unless specified that shown or specified which may be ordered by the Engineer will ce with the provisions of the General Conditions of Contract. 1993 21-1721. PROTECTIVE TREATMENT OF STEELWORK ‘De “SUNIVEBUWAL INZIBWY BYAHASOWLV INSIGNY ONY SHNLVEAdW3L SOVIUNS ILI N33ML39 dIHSNOLLVTH. AMIGINNH 3AUWTaY INaOuad 06 08 oe 09 os ov. oe, oz Jem Jo uoHesuepL0d ProAe 0} aunje1odus {Ue4l 96St esnjeeduso) se Burpunos Hdvuo 40 asn a14WVvxa ‘e0e}ns jejous "4659 HY UENID “hire Bis 3 2 7 z 5; ‘BUNLVH3dW3L 3OV4UNS TW13W WOWININ 8 2 8 Z {SESE - Stand Spectcabons for Ege Consrction- 30 Januay 21-18MINISTRY OF PUBLIC WORKS DIRECTORATE GENERAL OF HIGHWAYS REPUBLIC OF INDONESIA STANDARD SPECIFICATIONS FOR BRIDGE CONSTRUCTION SECTION 22 este TION AND ERECTION OF INOR METALWORK ITEMS JANUARY 1993 DOCUMENT No. BMS8-S.ETABLE OF CONTENTS 22. FABRICATION AND ERECTION OF MINOR METALWORK ITEMS 22.1. GENERAL 22-1 22.2. MATERIALS 22-1 22|2.1. Specifications 22-1 22|2.2. Testing of Materials 22-1 22|2.3. Storage of Materials 22-2 22.3. WELDING 22-2 22.4. STRAIGHTENING MATERIALS 22-2 22.5. CUTTING AND SPLICING 22-2 22.6. BEARINGS 22-3 22.7. RAILINGS 22-3 22.8. PROTECTIVE TREATMENT 22-3 22.9, PACKING AND DELIVERY 22-4 2219.1. Marking for Final Erection 22-4 22|9.2. Packing and Marking 22-4 2219.3. Transport and Handling 22-4 22.10. ERECTION OF MINOR METALWORK 22-4 22110.1. General 22-4 2210.2. Lamp Standards 22-4 22110.3. Name Plates 22-4 22.11. QUALITY OF WORKMANSHIP AND INSPECTION 22-5 22.12. MBASUREMENT AND BASIS OF PAYMENT 22-5 2212.1. Mass of materials 22-5 22.12.2. Basis of Payment 22-5 for Bngye Canatucton i22. FABRICATION AND ERECTION OF 22.1. GENERA| This section covers th MINOR METALWORK ITEMS L fabrication and erection of minor metalwork items. 22.2. MATERIALS 22.2.1. Specifications Structural grade steel “Structural Steel’ The dimensions of hot piling beams shall con Requirements for Roll The dimensions of 1 appropriate reference publication as shown on the Drawings. The steel shall be sup) Excessively rusted, b Cast Iron, Copper, zi relevant requirements AASHTO M 105 AASHTO M 138 AASHTO M 120 AASHTO M 107 AASHTO M 163 tag (as (as a (as Nic! Aluminium shall be of with the relevant re Standards and Data’. 22.2.2. Testing The Contractor shall s comply with the requi other tests called for Engineer. hall conform to the requirements of AASHTO M 183 (ASTM A 36) rolled structural steel sections with the exception of rolled steel lorm to the requirements of AASHTO M 160 (ASTM A 6) ‘General 1d Steel Plates, Shapes, Sheet Piling and Bars for Structural Use’. lled steel piling beams shall conform with those given in the ied in accordance with the provisions of AASHTO M 160. nt or damaged steel will be rejected. nc, Bronze and Corrosion Resistant Stee! shall conform to the f the following standards TM A 48) ‘Grey Iron Castings’ {TM 8 152) ‘Copper Sheet, Strip, Plate and Rolled Bar’ ITM B 6) ‘Zinc Metal (Slab Zinc) TM B 22) ‘Bronze Castings for Bridges and Turntables’ TM A 743) ‘Corrosion Resistant Iron-Chromium, tron-Chromium- el and Nickel Based Alloy Castings for General Use’ in alloy and temper type as shown on the Drawings and shall comply Juirements of the Aluminium Association (U.S.A.). ‘Aluminium f Materials pply evidence satisfactory to the Engineer that all materials or parts ements of the standard Specifications referred to herein and with y this Specification and/or otherwise as may be specified by the n= 28 Jenny 1993 22-122. FABRICATION AND ERECTION OF MINOR METALWORK ITEMS Test certificates shall show the results of mechanical tests and chemical analysis (where applicable) of the material or parts used in the work. No material or part shall be used in the work until it has been identified with the tests to the satisfaction of the Engineer. The costs of all testing shall be borne by the Contractor. 22.2.3. Storage of Materials All materials, whether fabricated or not, shall be stored above ground on platforms, slabs, or other supports, and adequately protected against corrosion. 22.3. WELDING All welding of steel shall comply with the requirements of the AASHTO - AWS ‘Bridge Welding Code’. The welding shall be carried out under the immediate and continuous supervision of a Person who, in the opinion of the Engineer, has had suitable training and practical experience in the execution of this form of construction. The welding shall be carried out by welders who, in the opinion of the Engineer, have had suitable training and practical experience of this form of construction. Welding shall not be done when the surfaces are moist, during periods of strong wind, or in wet weather unless the work and the welding operators are adequately protected. Welding of aluminium shall be carried out in accordance with AS 1665 ‘SAA Aluminium Welding Code’ or the equivalent American Welding Society standard 22.4. STRAIGHTENING MATERIALS All plates shall be flat, and rolled shapes and bars straight before marking out or being worked. Straightening shall be done by methods which will not damage the material. Sharp kinks and bends will be cause for rejection, Where hot bending is carried out the material shall be bent by suitable methods within the temperature range 600 to 650 degrees Celsius (cherry red). After bending the material shall be allowed to cool slowly in ait to ambient temperature. While cooling the work shall be protected from draughts or other rapid movements of air. 22.5. CUTTING AND SPLICING Steelwork may be cut by flame cutting, sawing or shearing unless specified otherwise. Surfaces produced by such cutting shall be finished square (unless a bevelled edge is called for) true and smooth to the required dimensions. 22-2 [USES Stans Sonsicavons for Brape Canstucton = 26 Janey 1883Where the finish of c 22. FABRICATION AND ERECTION OF MINOR METALWORK ITEMS it edges is not satisfactory, they shall be ground or machined to the satisfaction of the Engineer. All corners on exposed edges shall be rounded to a radius of approximately 2 mm. Unless consented to y the Engineer splices will not be permitted other than at points shown on the Drawings. Should the Contractor desire to splice any members elsewhere, details of the design ind position of the proposed splices shall be submitted for consent Fabrication of the members concerned shall not proceed until this consent has been obtained. 22.6. BEARINGS The surfaces of sole|plates of girders shall be finished to the grade as shown on the Drawings or directed If necessary the under by the Engineer and shall have full contact with the girder flanges. iside of the flange plate and the top surface of the sole plate shall be machined to obtain full contact. The top surfaces of base plates and the bottom surfaces of sole plates shall bq machined to the surface finish shown on the Drawings. All sharp edges of bearing plat welded. Cast pedest: and shall be rough fi is shall be slightly rounded except in the case where an edge is to be Is shall be machined on surfaces that are to be in contact with steel, ished on surfaces that are to be in contact with concrete. Sliding plates shall be finisheti as shown in the Drawings. In finishing the surfaces of expansion bearings, the cut of the tool shall be in the direction of the expansion. Edges of bearing plates that will be in contact with roller flanges shall be machined smooth and shall be parallel with the roller| flanges. Sole plates, or the holes for the attachment of sole plates shall be accurately fo the Drawings. ated on girders and within the dimensional tolerances as shown on Rollers and rockers stall be machined to a uniform radius and the surface finish shall be in accordance with that|shown on the Drawings. Rollers of an approved cold finished steel bar having a smooth rue surface need not be machined. 22.7. RAILINGS. Steel railings shall bf fabricated and erected in accordance with the requirements of Section 25 of this Specification. 22.8. PROTEC Protective treatment, shall be applied to tt sTIVE TREATMENT lof a type as shown on the Drawings or in the Special Specifications, le minor metalwork items in accordance with the requirements of Section 21 of this Specification BUSES - Stace Spetcarons tor Budge Consnucten «26 Jenny 1999 22-322, FABRICATION AND ERECTION OF MINOR METALWORK ITEMS 22.9. PACKING AND DELIVERY 22.9.1. Marking for Final Erection Each part shall be marked with approved distinguishing marks and stamped with durable markings. Paint of different colours shall be used to distinguish similar parts. Two (2) copies of drawings showing these markings shall be supplied free of charge to the Engineer when the metalwork is despatched. 22.9.2. Packing and Marking All open joints, ends and projecting parts shall be protected from damage in transit in such ‘manner as to stiffen the member and prevent distortion. Shipping marks shall be carefully stencilled on each piece in a conspicuous position. Members shall have their weights clearly marked upon them. 22.9.3. Transport and Handling The method of transporting and of handling the metalwork shall be subject to the consent of the Engineer. Special care shall be taken in the packing and methods of support and lifting during transport and handiing of all metalwork to prevent distortion and damage to the metalwork and its protective coating, 22.10. ERECTION OF MINOR METALWORK 22.10.1. General Minor metalwork items shall be installed as shown on the Drawings or as specified in other Sections of this Specification or the Special Specifications. 22.10.2. Lamp Standards The lamp standards shall be placed, at the locations as shown on the Drawings, vertically with the outstand at right angles to the carriageway centreline. Each lamp standard shall be inspected in position by the Engineer before being attached permanently to the deck. 22.10.3. Name Plates The Contractor shall fix the name plates at the ends of the bridge on the right hand side as the bridge is approached 22-4 MSS. E Stnais Spactemens fo Badge Contucton = 26 January 198322, FABRICATION AND ERECTION OF MINOR METALWORK ITEMS The location and met! Engineer. 22.11. QUALIT/ The Engineer shall hi premises for the puri not in accordance wit be made good. The C| required in connectior 22.12. MEASU} 22.12.1. Mass of The mass of minor st with the mass calci weighing, For the purpose of m below, such as lamp expansion dams, roa brackets, post, cond will be considered as| Unless otherwise pro the following weights: Unit weights, kilograr 22.12.2. Basis o The item for metalw equipment and any of Payment for the iter separate payment wil Al Br Ci Ir Ir Ir sth ek zi }od of fixing shall be as shown on the Drawings or as directed by the ]¥Y OF WORKMANSHIP AND INSPECTION ve full liberty at all reasonable times to enter the Contractor's se of inspecting the work. Any work found defective or which is the Drawings or this Specification may be rejected and shall at once ntractor shall supply free of charge all labour, tools and scaffolding with the inspection of the work. JREMENT AND BASIS OF PAYMENT materials el items supplied under this Contract will be paid for in accordance llated from the dimensions shown on the Drawings and not by asurement for payment components fabricated from metals listed tandards, alloy steel plates, anchor bolts and nuts, shoes, rockers, way drains and scuppers, bolts embedded in concrete, cradles and jit and ducts, structural shapes and sheet plates for pier protection Iminor steel items. ded, the weight of metal paid for will be computed and based upon 1S per cubic metre sminium, cast or rolled 2,800 Nze OF Copper alloy 8,700 pper sheet 9,000 In, cast 7,200 in, malleable 7,600 in, wrought 7,900 el, cast or rolled, including alloy, copper 7,950 ring and stainless 1c 7,300 Payment irk will include full payment for providing all labour, materials, tools, her work incidental to completion of metalwork. will include jigs, cleaning, protective coatings and delivery and no Il be made for any of these. fer Bdge Construction «26 Janey 1993 22-522, FABRICATION AND ERECTION OF MINOR METALWORK ITEMS All materials, tools and equipment supplied by the Contractor which do not form part of e the completed works shall remain the property of the Contractor unless specified otherwise. ‘Any work in addition to that shown or specified which may be ordered by the Engineer, will be paid for in accordance with the provisions of the General Conditions of Contract. 22-6 OMSS.5.E- Sunde Spactemons fr Budgr Contucton «26 January 1983Au STA FOR DIRECTORATE GENERAL OF HIGHWAYS MINISTRY OF PUBLIC WORKS REPUBLIC OF INDONESIA DARD SPECIFICATIONS RIDGE CONSTRUCTION SECTION 23 BEARINGS . Ls ON is, cr SS JOINTUN Cagd 1a AND RUSS JANUARY 1993 DOCUMENT No. BMS8-S.ETABLE OF CONTENTS 23. BEARINGS 23.1 GENERAL 23.2. UNREINFORCED ELASTOMERIC BEARING PADS AND STRIPS - SUFRPLY 23.2.1. General 23.2.2. Elastomer 23.2.3. Pads and Strips 23.2.4. Test Certificates 23.3. ELASTOMERIC BEARINGS - LAMINATED - SUPPLY 23.8.1. General 23.8.2. Elastomer 23.8.3. Bearings 23.8.4. Delivery of Bearings 23.8.5. Test Certificates 23.4. ELASTOMERIC BEARINGS - INSTALLATION 23.4.1. Marking and Delivery of Elastom 23.1.2. Installation of Elastomeric Bearings 23.5. STEEL BEARINGS Bearings 23.5.1. General 23.5.2. Materials 23.5.3. Pins and Rollers 23.5.4. Workmanship 23.5.5. Testing 23.5.6. Tolerances 23.6.7. Cleaning 23.5.8. Workshop Assembly 23.5.9. Acceptance 23.6. INSTALLATION OF STEEL BEARINGS 23.6.1. General 23.6.2. Placing 23.6.3. Checking, Cleaning and Lubrication 23.6.4. Tolerance on Final Installation 23.7. POT TYPE BEARINGS - SUPPLY 23.7.1. General 23.7.2. Information To Be Supplied 23.7.3. Bearing Proportions and Materials 23.7.4. Properties of Materials 23.7.5. Inspection of Bearings 23.7.6. Testing of Bearings 23.7.7. Test Certificates 23.7.8. Protective Treatment 23.7.9. Marking and Delivery 23.8. INS|TALLATION OF POT BEARING 23.9. PROPRIETARY BEARINGS 23.8.1. Responsibility 23.0.2. Testing 23.8.3. Rejection of Bearings 23.10. MEASUREMENT 23.11. PAYMENT 23-1 23-1 23-1 23-4 23-1 23-3 23-6 23-6 23-6 23-6 23-8 23-8 23-10 23-10 23-10 23-11 23-11 23-11 23-12 23-12 23-12 23-13 23-14 23-14 23-14 23-14 23-14 23-14 23-15 23-15 23-16 23-16 23-16 23-16 23.47 23-17 23-18 23-19 23-19 23-20 23-20 23-20 23-20 23-21 23-22 23-22 23-2223.1. GENERAL This section covers 23. BEARINGS 1@ supply and installation of the bridge bearings in accordance with the requirements of this Specification and as shown on the Drawings. The Contractor shall xercise the utmost care in setting out and fixing all bearings in their correct positions, and in ensuring that uniformity is obtained in all bearing surfaces. Bearings shall be ha \dled with care and stored under cover by the Contractor. The Contractor shall be responsible for any costs involved in making good damage which may occur after delivery. Expansion bearings temperature. Where from the nominated direction regarding ar lare designed and dimensioned for installation at a nominated Ithe temperature is likely to vary by more than + 5 degrees Celsius femperature, the Contractor shall request the Engineer to give a 'y allowance which shall be made in setting the bearings. Where shown on the| Drawings or in the Special Specifications that the Bearings will be supplied by the Empl yer only the relevant installation clauses of this Section shall apply. 23.2. UNREINFORCED ELASTOMERIC BEARING PADS AND STRIPS - SUPPLY 23.2.1. General Pads and strips shall other materials so co be extruded initially al 23.2.2. Elastomer be manufactured from natural rubber or chloroprene together with pounded and cured as to give the properties specified. Strips shall \d both pads and strips shall be vulcanised in a mould under pressure. The elastomer to be used in the manufacture of the pads or strips shall be tested as set out in Table 23.1. Thes approved laboratory the specimens may taken from every 25( the requirements spe} Material which does in the manufacture of tests shall be at the Contractor's expense and shall be done at an Two days notice shall be given so that preparation and/or testing of Je observed by the Engineer, if so required. Three samples shall be kg batch of mixed elastomeric material and each sample shall meet ified jot comply with the requirements stated in the table shall not be used pads or strips. 23.2.3. Pads and Strips a. ensit Pads and strips shall tolerances set out in ns ye manufactured to the dimensions stated on the Drawings within the (Table 23.2. Strips shall be supplied in lengths of not less than 1.8 fer Bdge Centuctan -# Faby 1993 23-123. BEARINGS. ™m unless shown otherwise on the Drawings. Pads and strips which do not comply with the requirements specified may be rejected b. Testing i. General Testing of pads and strip samples will be arranged by the Engineer without charge to the Contractor. All pads shall be tested. Pads with holes shall be tested with holes plugged temporarily with elastomeric plugs having similar properties to the pads. ‘The samples of strips for testing shall be without holes. A minimum of three samples shall be tested. One additional sample shall be tested for each 20 m or part thereof in cases where the overall length of strip supplied is in excess of 60 m. Sample pieces of strips, 0.4 m long, for testing, shall be manufactured with the strips and may be cut from lengths of strips supplied for the bridge. No separate payment will be made for these samples. The equipment used for testing shall be capable of determining compressive and shear loads to within + 3% and deflections to within +1%. Where necessary to achieve the specified accuracy of testing, equipment shall be calibrated and results obtaining corrected accordingly. Testing shall be done within a temperature range of 15 degrees Celsius to 25 degrees Celsius. i“ ii Stiffness in Compression Each pad and sample of strip shall be loaded to 1.5 times the nominal design compressive load given in Tables 23.3 and 23.4 and the applied loading shall then be reduced to 0.1 times the nominal design load. The bearing shall again be loaded to 1.5 times the nominal design load and held for two minutes. The load shall be again reduced to 0.1 times the nominal design load and this load shall be maintained for one minute when deflection indicator gauges shall be set at zero. The pad or strip sample shall then be loaded at a uniform rate over a minimum period of one minute to 1.1 times the nominal design load and this load shall be maintained for one minute. Gauge readings shall then be taken to evaluate the compressive stiffness of the Pad or strip sample over the range of 0.1 to 1.5 times the nominal design load. Pads or strips represented by the sample tested, which exceed a tolerance of +25% on the required compressive stiffness given in Tables 23.3 or 23.4 may be rejected. iii, Stiffness in Shear After completion of the test of stiffness in compression, all pads and strip samples shall be tested in shear in pairs selected at random. A plate shall be centred between each pair to permit shear loads to be applied to the plate ina direction parallel to the short dimension to impose equal shear deflections on the pads or samples whilst they are under a compression equal to the nominal design compressive 23-2 GM58.5€ Stade Soestcabont for Brige Conssten - 6 Fabrumy 1883load given in Tables value for the duratior Prior to the commenc: to a maximum shear Tables 23.3 or 23.4 and compressive load After again applying ¢} shear at a uniform fi deflection given in Tat Each of the two pad: bearing to enable th Subsequent pads or bearings and its stiffn} 23. BEARINGS 3.3 or 23.4. The compressive load shall be kept constant at this of the test. ment of the test, the pad or strip samples shall be deflected in shear leflection of 1.5 times the nominal design shear deflection given in ind the shear load maintained for two minutes. Both the shear load shall then be released. 1 compressive load, the pads or strip samples shall be deflected in ite of about 25 mm per minute up to the nominal design shear le 23.3 or 23.4 and the force corresponding to this deflection noted. or strip samples tested initially shall be tested in turn with a third shear stiffness of the three individual bearings to be calculated. \strip samples shall then be tested with one of the three known '$S at the nominal design shear capacity calculated. Any one of the three original bearings tested may be paired with an unknown bearing provided their compressive stiffnes: given sufficient time es are similar and that the bearing subjected to repeated testing is 0 recover between tests to avoid significant hysterisis effects. Pads or strips represented by a sample which exceed a tolerance of + 20% will be rejected. iv. Visual Faults During the tests for strip sample shall be cured elastomer etc. lompression and shear stiffnesses, close observation of the pad or jaintained so as to detect any fault or variation due to inadequately Should any pad or strip sample exhibit any signs of failure such as : split per sign) then, unless the Cont satisfactorily, such p: 23.2.4. Test Cert The Contractor shall from the tests set our ing lanent deformation or icantly irregular or unsymmetrical surface bulging factor can demonstrate to the Engineer that the fault can be rectified ids or strips represented by the samples, shall be rejected. ificates upply @ copy of the test certificate showing details of the results in Clauses 23.2.2, 23.3.3 for each sample of the elastomer used in the manufacture of the bearings. The test certificate, showing details of the results from the tests set out in C| lauses 23.2.3, 23.3.3.b for the bearings, shall show the hardness and stiffness in compression and shear and note whether any tolerances have been exceeded or whether lany faults have been observed for Brage Corsten «6 Fata 1899 23-323. BEARINGS. Table 23.1 - Properties of Elastomer Property Method of Test ee | Hardness ASTM D 2240 60 + 5 points Ultimate Tensile ASTM D 412 4.00 min Strain cr) Tensile Strength ASTM D 412 17.5 MPa min Tear Resistance ASTM: 624 Die C 40.0 kNim min Compression set ASTM D 395 B 25% max 22 hrs 70 degrees Celsius Ozone resistances | ASTM D 1149 No cracking visible by eye 20% strain at 40 degrees _| after 100 hours Celsius £1 degrees Celsius and 1 ppm Accelerated ageing | ASTM D 573 Maximum permissible (70 hrs at 100 degrees —_} changes in properties. Celsius) Hardness +15, Tensile strength + 15% @ - 40% Evidence of recent testing of identical material may be accepted by the Engineer. Table 23.2 - Tolerances on Dimensions Tolerance (mm) Dimension Pads Strip Plan Dimensions 42.0 | + 2.0 width Bearing thickness +10 | +10 Out of parallel between 10 Os top and bottom surfaces Holes: — diameter +20 | +20 location +20 | +20 23-4 MSO E «Stands Sonctcouent for Brage Canstucton «6 Fabrumy 199923. BEARINGS Table 23.3 - Test Data for Pads Pads Size (mm) a hee ae 350x250x25 | 450x250x25 Shape Facto} 2.92 3.20 Hardness 60+5 60 +5 Nominal design compressive load (kN) 180 235 Compressive stiffness (kN/m)* 100000 142000 _| Nominal design shear deflection (mm) 12.5 12.5 Shear stiffness (kN/m) 2900 3700 Table 23.4 - Test Data for Strips a Strips Size (mm) (no holes| 400x65x20 400x95x20 | 400x125x2 (or, (or, 5 400x63x19) | 400x95x19) Shape Factor 1.40 1.92 1.90 Hardness 60 +5 60+5 60 +5 Nominal Design Compressive 58 80 105 Load (kN) | Compressive stiftngss 20000 35000 38000 (kNim)* Nominal design shear 10 10 12.5 deflection (mm) Shear stiffness (kN/m) 1100 1600 1650__ | . Compressive stiffness values taken from Fig. 18.6 and shear stiffness values from Fig. .5 (average of Memo 802 and HRB curves - zero to 50% strain) of NAASRA Bridge Design Specification - 1976. EMSE.S.€ -Stnaud Gowstcaong for Sadge Contucton 6 Febery 1983 23-523. BEARINGS 23.3. | ELASTOMERIC BEARINGS - LAMINATED - SUPPLY 23.3.1. General All bearings shall comply with the requirements of AASHTO M 251 ‘Laminated Elastomeric Bridge Bearings’ except where modified by this Specification. Bearings shall be made from natural rubber and other materials so compounded and cured as to give the properties specified. However, consideration will be given to the use of elastomeric materials other than natural rubber, subject to the approval of the Engineer to any variations proposed to the properties specified. Layers of elastomeric material shall be bonded to steel plates during vulcanisation in a mould under pressure. Bearings shall comply with the dimensional and shear and compressive stiffness requirements specified in Tables 23.5, 23.6 and 23.7. 23.3.2. Elastomer The elastomer to be used in the manufacture of the bearings shall be tested as set out in Table 23.5. These tests shall be done at an approval laboratory and two days notice shall be given so that preparation and/or testing of the specimens may be observed by the Engineer, if so required. Three samples shall be taken from every 250 kg batch of mixed elastomeric material and each sample shall meet the requirements specified Material which does not comply with the requirements stated in Table 23.5 shall not be used in the manufacture of the bearings. 23.3.3. Bearings Tolerances on Dimensions Bearings shall be manufactured to the dimensions as shown on the Drawings within the tolerances given in Table 23.6. Bearings which do not comply with the requirements specified may be rejected. b. Testing i. General All bearing shall be tested at the Contractor's expense. Tests shall be done at an approved laboratory and in the presence of the Engineer or his Representative who shall be given two days notice of the tests. The equipment used for testing shall be capable of determining compressive and shear loads to within +3% and deflections to within +1%. Where Necessary to achieve the specified accuracy of testing, equipment shall be calibrated and results obtained corrected accordingly. Bearings shall only be tested after a minimum period of two days has elapsed after pressure moulding 23-6 OMSE.SE .Staamd Sovcteatont for Brige Corstucton «6 Fabrumy 1883,Each bearing shall ‘as shown on the Dré Bearings which exci 23, BEARINGS Stiffness in Compression tested for stiftness in compression. The rated load at zero shear is ings. ied the relevant tolerance given in Table 23.7 on the compressive stiffness as shown of the Drawings may be rejected. iii, Sti After completion of ness in Shear the tests on stiffness in compression, all bearings shall be tested in shear. (The rated load at maximum shear and shear deflection capacity are given on the Drawings). The effective shear exceed a tolerance tiffmess at zero shear is shown on the Drawings. Bearings which +20% on this shear stiffness shall be rejected. iv. tt with Applied Rotation ‘One representative bearings, or part the shall be subject to ar zero shear rounded 1 non-standard bearin, axis of the bearing On completion of th accordance with Ci determined. Should 10%, the bearing, a ‘ating selected by the Engineer's Representative from every twenty reof, of each size of bearing shall be tested. Bearings to be tested angular rotation equivalent to the rotational capacity at rated load at the nearest 0.005 radian (or given on the Drawings in the case of js). The angular rotation shall be applied at right angles to the long hile applying the rated load at zero shear. ie rotation test the bearing shall again be loaded in compression in uses 23.3.3.b.ii, 23.7.4.b above and its compressive stiffness this stiffness differ from that previously determined by more than id those bearings represented by it, may be rejected. v. Vigual Faults During the tests for of the bearings shall elastomer to steel b Should any bearing + spl + pe + sig then, unless the Con} satisfactorily, such ompression and shear stiffness and under rotation, close observation be maintained so as to detect any fault or variation due to lack of nd, misplaced plates or inadequately cured elastomer etc. xhibit any signs of failure such as : itting manent deformation or nificantly irregular or unsymmetrical surface bulging. actor can demonstrate to the Engineer that the fault can be rectified earings shall be rejected. fer Brape Coneiuctan «8 Febuay 1993 23-723. BEARINGS. 23.3.4. Delivery of Bearings No bearings shall be delivered to site prior to a Release Note being issued by the Engineer or his Representative. The issue of such a note will be dependent on each individual bearing complying with Clauses 23.2.2, 23.3.3 of this Specification and exhibiting satisfactory workmanship. 23.3.5. Test Certificates The Contractor shall supply a copy of the test certificates showing details of the results from the tests set out in Clauses 23.2.3, 23.3.3.b for each sample of the elastomer used in the manufacture of the bearings, and of the hardness and stiffness in compression of the bearings and note whether any tolerances have been exceeded or whether any faults have been observed Table 23.5 - Properties of Elastomer 20% strain at 40 degrees Celsius +1 and 1 ppm. after Properties Method of Test Requirements Hardness. ASTM D 2240 48 min Ultimate Tensile Strain 5.75 min Tensile Strength ASTM D 412 17.5 MPa min Tear Resistance ASTM D 624 - Die. C 40.0 kN/m min Compression Set ASTM D 395 Method B 25% max (22 hrs 70 degrees Celsius) Ozone Resistance* ASTM D 1149 No cracking visible by eye 100 hrs Accelerated Ageing ASTM D 573 Maximum permissible change in properties Hardness +4 Tensil le Strength +10% Ultimate Tensile Strength 215% Static Modulus in compression and shear ** ASTM D 945 Values to be recorded Three samples per job where required by the Engineer. Evidence of recent testing of identical material may be accepted by the Engineer. 23-8 2MSE-SE «Stacia Spectcatont for Sige Canscton «8 Fairy 1983Table 23.6 - Tolerances on Dimensions 23, BEARINGS Tolerance (mm) a These dim subsequen} the bearin, s. Dimension Rectangular Rectangular ss 350x 170mm | < 350x170 mm and and Circular Circular <= 330 mmo = 330 mmo Plan dimensions +20 +40 Bearing thicknes: Ts 1Pomm +10 +10 T > 1P0 mm + 2.0 + 2.0 Rubber side cover + 2.0 +40 Outer rubber laygr thickness * £05 £05 Inner rubber layef thickness * +05 +10 Out of parallel between to and 10 +20 bottom surfaces| or between any two non-adjacent plates * Table 23.7 - Tolerances on Compressive Stiffness Compressive Layer Thickness Tolerance Deflectign* (mm) (%) (mm) < 0.75 6 30 9,12, 15,18 25 0.75 to 1.25 6 28 9, 12, 15,18 20 1125 to 2.5 6 25 9, 12, 15, 18 20 5 to 4.0 6 20 9,12, 15,18 15 >4 6 15 I 9, 12, 15, 18 15 E The tolerat properties ‘of compre} : As measut sive deflection. nsions may be determined be probing or drilling a small diameter hole ly plugged with identical material to that used in the manufacture of \ce for compressive stiffness is based on allowances for variations in elastomer, layer and overall bearings thicknesses and measurement fed from 0.1 to 1.1 times the rated compressive load at zero shear. 2MSESE «Stnaand Spentcaer 23-923. BEARINGS. 23.4. ELASTOMERIC BEARINGS - INSTALLATION 23.4.1. Marking and Delivery of Elastomeric Bearings Each elastomeric bearing shall be clearly labelled or marked with the part number or type, or other specified identification number. The bearings shall be wrapped in a double thickness of reinforced paper, lapped and taped. They shall be packed in timber crates, with styrene inserts and packing to prevent Movement and to protect corners and edges. The crates shall be of substantial construction, well braced and strapped and marked with the contents. Care shall be taken to avoid damage to the bearings during transport and handling prior to and during installation. 23.4.2. Installation of Elastomeric Bearings a. Bearing Pedestals Pedestals shall be cast monolithic with the substructure concrete with aggregate not less than 10 mm diameter. Alternatively they may be cast afterwards with a construction joint set at least 25 mm below the top of the supporting concrete or bonded to the concrete with an approved bonding agent after scabbling. Pedestals shall be cured in accordance with the requirements of Section 8 this Specification for a minimum period of 7 days. The bearing pedestals shall not be loaded before 10 days after casting Cored holes shall be provided in the position shown on the Drawings. Upper surfaces of pedestals shall receive a Class 2 finish in accordance with the requirements of Section 8 of this Specification. Tolerances on line and level of the bearing surfaces shall in accordance with the requirements of Section 8 of this Specification with the additional requirement that the permissible deviation at any point under a 30Q mm straight edge placed level in any direction is 1 mm. b. Mortar Pads Mortar pads, where shown on the Drawings, shall be a stiff cement mortar as specified in Section 8 of this Specification Concrete surfaces shall be treated as for pedestals before placing mortar and shall be cool and damp immediately before mortar placing. Mortar shall be compacted by hammering and shall be trowelled and extended @ minimum of 25 mm beyond the bearing edge and finished to a neat inclined face. 23-10 EMSS. - Straus Souccatons for Grege Construction «6 Fabry 1983,Finish and tolerance hessian for 7 days, o| Elastomeric bearings 23. BEARINGS shall be as for pedestals. The mortar shall be cured under damp alternatively as consented to by the Engineer. installation shall be accurately aligned on the pedestals or mortar pad in the position shown on thp Drawings. The superstructure concrete, if cast in place, may be cast directly over the bearing provided that there is no distut a minimum 25 mm hi Where steelwork or placed directly onto tt member shall be lifte bance to the bearing during these operations and also that there is izontal extension of the concrete soffit all around the bearing edge. recast concrete is to be placed on the bearing the member may be fe elastomeric bearing. If any gaps greater than 1 mm occur then the to permit coating the top of the bearing with an excess amount of an approved epoxy mbrtar and the member reseated. Any excess of mortar squeezed out is to be removed im| surfaces made good. Placing of the bearing the presence of the restrained as neces: operations. mediately before it has set and the bearing cleaned and adjacent |, Mortar and steel or concrete member shall only be carried out in Engineer's Representative and the bearing shall be temporarily ry to avoid any disturbance in position during member placing 23.5. STEEL BEARINGS 23.5.1. General The requirements of t rockers, steel hinges requirements of Sect] 23.5.2. Material: Structural steel shall on the Drawings. Cast steel shall be to. 192 (ASTM A 486) ‘ Forged steel shall be for General Use’. Stainless steel rocker grade suitable for fre Parts in actual bearin| the Drawings but is section shall apply to bearings generally of steelwork, sole plates, r anchors used to support or restrain movements of the bridge. The lon 19 of this Specification shall generally apply. omply with AASHTO M 183 (ASTM A 36) with the grade as shown [AASHTO M 105 (ASTM A 48) ‘Grey Iron Castings’ and AASHTO M Steel Castings for Highway Bridges’. io AASHTO M 102 (ASTM A 668) ‘Steel Forgings, Carbon and Alloy, and roller bearings shall be machined from plates and bar stock of machining and of ultimate tensile strength not less than 500 MPa. shall be hardened and tempered to achieve hardness as shown on jot less than Brinell Hardness Number 350 for parts hardened throughout. Stainless steel shall be supplied with a suitable milled finish. for Bator Consructon «6 February 1999 23-1123. BEARINGS Proprietary roller steel of surface hardened, fully hardened or high tensile alloy steels shall have materials and physical properties and suitability for long term service, including Characteristics, satisfactorily demonstrated to the Engineer prior to acceptance. 23.5.3. Pins and Rollers Pins and rollers unless required to be of corrosion resistant steel or of approved proprietary type shall be manufactured from high tensile steel forged bars or cold finished carbon steel shafting as consented to by the Engineer. Bearing plates in contact with a roller shall have a Brinell hardness number equal or greater than the roller hardness number. 23.5.4. Workmanship ‘The manufacture shall be carried out by an organisation experienced and qualified to undertaken precision engineering of this type and be subject to the consent of the Engineer. Castings shall be true to the forms and dimensions shown on the Drawings and shall be free from pouring faults, sponginess, cracks, blow holes and other defects on position affecting their appearance or strength. Warped or distorted castings will not be accepted. Exposed surfaces shall be smooth and dense All castings shall be cleaned by sand or shot blasting to remove sand or scale and to present a clean uniform surface. Allirregularities, fins, or risers shall be ground off flush with the adjacent surface. Castings with visible cracks, blow holes, or similar blemishes shall be rejected if the imperfections are located in bearing surfaces or cannot be remedied to the satisfaction of the Engineer. Imperfections which are not located in bearing surfaces shall be cleaned out, filled with weld metal of the appropriate composition and ground flush Rollers and bearing parts shall be machine accurately to the dimensions and surface finishes as shown in the Drawings and within the specified tolerances. Finish of all parts in the bearing shali be as shown’ on the Drawings or, if not shown, shall be finished by grinding to a uniform texture with a 80 to 100 grit size and then finally polished with an abrasive of 150 grit size. 23.5.5. Testing Tensile test pieces shall be prepared from test bars representative of each cast steel melt or high tensile steel bar stock and submitted to the Engineer for testing. Test pieces shall be cast attached to one or more items cast each melt and shall be marked to correspond with the castings they represent before being despatched in the presence of the Engineer. 23-12 EMS.S.E-Stncts Spucieaton for Badge Cente - 6 Fabry 1993,23, BEARINGS In the event of failure of the sample to meet the specified requirements the Engineer may order two additional ‘samples to be tested. Where welding of pafts of a bearing is required the Engineer reserves the right to require submission in advar accordance with the| ice of proposed welding procedures and sample welded joints in requirements of Section 19 of this Specification. 23.5.6. Tolerances Nominal diameter of rollers +0.05 mm to -0 Out of flatness of rollers +0.15 mm to -0 Dimensions over cast surfaces +1.5 mm to -1.5 mm {not machined or grqund) Thickness of metal +1.5 mm to 0 Dimensions over machined or ground surfaces. +0.15 mm to 0 High Tensile steel - dast stee! +1.5 mm to -0.80 mm The overall dimensions of the assembled bearing shall be within +3 mm of the dimensions shown on the Draw} assembled bearing sI ings. When set to be parallel the upper and lower surfaces of the all be parallel within a tolerance of +0.1 degrees. All measurements shall be made with steel rule or other device calibrated at a temperature of 20 degrees Celsius, Surface roughness, recommendations of "Method and Instru . sur . su The radius of the cor 1 mm of that of the The clearance betw} exceed 1 mm. R, machined surfaces, measured in accordance with the BS 1134 ‘Method for the Assessment of Surface Texture’ Part 1 jentation’ should not exceed the following values : faces in static bearing 6.0 um ifaces in moving contact 1.5 um Wwex surface of a curved rocking or rotating bearing should be within Imating concave surface. en bearing guides and the corresponding guided part should not The rollers of expansion bearing should not vary in diameter by more than 0.3 mm. In knuckle and leaf bea of the seating shoul Machined steel key: ings the difference between the diameter of the pin and the diameter not exceed 0.5 mm. locating parts of bearings in relation to each other shall be drive fit. Bearing parts shall be suitably held together with temporary bolts to prevent misalignment and damage of the Bearing sets shall b¢ lomponents during transport and erection. packed in stout wooden crates for delivery purposes. BSE. «Standard Spectcet fer Brdge Gonetucten «5 Febuary 1993 23-1323, BEARINGS. 23.5.7. Cleaning All steel parts of bearings other than machined surfaces shall be cleaned by blasting to Present a clean and uniform surface in accordance with the requirements for painting steel work (Section 21 of this Specification refers). 23.5.8. Workshop Assembly After assembly of the completed bearing in the workshop matching parts shall be suitably and permanently marked to identify the part number and location in the bridge. Bearing parts need not be interchangeable unless specified. 23.5.9. Acceptance Preliminary acceptance will be given by the Engineer at the works subject to satisfactory load testing as specified. Unless otherwise specified load testing shall not be required for steel bearings which are fully designed and fabricated as shown on the Drawings. Final acceptance will not be given until bearings have been checked in place. 23.6. INSTALLATION OF STEEL BEARINGS 23.6.1. General Bearings shall be placed in the positions as shown on the Drawings with all bearing surfaces in full contact and to the tolerances as specified. Roller and rocker bearings shall be placed so that their axes of rotations are horizontal and normal ta the direction of movement of the members they support. Upper and lower bearing plates shall be set horizontal in both directions. 23.6.2. Placing Pedestal concrete below the bearings shall be cast to the levels shown on the Drawings with cored holes for holding down bolts accurately set in position by template and the clearance as shown provided to the underside of the bearing, The bearing shall be placed over the concrete and brought to the required level and grade by means of leveling bolts or wedges and shims. Alternatively after setting of the mortar in the cored holes the level of the bearing may be adjusted by use of supporting nuts on the holding down bolts. ‘The gap between the top of the concrete and the lower bearing plate and the holding down bolt core holes with bolts installed shall be completely filled with mortar. 23-14 MSE. Strcud Soee ter Bnsge Conseuctan «6 Fabuay 1899Mortar shall comply constituents shall be suitable for ramming Samples of the mortar mm cube moulds and! mortar cubes when t Drawings. All concrete surfaces saturated with water operations are to be are the minimum pra Mortar shall be ramm| on a hardwood ramm¢ progressing outward: 23. BEARINGS Iwith the requirements of Section 8 of this Specification. The Ithoroughly mixed with sufficient water to achieve a consistency into place. 30 minutes after completion of mixing shall be rammed into four 75 cured as for concrete. The minimum compression strength of the sted at 28 days shall be not less than 30 MPa or as shown on the (0 be in contact with the mortar shall be thoroughly cleaned and kept for a period of not less than 24 hours before placing mortar and farried out when the surface temperatures of the exposed bearings ical. 1d into position using approved percussion tools by hammer blows '. Where possible mortar shall be placed and rammed from all sides from the centre of the bearing until the gap is completely filled Where necessary the| mortar in place shall be restrained against movement during the ramming of additional mortar. No mortar shall be us At each edge of the extending a minimum uniform inclined face. After placing and fini or other temporary sui the bearing or plate sI Exposed faces of the| Placing of the bearing 1d later than 30 minutes after completion of mixing, bearing the mortar shall be suitably compacted and trowelled lof 50 mm beyond the edge of the bearing and finished to a neat and hing the mortar the bearing shall be checked for position and shims ports removed and the mortar made good. If the bearing has moved all be lifted, the mortar removed and the whole procedure repeated. Imortar shall be cured under damp hessian for 7 days. land mortar shall be carried out only with the consent of the Engineer. 23.6.3. Checking, Cleaning and Lubrication Before erection each parts shall be made g} All bearings with slidi lubricant immediately, \earing shall be uncrated, disassembled and checked. Any damaged 10d to the approval of the Engineer. 19 surfaces shall be cleaned and lightly lubricated with an approved before erection. 23.6.4. Tolerance on Final Installation The Contractor shall the bearings once inst interference or obstr sition the bearings accurately in the structure and shall ensure that lled are capable of developing their full movement capacities without ction for Sage Conetucton = 6 February 1999 23-1523. BEARINGS Bearings shall be located within the following tolerances : . deviation from true plan or level position 5mm . deviation from horizontal 0.1 degrees . deviation in skew in plan with respect to 1 degrees longitudinal centre line of bridge 23.7. POT TYPE BEARINGS - SUPPLY 23.7.1. General Each bearing shall consist of a disc of elastomer confined in a steel pot to the design and type as shown on the Drawings or in the Special Specifications. Horizontal movement, if required, shall be provided by means of a polytetra fluoroethylene (PTFE) pad sliding against a smooth, truly plane stainless steel mating surface. 23.7.2. Information To Be Supplied The Contractor shall supply to the Engineer the following information for each bearing type : . name of manufacturer . rated load and movement capacities . overall height of bearing . diameter and thickness of elastomeric disc . dimensions and thickness of PTFE sliding pad for expansion bearings. 23.7.3. Bearing Proportions and Materials a. Pot and Elastomer Each bearing shall be proportioned so that at the maximum vertical load shown on the Drawings, the average pressure on the elastomeric disc does not exceed 40 MPa. The dimensions of the elastomeric disc shall be such that, at the design rotation, the vertical strain at the edge of the disc does not exceed 0.15. 23-16 SESE. Stace Seetcatene for rape Construction «6 February 199323. BEARINGS b. Expansion Bearings For expansion bearings, the PTFE pad shall have a minimum thickness of 4 mm and a maximum thickness pf 6 mm and shall be restrained by recessing it into the backing material to a depth of half the thickness of the PTFE. The mating surface shall consist of approved stainless steel sheet. ‘The backing material to the PTFE and mating surface shall be sufficiently rigid to ensure that the PTFE layer is uniformly loaded. The average pressure on the PTFE layer shall not exceed 30 MPa undef the minimum load and 45 MPa under the maximum load. Where guides are provided on expansion bearings to resist transverse forces, these shall be faced with filled PFE or similar material. 23.7.4. Properties of Materials a Elastomel ‘The elastomer shall b¢ tested in accordance with the Australian Standards shown in Table (23.1 and the properties of the compounded and cured elastomeric material shall comply with the requirements of Table 23.1. Three samples shall be tested from every 250 kg batch or less of mixed elastomeric material and each sample shall meet the requirements specified. b. PTFE (Polytetrafluorethylene) The PTFE sliding pad|shall consist of unfilled PTFE sheet. The resin used in the {nanufacture of PTFE sliding pads shall be 100% virgin material with a relative density of 4.13 to 2.23 and durometer hardness of 50 to 65 Steel Other Than Stainless Steel ‘The steel, other than stainless steel, used in the manufacture of the bearings shall conform to AASHTO M 183 (ASTM A 36) and any welding shall comply with the requirements of Section 19 of this Specification. d. Stainless} Steel ‘The stainless steel used in the manufacture of the sliding surface shall conform to AASHTO M 163 (ASTM A 743} Grade CK-20, and the sliding surface shall be finished with a surface roughness of not greater than 0.4 microns Centre Line Average (C.L.A.) 23.7.5. Inspection of Bearings Each bearing shall be |dismantled and visually inspected by the Engineer's Representative at the manufacturer's works prior to delivery. BMSE:SE -Staame Spectcaton| er Bdge Conttucten 6 Feousy 1993 23-1723, BEARINGS 23.7.6. Testing of Bearings General One representative bearing selected by the Engineer's Representative from every lot of 10 bearings, or part thereof, of each size and type of bearings delivered at one time, shall be tested. The cost of this testing shall be borne by the Contractor. Testing shall be carried out at a laboratory approved by the Engineer and the method of testing the bearings shall be subject to the approval of the Engineer. The equipment for testing bearings shall be capable of determining loads to an accuracy of +3% and deflections to + 1% . Where necessary, to achieve the specified accuracy for testing, equipment shall be calibrated and test results corrected accordingly. All testing shall be carried out in the presence of the Engineer or his Representative, who shall be given at least two days prior notice of the test. b. Test Loads Bearings shall be loaded in compression to 1.5 times the maximum vertical load shown on the Drawings and the load shall be maintained for a minimum of three minutes. Bearings which are required to resist lateral forces shall be further tested to 1.5 times the lateral load stated on the Drawings while loaded in compression to the minimum vertical load shown on the Drawings. The load shall be maintained for three minutes. Cc. Test for Coefficient of Friction In addition to testing to the requirements of Clauses 23.3.3.b.ii, 23.7.4.b for vertical and lateral forces, the coefficient of friction of sliding surfaces of expansion bearings shall be determined. The value of the coefficient of friction shall be taken as the average result of five tests and shall be determined for both maximum and minimum vertical loads shown on the Drawings. The sliding surfaces shall not be lubricated before doing the tests but the bearings may be given two preliminary sliding runs under load prior to taking the test readings. The friction coefficient of the sliding surfaces shall not exceed the values given in Table 23.8 for the relevant stresses on the PTFE surface. Values shall be interpolated for immediate bearing pressures. Table 23.8 - Friction Coefficient of Sliding Surfaces Bearing Pressure SMPa | 15 MPa | 20MPa | 30 MPa or greater Friction Coefficient | _0.08 0.05 0.04 0.03 23-18 Insts -Stnaie Sptcticavon tor tge Connuct23. BEARINGS Test for Rotation When so stated on tihe Drawings, one bearing of each type shall be tested in rotation to the value for rotation shown on the Drawings rounded upwards to the nearest 0.005 radians while being \baded in compression to the maximum vertical load shown on the Drawings. Bearings Which are required to resist lateral forces shall also have the specified lateral load stated on|the Drawings applied during this test. Failure tq Meet Requirements If any bearing exhibits any signs of failure such as splitting or permanent deformation of the elastomer teating, cracking or permanent deformation of the PTFE sliding surface cratking or permanent deformation of the sealing ring or other part of the beefing abrasive marks indicating abnormal contact between the metal surfaces of the bearing plates or piston, and the pot.it shall be rejected. If a bearing is rejected, two additional bearings from the batch it represents shall be tested. If both bearings meet the requirements of this Specification, the remaining bearings in the batch shall be acceptbd. Otherwise each remaining bearing in the batch shall be tested to determine its complignce with the Specification. 23.7.7. Test Certi cates The Contractor shall] supply copies of the test certificates showing details of the test results of each sample of elastomer and each bearing tested. The test certificates shall show whether any folerances have been exceeded or whether any faults have been observed. 23.7.8. Protective Treatment The protective treatment for exposed parts of metal bearings shall consist of abrasive blast cleaning and the application of an approved primer followed by the application of an approved finishing paint in accordance with the requirements of this Specifications. Stainless steel sliding surfaces of expansion bearings shall receive no protective treatment and care shall be takdn to protect these surfaces from being damaged or coated during the application of the prdtective treatment. MSE - Stndae Specicnon e Conevucton «8 Febusry 1993 23-1923, BEARINGS. 23.7.9. Marking and Delivery All bearings shall be suitably marked to identify their location in the bridge. Mating parts of bearings shall also be suitably and permanently marked and shall be ‘supplied in sets held together with metal transit clips and/or bolts to prevent misalignment and damage of the components during transport and erection. The transit clips and/or bolts shall not be removed until final installation in the bridge. No bearing shall be delivered to the bridge site prior to issue of a Release Note by the Engineer or his Representative. The issue of such a note will be dependent on each individual bearing complying with the various Clauses of this Specification and exhibiting satisfactory workmanship. 23.8. INSTALLATION OF POT BEARING Location bolts shall be grouted into cored holes as shown on the Drawings using a sand- cement mortar consisting of 3 parts sand to one part cement. Bearings shall not be placed over these bolts until the mortar has cured for at least 7 days Bearings shall then be placed over the location bolts and brought to the levels shown on the Drawings by adjusting the levelling nuts. The bearings shall be horizontal. The gap between the top of the concrete and the lower bearing plate shall then be completely filled with mortar, rammed into position using approved percussion tools or by hammer blows on a hardwood rammer. Where possible the mortar shall be placed and rammed from all sides progressing outwards from the centre of the bearing. Where Necessary the mortar in place shall be restrained against movement during the ramming of additional mortar The strength of the mortar shall be Class 40 in accordance with the requirements of Section 8 of this Specification. Concrete pedestals shall be cured under damp hessian for at least 7 days before any load is transferred to the bearings. 23.9. PROPRIETARY BEARINGS 23.9.1. Responsibility The Contractor shall arrange for the design, manufacture, testing and installation of all bearings in accordance with the requirements of this Specification and the Drawings and with the consent of the Engineer. Bearings shall generally be similar to the manufacturer's proprietary type or system as shown on the Drawings and any acceptance of other types will be at the sole discretion of the Engineer. 23-20 mass sanams $0 ne tr Brge Contveuen - 6 Fabry 1993All bearings shall be| suitably protected, ar Drawings. Prior to placing an o of good quality workmanship of corrosion resistant materials or }d meet all required loads, movements and rotation as shown on the fer for the manufacture of the bearings the Contractor shall provide As soon as possible ar the commencement of the Contract and at least eight (8) weeks a the following inform: tion to the Engineer for his consent : * Tha name and location of the proposed manufacturer * Dimensions and general details of the proposed bearings, including coefficient of friction of rolling and sliding surfaces, allowable rotations, rotational moment of restraint * Proposed temporary or permanent fixing or anchorage details as required * Test facilities available and testing procedures proposed * Evidence of satisfactory performance under similar conditions of bearings of Following written acc general details of the| The Contractor shall for the bearing at le consent of the Eng specifications of mat clearances, tempora programs, 23.9.2. Testing Each bearing shall be| the full cost of testint ‘The Contractor shall approval before any loads to an accuracy Each bearing shall be working load shown vertical deflections m} Tests to establish the| for each of five pos| bearing. The impose of friction should be The Contractor shall each bearing to be m jimilar type produced by the manufacturer eptance by the Engineer of the proposed bearing manufacturer and bearings the order for bearing manufacture may be placed. jubmit four (4) copies of detailed and dimensioned working drawings ist four (4) weeks prior to commencement of manufacture for the ineer. These drawings shall show all relevant information and rials relating to performance, materials, bonding, surface protection, 'y clamps, installation procedures and proposed detailed testing ‘subject to load testing as follows or as agreed by the Engineer and shall be borne by the Contractor. rovide the Engineer with full details of the testing arrangement for festing commences. The equipment shall be capable of measuring lof + 2% and deflections to + 1%. loaded in compression to a maximum proof load of 1.5 times the Wn the Drawings. The load shall be applied in 20% increments with jeasured at each increment. Icoefficient of friction of sliding or roller type bearings should be made ltions equally spaced across the total range of movement of the vertical loading should be the design dead load and the coefficient ased on the greatest load required to move the bearing. Iso arrange for the Brinell Hardness of the roller and roller plates of asured and the results supplied to the Engineer before load testing. BMSESE «Standard Speteanos for Gre Construction «6 Febtay 1983 23-2123, BEARINGS All other testing shall be carried out as considered necessary by the Engineer and in agreement with the Contractor with regard to the formal acceptance by the Engineer for ‘the type and details to be supplied. The bearings shall then be totally dismantled and all bearing parts inspected for imperfections, wear or flattening. Micrometers shall be used for all appropriate measurements. Bearing tests shall be carried out in the presence of the Engineer and the Contractor shall provide at least seven (7) days notice of the testing dates. 23.9.3. Rejection of Bearings Any bearing which as a result of inspection, measurement or testing as specified or after dismantling is found to contain any of the following faults shall be rejected and replaced at the Contractor's expense : . visual defects . indentations in bearing plates greater than 0.5% of the roller diameter . residual deflections of any roller of greater than 0.1% diameter ° bearing plates having a Brinell Hardness Number less than the roller * coefficient of frictions of sliding surfaces greater than those accepted and agreed by the Engineer in the details as supplied by the manufacturer. 23.10. MEASUREMENT Measurement, for payment, of bearings shall be based on the number of bearings supplied, inspected and accepted by the Engineer and installed in accordance with this Specification. 23.11, PAYMENT The item for bearings will include full payment for providing all labour, materials (except materials specified to be supplied by the Employer!, tools, equipment and any other work incidental to the supply and installation of the bearings. Payment for the item will include handling, storage, temporary supports, placing, Construction of bearing pedestals (where applicable), placing holding down bolts (where applicable) and finishing and no separate payment will be made for any of these. All materials, tools and equipment supplied by the Contractor which do not form part of the completed works shall remain the property of the Contractor unless specified otherwise. 23-2223, BEARINGS ‘Any work in addition td that shown or specified which may be ordered by the Engineer, will bbe paid for in accordance with the provisions of the general condition of Contract. 23-23MINISTRY OF PUBLIC WORKS DIRECTORATE GENERAL OF HIGHWAYS REPUBLIC OF INDONESIA STANDARD SPECIFICATIONS FOR BRIDGE CONSTRUCTION SECTION 24 EXPANSION JOINTS JANUARY 1993 DOCUMENT No. BMS8-S.E24, TABLE OF CONTENTS EXPANSION JOINTS 24.1, 24.2. 24.3. 24.4. 24.5, 24.6. 24.7. 24.8, 24.9. 24.10. GENERAL STEEL REINFORCED ELASTOMERIC JOINTS 2412.1. Materials 2412.2. Placing of Jointing COMPRESSED ELASTOMERIC JOINT SEALS 24/3.1. Materials 24|3.2. Fabrication of Joint Steelwork 2413.3. Placing of Joint Steelwork 2413.4. Placing of Preformed Neoprene Seal PREFORMED EXPANSION JOINT FILLERS 24.4.1. Bituminous Impregnated Fibre 24.4.2. Sponge Rubber 3. Cork and Self-Expanding Cork 4. Bitumen Impregnated Foam Strips 5. Physical Requirements 6. Installation L PLATE EXPANSION JOINTS 1. General .2. Sliding Plates 5.3. Finger Plates IRTIFICATION AND ACCEPTANCE ITERNATIVE PROPRIETARY TYPE DECK JOINTS. ST INSTALLATION TESTING -ASUREMENT, YMENT 24-4 24-1 24-1 24-2 24-3 24-3 24-4 24-4 24-5 24-6 24-6 24-6 24-6 24-6 24-6 24-7 24-8 24-8 24-8 24-8 24-9 24-9 24-10 24-10 24-10 cf Cantante Stands Seagieanons fr Brags Carson24.1. GENERAI This section covers tt Provision for expansio| ‘on the Drawings. Expansion details are 27 degrees Celsius, 24. EXPANSION JOINTS je Supply and installation of expansion joints. and contraction in the deck, footways and kerbs shall be as shown jesigned and dimensioned for installation at a mean temperature of unless shown otherwise on. the Drawings or in the Special Specifications. Wherg the ambient temperature is likely to vary by more than 5 degrees Celsius from 27 degre request the Engineer setting the expansion Joint gaps shall be co} of +3 mm Epoxy resin and epox| Specification. jes Celsius (or other nominated temperature), the Contractor shall give a direction regarding any allowances which shall be made in jjoints. structed as shown on the Drawings to a cross-sectional tolerance mortar shall comply with the requirements of Section 18 of this Where shown on the Drawings or in the Special Specifications that the Expansion Joints will be supplied by the Employer only the relevant installation clauses of this Section shall apply. 24.2. STEEL REINFORCED ELASTOMERIC JOINTS 24.2.1, Materials The Contractor shall s\ as shown on the Dra Angled jointing sectior height shown on the Prior to placing the j completely enclosed i in-silicate paint by the application of the pain| the satisfaction of th work in the schedule i Expansion joint mate| Contractor to prevent to the satisfaction of t Associated steel plate} pply all reinforced elastomeric jointing in accordance with the details ings, including clipped washers, neoprene cavity plugs and sealant. 's for kerbs and parapets shall be supplied cut for a mitre joint to the rawings, inting in position it shall be inspected and all steel portions not elastomer shall be coated with two field coats of an approved zinc- Fontractor, as directed by the Engineer's Representative. Before the the area to be coated shall be cleaned to a bright metal surface to Engineer's Representative. Bidders shall make allowance for this rem for deck expansion joints. No separate payment will be made. ials shall be handled with care and stored under cover by the damage. Any damage occurring after delivery shall be made good he Engineer's Representative and at the expense of the Contractor. shall also be supplied by the Contractor. lo Beage Censvucuon - 26 January 1993 24-124. EXPANSION JOINTS 24.2.2. Placing of Jointing Where jointing is seated directly on concrete any depressions shall be brought to the Correct profile by filling with approved epoxy mortar, and any high areas shall be corrected by grinding, Areas to receive epoxy mortar shall be prepared in accordance with the manufacturer's recommendations. The jointing shall be securely anchored by fixing bolts grouted in position by epoxy resin. No holes shall be drilled for fixing bolts within 7 days of concreting. Holes for the bolts shall be drilled to the size and depth shown on the Drawings. Prior to placing the epoxy resin the holes shall be prepared in accordance with the manufacturer's recommendation and to the satisfaction of the Engineer. The fixing bolts shall be set accurately to fit the jointing. Epoxy resin shall be cured for a minimum of 24 hours before jointing. Bolts which do not fit shall be removed and reset at the expense of the Contractor. Sections of the jointing making the completed joint shall be set so as to produce a straight line. The fixing bolts shall not be placed in position until at least four (4) weeks after stressing is completed in post tensioned box or slab structures. Prior to placing sections of jointing, contact surfaces shall be cleaned to remove all grease, tar, paint, oil, mud or any other foreign material that may affect adhesion of the sealant. Sealant shall only be applied to dry contact surfaces. Sufficient sealant shall be applied to. the contact surfaces to cause extrusion of sealant when the jointing is fixed in position. Sealant shall be spread for only one jointing section at a time. For structures with one way crossfall, the first section of the jointing shall be installed at the lower kerb line and placing shall continue progressively towards the opposite kerb. Two closing sections adjacent to the higher kerb shall be cut to the required lengths as specified herein For structures with two way crossfall, jointing shall be installed progressively from the kerbs towards the change in pavement crossfall. Two closing sections at the highest part Of the road cross section shall be cut to the required length as specified herein. Steel reinforced elastomeric jointing on footways, if applicable, shall be installed progressing from the kerb towards the edge of the deck. Bolts shall be fully tightened prior to placing adjoining sections. Ends of sections shall be wire brushed and covered with sufficient sealant to cause extrusion of sealant when bolted in position. Each section shall be wedged tightly against previous sections and shall be held in that position until the bolts are tightened. Alll excess sealant shall be removed. Bolts shall be initially tightened and subsequently retightened after a minimum period of one hour in to the torques as shown on Table 24.1 24-2 OMS. - Staal Spucticatont lor Brage Conrtucton = 26 Janay 198324, EXPANSION JOINTS Table 24.1 - Bolt Diameter Initial Torque Final Torque after minimum of 1 Hour (mm) (Newton-metre} (Newton-metre) 1 60 60 16 90 90 20 115 115 24 135 135 30 200 200 The butting joint betw) and this joint shall be of the jointing have b| placed in position and| The sections to be cu band saw equipped wil resulting joint shall be The cost of this wor expansion joints. Final sealing of the fini of installation. All exp| shall be filled with sez plates shall be filled Bolt cavities shall be cl plugs sufficient sealank the plugs. All excess sealant sha| 24.3. | COMPRE; 24.3.1. Materials The Contractor shall accordance with the Associated steel plate Expansion joint mate! Contractor to prevent satisfaction of the Eng in the opinion of the en two Closing sections of the jointing shall be scarfed 45 degrees jocated at least 1.2 m from the kerb invert. After all other sections "en fixed in position the two closing sections shall be temporarily ‘the location of the scarfing cuts shall be carefully marked. shall then be removed and cut with a power driven deep throated ha tilting table, or other method consented to by the Engineer. The ight fitting and to the satisfaction of the Engineer's Representative. shall be deemed to be included in the schedule item for deck hed expansion joint shall be completed immediately after completion sed ends, joints between units, and other areas of possible leakage lant. All voids between the sides of the jointing and concrete or ith sealant leaned and plugged with neoprene cavity plugs. Prior to placing the shall be placed in the cavities to cause extrusion of the sealant by I be removed from the jointing and adjacent areas. SED ELASTOMERIC JOINT SEALS supply the preformed neoprene seal, sealant and adhesive in fetails shown on the Drawings. shall also be supplied by the Contractor. als shall be handled with care and stored under cover by the damage. Any damage to the materials shall be made good to the ineer’s Representative and at the expense of the Contractor. Where ngineer, the neoprene seal is damaged sufficiently to require its Bdge Conscton «26 Janay 1989 24-324. EXPANSION JOINTS replacement the Contractor shall bear the cost of such replacement. a. Epoxy Mortar Epoxy mortar shail comply with the requirements of Section 18 of this Specification. b. Fixing Bolts For Reinforced Elastomeric Jointing Fixing bolts shall be of the type and size shown on the Drawings and shall comply with the current ANSI B18 ‘Metric Heavy Hex Bolts and Nuts’ and be hot dipped galvanized in accordance with the current AASHTO M 232 (ASTM A 153) ‘Zinc Coating (Hot Dip) on Iron and Steel’ Classification ‘C’ c Joint Steelwork Steel used for the fabrication of joint plates shall comply with the requirements of Section 22 of this Specification. 24.3.2. Fabrication of Joint Steelwork Joint plates shall be fabricated in accordance with the requirements of Section 22 of this Specification and shall be hot-dip galvanized in accordance with the requirements of Section 21 of this Specification. 24.3.3. Placing of Joint Steelwork The Contractor shall take care to prevent damage to joint plates and the protective coating. If any damage occurs, the plates and coatings shall be made good by the Contractor to the ‘Satisfaction of the Engineer's Representative and at the Contractor's expense. Prior to concreting, joint plates including anchors shall be cleaned to remove oil, rust, loose aint, dirt and other deleterious material. Plates shall be set to the line and grade shown on the Drawings, and the expansion gap adjusted as required for temperature. Plates shall be held firmly in place during concreting. Butted joints in plates shall be sealed to prevent leakage of mortar during concreting. . « Temporary bolts or other fixings which prevent relative movement of adjacent parts of the joint shall be removed as soon as the concrete has set sufficiently to hold the expansion Plates in their specifiéd positions but shall be removed within six (6) hours of concreting unless otherwise directed by the Engineer. No loads shall be placed on the plates until at least seven (7) days after concreting into position. In the case of skew joints, kerb and parapet masking plates shall be fixed in position as shown on the Drawings. 24-4 BMSS.5.E- Stance Spuctcaons Io eign Construction - 28 Jewry 199324. EXPANSION JOINTS. 24.3.4, Placing of Preformed Neoprene Seal The neoprene seal shy The neoprene seal sh: ll only be installed by tradesmen skilled and experienced in placing I! extend in one continuous length across the bridge. Joins shall not this jointing and the sis shall be done in the presence of the Engineer's Representative. be made by the Contr neoprene seal shall b to by the Engineer. with xylol or toluol p| evaporated the adhe: together under manu: in the joint until at le Where the neoprene i or depressions in the and irregularities shal receive epoxy mortar of this Specification. ctor unless shown on the Drawings. Where splicing is required the cut by a bandsaw with a wetted blade or other method consented jeal ends to be joined together shall mate neatly and shall be cleaned ior to application of the adhesive. When the cleaning solvent has ive shall be applied to one seal end only and the two pieces held || pressure for at least two (2) minutes. The seal shall not be inserted st ten (10) minutes after the splicing is complete. placed in a concrete faced joint any spalling, honeycombing, cracks [concrete shall be made good by filling with approved epoxy mortar be corrected by grinding to produce a plain even surface. Areas to Ishall be prepared in accordance with the requirements of Section 18 Immediately prior to placing the sealant, contact surfaces shall be cleaned to remove all moisture, grease, tar, the sealant. Concret loose particles shall Neoprene seal to wh} Sealant shall only be be sufficient to ensurf the neoprene seal sid is fixed in position. neoprene seal and thi its bonding capacity. finished surfaces of tt joint shall not com} Representative. The neoprene seal sh} by the Engineer. Su under the Contract it is below the top of] pressed down to the paint, oil, mud or other foreign material that may affect adhesion of surfaces which contact the neoprene seal shall be wire brushed and je removed by the use of clean, dry, oil free air. The sides of the ich sealant is to be applied shall be cleaned with xylol or toluol. plied to dry surfaces. The rate of application of the sealant shall that all contact surfaces are completely covered, all serrations on 9s filled, and that extrusion of the sealant occurs when the neoprene ealant shall not be applied more than 2 metres in advance of the neoprene seal shall be placed in position before the sealant has lost Precautions shall be taken to prevent splashing of the sealant on the je bridge. Application of the sealant and insertion of the seal into the ence until the joint has been inspected by the Engineer's Il be inserted by a method and the use of equipment consented to h consent will not relieve the Contractor from his responsibilities he neoprene seal shall be pressed uniformly into the joint gap until [the joint to the depth indicated on the Drawings and should not be stops. The neoprene seal shall not be stretched during installation. Immediately after completion of the installation areas of possible leakage shall be filled with sealant. A uniform between the top fac: illet of sealant 6 mm wide shall be neatly run along the junction of the neoprene seal and the side of the joint. All excess sealant shall be removed fron] the jointing and adjacent areas by the use of a cloth moistened with solvent. tor ergs Constucton «26 Janay 1999 24-524. EXPANSION JOINTS 24.4. | PREFORMED EXPANSION JOINT FILLERS 24.4.1. Bituminous Impregnated Fibre Bituminous fillers shall be in accordance with AASHTO M 33 (ASTM D 994). This filler shall consist of preformed strips made of cane or other approved fibres of a cellular nature ‘securely bound together and then uniformly saturated with bitumen, or strips formed from clean granulated cork securely bound together by a suitable bituminous binder and encased between two layers of saturated felt or two layers of glass fibre felt. The joint filler shall be installed in not less than one metre lengths. 24.4.2. Sponge Rubber Sponge Rubber fillers shall be in accordance with AASHTO M 153 (ASTM D 1752) Type |. Sponge rubber joint filler shall consist of preformed strips of durable elastic sponge rubber compound, using synthetic rubber or natural rubber as a base and containing no reclaimed rubber. Unless otherwise specified, the sponge rubber shall have a cement grey colour to blend with the concrete in appearance. 24.4.3. Cork and Self-Expanding Cork Cork fillers shall be in accordance with AASHTO M 153 (ASTM D 1752) Types Il and Ill. The joint filler consist of preformed strips that have been formed from clean granulated cork particles securely bound together by a synthetic resin. 24.4.4. Bitumen Impregnated Foam S: Bitumenous strips shall be in accordance with AASHTO M 213 (ASTM D 1781). The strips consist of flexible polyurethane foam impregnated with bitumen. At least 35 percent by weight of the finished product shall be bitumen uniformly distributed throughout the cross- section of the material. When used in vertical joints the strips shall be supplied with full self-adhesive backing paper. The uncompressed thickness shall be not less than the joint thickness shown on the Drawings unless otherwise directed by the Engineer. 24.4.5. Physical Requirements Preformed strips of expansion joint filler shall be of such character as not to be deformed or broken by twisting, bending, or other ordinary handling conditions. Any expansion joint filler that has been damaged shall be rejected. When required by the Engineer test samples shall be taken of the preformed strips. Each sample shall consist of sufficient material to provide four test specimens measuring 125 mm by 125 mm. Separate test specimens shall be tested for recovery after compression, extension, and in the case of self-expanding cork, a test specimen shall be tested for expansion 24-6 BUSES «Stands Spctcatont for Se Consston «28 January 1882a. Recover 24. EXPANSION JOINTS. The test specimen shall be compressed with a load not less than 0.5 MPa nor greater than 5.00 MPa. The test test. The load shall minutes after release its thickness before t the test specimen shi material to 50 percent after each application. have recovered of at b. Extrusion) pecimen shall be compressed to 50 percent of its thickness before then be released immediately after application. At the end of 10 the load, the specimen shall have recovered at least 75 percent of ist. In the case of failure to comply with the foregoing requirements | be given three applications of a load sufficient to compress the of its thickness before test. The load shall be released immediately At the end of 1 hour the third application of the specimen shall least 75 percent of its thickness before test. Test specimen shall be compressed to 50 percent of its thickness before test with three of its edges restraines c Expansiot In the case of self-exy immersed in boiling w1 of the thickness befor 24.4.6. Installatiai . The amount of extrusion of the free edge shall not exceed 7 mm. nding cork expansion joint filler only, the test specimen after being iter for 1 hour shall have a final thickness not less than 140 percent le test. in Expansion joint materials shall be handled with care and stored under cover by the Contractor to prevent] Any damage occurrin, and at the expense o} Surfaces of joint slot: material and dirt and Preformed expansion position until immedial surfaces of the joint a} placed until the secor The contact surfaces with two applications Of the filler. Concret dislodge the filler stri Before expanding corl tape shall be placed 1 Approximately four h of the preformed cor! The cork joint filler shi damage. after delivery shall be made good to the satisfaction of the Engineer the Contractor shall be thoroughly cleaned with a wire brush to remove all loose jebris, then washed or jetted out. joint filler (other than tubular joint fillers) shall not be placed in ely prior to the placing of the abutting concrete. If the two concrete e to be placed at different times this type of joint filler shall not be id face is about to be placed the abutting concrete and the preformed joint filler shall be covered f approved contact adhesive as recommended by the manufacturer shall be placed, compacted and floated so as not to damage or s. type preformed joint filler is placed in position a strip of masking seal the top edge of the filler. lurs after finishing of the concrete, the masking tape on the top edge expansion joint filler shall be removed. | be kept moist for four days after placing of the concrete. Where Jo Badge Consuacion 26 January 1883 24-724. EXPANSION JOINTS membrane curing is permitted special provision shall be made for wetting the cork joint filler to ensure its pre-compression is properly relaxed Sealants shall be installed in accordance with the manufacturer's recommendations and all appropriate requirements for joint face priming and provision of bond breakers over joint fillers shall be implemented. Sealants shall be finished approximately 3 mm below the upper surfaces of the joint. Joint materials spilt or splashed onto finished surfaces of the bridge during joint filling operations shall be removed and the surfaces made good to the Engineer's approval No joint shall be sealed until inspected by the Engineer and consent is given to proceed with the work. 24.5. STEEL PLATE EXPANSION JOINTS 24.5.1. General Care shall be taken to prevent damage to expansion joint plates or any protective coating. If any damage occurs, the plates and coatings shall be restored by the Contractor in accordance with the requirements of Sections 21 and 22 of this Specification to the satisfaction of the Engineer. Plates including anchors, shall be free of oil, rust, loose paint or other similar material before concreting. Plates shall be placed to the line, grade and expansion gap shown on the Drawings (with any adjustment required for temperature). Particular care shall be taken with the top surface of the plates. Plates shall be firmly held in place during concreting. Butted joints in deck plates shall be sealed with masking tape to prevent leakage of mortar during concreting. Any temporary bolts or other fixings which prevent relative movement of adjacent parts of the joint shall be removed as soon as the concrete has set sufficiently to hold the expansion plates in their correct positions. In any case temporary bolts or other fixings shall bé removed within six (6) hours of placing concrete unless otherwise directed by the Engineer. 24.5.2. Sliding Plates Care shali be taken to obtain close fitting of sliding parts. Sliding surfaces shall be kept clean at all times. The top surfaces of the plates shall be kept free of any loads until at least 7 days after casting the adjacent concrete 24.5.3. Finger Plates Care shall be taken to ensure that the fingers are placed parallel to the direction of Movement, and that the specified clearance and any adjustment required for temperature is maintained between fingers, both laterally and in the direction of movement. The top surfaces of each pair of plates shall be flush. 24-8 MS6-5. «Stans Spectcatens for Brgpe Canetction = 26 January 1999Drainage gutters and 24. EXPANSION JOINTS pipes shall be placed so as to discharge water clear of piers and abutments. The joints and drainage facilities shall be thoroughly cleaned before the end of the maintenance period. The top surfaces of the plates shall be kept free of any loads until at least 7 days after casting the adjacent 24.6. CERTIFIC Acceptance of the pr procedures as specifi procedure shall apply) Procedure 1 The Contractor shall the test requirements| name or trade name conformance with. th Each certificate so fut supplying the joint se} Procedure 2 The Contractor shall testing laboratory ini oncrete. ATION AND ACCEPTANCE formed elastomeric joint seals shall be based on one of the following sd. Unless specified otherwise in the Special Specifications the first lurnish to the Engineer documentation indicating conformance with Each item of joint seal shall be identified with the manufacturer's ind shall be accompanied by the manufacturer's certificate attesting test requirements and a copy of the manufacturer's test report. nished shall be signed by the authorised agent of the manufacturer f furnish to the Engineer a certificate form an approved independent licating the material has been sampled, tested and inspected in accordance with the requirements of this Specification. Each certificate so furnished shall be signed by the aut Procedure 3 Testing by the Engine| Specification. Procedure 4 Any alternative meth lorised agent of the manufacturer. 1 of any or all properties in accordance with the requirements of this }d agreed between the Contractor and the Engineer. 24.7, ALTERNATIVE PROPRIETARY TYPE DECK JOINTS Proprietary type dec! comply in all respects| of movements and ro performance in the bi ‘Where alternative typ joints offered by the Contractor in lieu of the type, specified shall with the manufacturer's specifications and meet the required range ‘ations and be fit for the purpose of ensuring satisfactory long term idge. proprietary deck joints are proposed by the Contractor the following information shall be provided nai le and location of the proposed manufacturer and his local agent tr nage Consnacton - 26 Jensey 1989 24-9124. EXPANSION JOINTS dimensions and general details of the joint including material specifications, holding down bolt or anchorage details and installation procedures evidence of satisfactory performance under similar environmental Conditions of similar joints produced by the manufacturer. Any acceptance of alternative types will be at the sole discretion of the Engineer. All proprietary type deck joint shall be installed in accordance with the manufacturer's recommendations and with the general requirements of this Specification. 24.8. POST INSTALLATION TESTING When specifically shown on the Drawings a water tightness test shall be carried out. This test shall be performed not less than two weeks after completion of the installation of the deck joint Dykes shall be constructed across the footway and roadway to permit not less than § litres of water per minute to pass across all sections of the joint under a head of not less than 10 mm. This testing shall continue for 8 hours. The underside of the joint shall be monitored during and on completion of the testing for signs of any leakage. Any leakage shall be made good by the Contractor and a further test performed. Failure after a second test may be the cause for rejection of the joint. 24.9. MEASUREMENT Measurement. for payment, for supply and installation of bearings of-a type as shown on the Drawings or accepted by the Engineer under Clause 24.7 shall be based on the number of bearings supplied and installed and accepted for payment by the Engineer. 24.10. PAYMENT The item for expansion joints will include full payment for providing all labour, materials (except those materials specified to be supplied by the Employer), tools, equipment and any other work incidental to construction of the joints. Payment for the item will include handling. setting joint fixings, placing joint materials and (where shown on the Drawings) water tightness testing and no separate payment will be made for any of these. All materials, tools and equipment supplied by the Contractor which do not form part of the completed works shall remain the property of the Contractor unless specified otherwise. Any work in addition to that shown or specified which may be ordered by the Engineer, will be paid for in accordance with the provisions of the General Conditions of Contract. 24-10 BMSE.SE «Stade Soectcatons lor Beage Cantuctan «26 Janay 1989MINISTRY OF PUBLIC WORKS DIRECTORATE GENERAL OF HIGHWAYS REPUBLIC OF INDONESIA STANDARD SPECIFICATIONS FOR BRIDGE CONSTRUCTION SECTION 25 BRIDGE RAILING JANUARY 1993 DOCUMENT No. BMS8-S.ETABLE OF CONTENTS 25. BRIDGE RAILING 25.1 25.2. 25.3. 25.4. 25.5. 25.6. 25.7, 25.8. 25.9. Gel st ERAL RAGE OF MATERIALS. WELDING PRI TECTIVE COATING MATERIALS ERI CTION OF RAILINGS 25.6.1. General 25.6.2. Steel Pipe Railing 25.6.3. Steel Grille Railing 25. Gu 25. 25. 25. ME. PA 6.4. Aluminium Railing ARD FENCE RAILING 7.1. General \7.2. Materials 7.3. Erection ASUREMENT MENT 25-1 25-1 25-1 25-1 25-1 25-2 25-2 25-2 25-3 25-3 25-4 25-4 25-4 25-4 25-5 25-525.1. GENERAI This section covers t 25. BRIDGE RAILING je supply and erection of bridge railing Bridge railing includes that portion of the structure erected on and above the kerb, or roadway, for the protpction of pedestrians and traffic. Fabrication of bridge ilings shall be carried out in accordance with the requirements of Section 22 of this Specification Painting and galvanisi ing of bridge railings shall be in accordance with the requirements of Section 21 of this Specification. Where shown on the| Drawings or in the Special Specifications that the Railing will be supplied by the Empl iver only the relevant installation clauses of this Section shall apply. 25.2. STORAGE OF MATERIALS Railing material shall kept clean and free platforms, skids, or o 25.3. WELDIN 1@ handled and stored with care, so that the material and parts are rom damage. Railing materials shall be stored above ground on ier supports and kept free from grease, dirt and other contaminants. All welding shall be cafried out by the metallic arc process in accordance with the Drawings and Section 22 of t! satisfaction of the E ground to a smooth si with the requirements is Specification. Where the finish of exposed welds is not to the \gineer or his Representative, those welds shall be remedied and lape. Welding of aluminium railings shall be carried out in accordance of the Special Specifications. 25.4. PROTECTIVE COATING After erection all dar previously coated shi 21 of these Specific: ‘age to the protective coating shall be made good and areas not Il be thoroughly cleaned and coated both in accordance with Section tions. 25.5. MATERIALS Materials for bridge Specifications, and t Aa AY filings shall conform to the requirements of Section 22 of these the following (as relevant) HTOM 183 Structural Steel (ASTM A 36) HTOM 160 General Requirements for Rolled Steel Plates, Shapes, Sheet Piling and Bars for Structural Use (ASTM A 6) for Bidge Construction - 26 Janay 1893 25-125. BRIDGE RAILING AASHTO M 192 _ Steel Castings for Highway Bridges (ASTM A 486) . AASHTO M193 Cast Aluminium Alloy Railing Posts 25.6. ERECTION OF RAILINGS 25.6.1. General Posts for the support of steel pipe railings may be concrete or steel as shown on the Drawings. Concrete posts shall be cast in-situ in accordance with the Drawings and shall comply with the requirements of Section 8 of this Specification, Steel posts shall be fabricated as shown on the Drawings and in accordance with the requirements of Section 22 of this Specification. Protective treatment shall be as shown ‘on the Drawings and in accordance with the requirements of Section 21 of this Specification. Field cutting shall only be done with the written consent of the Engineer and in the Presence of the Engineer. All field cutting shall be done in a neat and workmanlike manner, and where required by the Engineer, the cut surface shall have striations and burrs removed by grinding. The protective treatment shall be repaired in accordance with the requirements of Section 21 of this Specification. Welding shall be carried out in accordance with the requirements of Section 22 of this Specification. The line and grade of the railing shall be as shown on the Drawings and the deviation of the railing from a smooth line and grade shall not exceed 3 mm. 25.6.2. Steel Pipe Railing The railings shall conform to the bridge curvature by means of a series of short chords between rail joints, except where the Drawings show shop bending. Unless otherwise specified or shown on'the Drawings, railing posts shall be vertical. Expansion joints shall be made as shown on the Drawings and shall enable relative movement of the parts joined. a. Steel Posts Bolted parts shall have effective contact without the interposition of gaskets or other flexible materials, except where indicated on the Drawings. Where bearing faces of bolted Parts are not parallel, tapered washers shall be used to compensate for the lack of Parallelism. The angle between the axis of the bolt and the surface under the bolt head or nut shall be in the range 90 + 3 degrees. Tapered washers shall be placed under the non- rotating component where possible. Bolt heads and nuts shall be tightened with a suitable wrench and where specified the nuts shall be effectively locked or the ends of the bolts 25-2 BMS8.S - Stace Sonctenons tor Bedge Contuctan «26 Jenamy 1893burred to prevent rei After the railing has Representative obtair requirements of Sect base plates as showr be brushed to a smo: and droppings shall 25. BRIDGE RAILING joval of the bolted parts. lbeen erected true to line and grade, the consent of the Engineer's jed and all connections made, dry pack mortar in accordance with the ion 8 of this Specification shall.be rammed into place beneath post on the Drawings. On completion, exposed faces of the mortar shall ith surface flush with the edges of the base plate and all mortar spots je removed. 25.6.3. Steel Grille Railing Pedestrian panels shall be erected to follow the line of the barrier railing. Railing shall be sleeved at all joints. Sleeves shall be connected to the rail on the low side of each expansion joint. Where the railing is supported on steel posts they shall be either mortared in sockets, set ‘on mortar pads, or set on steel supporting members as shown on the Drawings. Before the panels are| permanently fixed to the structure, the full length of the railing shall be aligned to achiev from a smooth line a| Bidders shall include the railing legs by at the profile as shown on the Drawings. The deviation of the railing \d grade shall not exceed 3 mm. n allowance in their tendered price to provide for packing or cutting amount not exceeding 20 mm to adjust for the camber or other variations of the structure. The use of packing Contractor is directe shall be done as dir provisions of the Ge Permanent connecti been approved by th a. Steel Po} After the railing has| ind the material used shall be to the consent of the Engineer. If the by the Engineer to increase the railing leg by more than 20 mm it jcted by the Engineer and shall be paid for in accordance with the eral Conditions of Contract. Ins shall not be made until the alignment of all parts of the railing has Engineer. ts been erected true to line‘and grade, the consent of the Engineer's Representative obtaiped and all connections made, dry pack mortar in accordance with the requirements of Sect base plates as.show! be brushed to a smo: and droppings shall 25.6.4. Alumini Prior to erection of t posts where contact Railings shall be ere, ion 8 of this Specification shall be rammed into place beneath post on the Drawings. On completion, exposed faces of the mortar shall th surface flush with the edges of the base plate and all mortar spots e removed. m Railing 1e railing @ coat of zinc chromate paint shall be applied to the base of is to be made subsequently with a cement mortar levelling pad. ‘ted so as to follow the finished grade and line as shown on the tar Bre Coneuctan = 26 Janay 1989 25-325, BRIDGE RAILING Drawings. Posts, unless otherwise shown on the Drawings or directed by the Engineer shall be perpendicular to the top of the concrete parapet or footway surface. Unless otherwise consented to by the Engineer, rail connectors shall be installed only at the locations shown on the Drawings. A lanoline based grease or similar shall be applied to the threads of set screws prior to fitting them to the aluminium components. A torque wrench shall be used when tightening the set screws and the tightening loads shall be within the specified torque range, as shown on the Drawings. Each line of railing on the bridge shall be first assembled in position , properly aligned and levelled, using the lower nuts on the anchor bolts, for the full length of the bridge for inspection by the Engineer before being permanently bolted up and/or fixed to the deck. After inspection and consent by the Engineer the line of railing shall be finally secured in Position by bolting down. Care shall be taken that the line and levels of the rails are not disturbed After the railing has been erected true to line and grade, the consent of the Engineer's Representative obtained and all connections made, dry pack mortar in accordance with the requirements of Section 8 of this Specification shall be rammed into place beneath post base plates as shown on the Drawings. On completion, exposed faces of the mortar shall be brushed to a smooth surface flush with the edges of the base plate and all mortar spots and droppings shall be removed. 25.7. GUARD FENCE RAILING 25.7.1. General The guard fence shall comprise guard rails, posts, blockouts and end wings assembled and anchored as shown on the Drawings. 25.7.2. Materials Guard rail and end wings shall consist of approved standard 2.6 mm corrugated galvanized steel sections. All materials, as shown on the Drawings, shall be supplied by the Contractor. 25.7.3. Erection Railing shall not follow any irregularity of deck. Where shown on the Drawings the rail elements shall be curved before erection, Rail sections shall be lapped in such a way that exposed ends do not face towards oncoming traffic. Threaded ends of all bolts shall be burred to prevent removal. The round-heads of the bolts shall face the traffic side of railing. Holes for special details may be field drilled or punched when approved by the Engineer. Terminal sections shall be 25-4 BMS8.S.E Stance Soucteaons fer Bdge Contuctan - 26 Jenny 1993attached to the ends rails, posts and bloc! Posts shall be bolted Drawings. Mortar shall be in aci completion exposed with the adjacent det Railing to be continu installed in accordant 25, BRIDGE RAILING f each installation and shall be lapped on the face of the rail. Guard fouts shall be assembled and anchored as shown on the Drawings. {to supporting members and/or set on mortar pads, as shown on the jordance with the requirements of Section 8 of this Specification. On surfaces of mortar shall be rubbed down to a smooth surface level k surface. 1d from the bridge deck onto the adjoining road approaches shall be e with the requirements of Section 2 of this Specification. 25.8. MEASUREMENT Measurement, for payment, of each type of steel railing will be based on the number of metres of railing fabricated and/or supplied (as applicable) and installed and accepted for payment by the Engi eer. 25.9. PAYMENT The item for paymen materials specified t incidental to the sup Payment for the item| coatings, fabrication bolts, welding of rai beneath posts(where will include full payment for providing all labour, materials (except be supplied by the Employer), tools, equipment and any other work ly and erection of the bridge railing as measured in Clause 25.8 . ill include the supply of all railing materials, jigs, cleaning, protective lof panels and posts, delivery of railing components to site, fitting up ls (and posts where applicable), supply and placement of mortar applicable) and repair to paint or metallic coating and no separate payment will be made for any of these. All materials, tools a} the completed worl otherwise. Any work in addition be paid for in accord: \d equipment supplied by the Contractor which do not form part of s shall remain the property of the Contractor unless specified ito that shown or specified which may be ordered by the Engineer will jance with the provisions of the General Conditions of Contract. OSES. «Stas Sorsteatan to Brags Convucten «26 Jano 1983 25-5DIRECTORATE GENERAL OF HIGHWAYS MINISTRY OF PUBLIC WORKS REPUBLIC OF INDONESIA STANDARD SPECIFICATIONS FOR BRIDGE CONSTRUCTION SECTION 26 TIMBER BRIDGES JANUARY 1993 DOCUMENT No. BMS8-S.E26. TIMBER BI 26.1. GE 26| 26| TABLE OF CONTENTS IDGES ERAL Scope Materials 26.2. ROUND TIMBERS 26| 26| 26| 26| 26| Grade Description Quality of Timber Dimensions Tolerances for Round Timber Protection 26.3. SAWN TIMBER 26| 26| 26| 26.4. ST 26| 26 26.5. TH 26| 26 26| 26| 26| 26| 26| 26! 26| 26) 26| 26| 26| 26) 26 26| 26.6. CA 26 26 26, 26, 26.7. Su 26 26, 26.8. Ss 26 Species Quality .3. Tolerances for Sawn Timber JACKING OF TIMBER 4.1. General 4.2. Special Requirements for Treated Timber Handling BER PILES 5.1. Preparation for Driving Timber Piles 5.2. Equipment for Driving Timber Piles 5.3. Pile Bearing Values 5.4. Driving Timber Piles 5.5. Penetration and Set 5.6. Potting 5.7. Silling 8. Splicing Cutting Off 0. Framed Bents 1, Tolerances on Finished Pile Positions 2. Marking of Piles after Driving 3. Protecting Untreated Timber Trestle Piles 4, Protecting Treated Timber Trestle Piles 5. 6. N Protection in Tidal Waters Test Piles 6.1. General 6.2. Special Methods for Treated Timber 6.3. Holes for Bolts, Dowels, Rods and Lag Screws 6.4. Bolts and Washers STRUCTURE 7.1. Abutment Sheeting 1.7.2. Haltcaps PERSTRUCTURE 8.1. Stringers and Corbels Special Treatment of Stringers 26.8.2. 24 8.3. Stringers in Skew Bridges 26.8.4. Dampcourse 26-1 26-1 26-1 26-3 26-3 26-4 26-4 26-5 26-6 26-6 26-6 26-6 26-6 26-7 26-7 26-7 26-7 26-7 26-8 26-8 26-8 26-8 26-9 26-9 26-10 26-10 26-10 26-11 26-11 26-11 26-12 26-12 26-13 26-14 26-14 26-14 26-15 26-15 26-15 26-15 26-16 26-16 26-16 26-17 26-17 26-17ble of Contents 26.9. 26.10. 26.11 26.12, 26.13. 26.14. DECKING 26.9.1. 26.9.2. 26.9.3. 26.9.4, 26.9.5, 26.9.6 26.9.7, 26.9.8. 26.9.9. 26.9.10. General Transverse Decking Longitudinal Decking Two Ply Timber Decks Kerbs Cross Beams Bolting Planks Cross Pieces Nosing Pieces Surfacing of Decking CONNECTIONS IRONWORK 26.10.1. General TIMBER PRESERVATION 26.11.1. 26.11.2 26.11.3. 26.11.4. 26.11.5. RAILING Petroleum Jelly Creosoting Special Requirements for Untreated Timber Painting Protection Against Termites MEASUREMENT PAYMENT. 26.14.1 26.14.2 General Timber Piles 26-18 26-18 26-18 26-19 26-19 26-19 26-20 26-20 26-20 26-20 26-20 26-21 26-21 26-21 26-21 26-22 26-22 26-22 26-22 26-23 26-24 26-24 26-24 26-2526.TIMBER BRIDGES 26.1. GENERAL 26.1.1. Scope This Section covers includes the supply ai timber construction n| The fabrication of st Section 22 of this Spi Supply and placeme Section 34 of this Spi 26.1.2. Material} a, Lumber ‘Sawn lumber and tim! and Piling, AASHTO the Engineer. Struct he construction of simply supported span timber bridges. It also id installation of timber piles for permanent work and any incidental t otherwise provided for in the Specification. pel Components shall be in accordance with the requirements of ification. it of concrete shall be in accordance with the requirements of ecification. and Timber (Solid Sawn) ler shall conform to the Specifications for Structural Timber, Lumber 1168, or equivalent local Timber, Lumber, or Piling acceptable to iral lumber and timber, or solid sawn lumber shall not be used in exposed permanent stfuctures without adequate preservative treatment. Where shown on the Drawings or in 1 1@ Special Specifications preservative treatments by the pressure method shall be in actordance with the requirements of the American Wood Preservers Association Standard ct Lumber and timber with adequate heartwood requirements (see AASHTO M168) or for temporary structures eed not require special preservative treatment, b. Structural Shapes Rods, plates and shapes shall be of structural stee! or wrought-iron and shall comply with the requirements of requirements of Sect c. Casting: Castings shall be cast 30 (ASTM A 48) ‘Gre Special Specifications, d. Hardwai Machine bolts, drift jection 22 of this Specification. Eyebars shall comply with the n 22 of this Specification. brey-iron, conforming to the requirements of AASHTO M 105 Class y Iron Castings ‘ unless otherwise shown on the Drawings or in the fe bolts, and dowels may be either wrought-iron or medium steel. Washers may be cast iron ogee or malleable iron castings, or they may be cut from medium steel or wri Specifications, Bolts shall have well f jught-iron plate, as shown on the Drawings or in the Special ged square or round heads shown on the Drawings or in the Special SUSESE Sundad Sectors fer endoe Cantacton «26 January 1883 26-126. TIMBER BRIDGES Specifications and square nuts with threads accurately and clearly cut to metric standards for a minimum length of four bolt diameters or 100 mm which ever is the greater. All nuts shall be well-fitting without play. Lengths of bolts shown on the Drawings are approximate only and the Contractor shall supply bolts of the correct length adequately threaded as shown on the Drawings or in the Special Specifications to allow for shrinkage of timbers. Ends of bolts shall be cut-off not more than one half the diameter beyond the nut. Nails shall be cut or round wire of standard form. Spikes shall be cut or wire spikes, or boat spikes, as shown on the Drawings or in the Special Specifications. Nails, spikes, bolts, dowels, washers, and lag screws shall be black or galvanised, as shown on the Drawings or in the Special Specifications. Unless otherwise shown on the Drawings or in the Special Specifications all hardware for treated timber bridges, except malleable iron connectors, shall be galvanised or cadmium plated in accordance with Section 21 of this Specification. Paint for Timber Structures Paint for timber structures, except as otherwise provided herein, shall conform to the Specification for White and Tinted Ready-Mixed Paint (Lead and Zinc Base), AASHTO M70. The paint shown on the Drawings or in the Special Specifications is intended for use in covering previously painted surfaces. When it is applied to unpainted timber, turpentine and linseed oil shall be added as required by the character of the surface in an amount not to exceed one eighth (1/8) litre each per litre of the paint shown on the Drawings or in the Special Specifications. The paint shall be either white or tinted as directed by the Engineer. ft. Timber Connectors i. General Connectors for treated timber structures, except those of malleable iron, shall be galvanised in accordance with AASHTO M 111 (ASTM A 123) and shall be of the type as specified in Clause 26.10 of this Specification (see Table | for Typical Dimensions of Timber Connectors). ii. Split Ring Connectors Split rings of 64mm inside diameter, 102mm inside diameter and 152 mm inside diameter shall be manufactured from hot rolled, low carbon steel conforming to AASHTO M 160 (ASTM A 6) ‘Structural Steel for Bridges’. Except for the 152 mm ring (which is rectangular in cross section) the metal section shall be bevelled from the central portion toward the edges to a thickness less than the mid section. It shall be cut through in one place in its circumference to form a tongue and slot. Connector grooves in timber shall be Cut concentric with the bolt hole and shail provide a snug fit. Inside groove diameter shall be larger than ring diameter in order that the ring will expand slightly during installation. 26-2 M85 Stands Soectcaions for Budge Consucton = 26 Janay 1893i, Th Tooth ring timber c 26. TIMBER BRIDGES oth-Ring Connectors Innectors shall be stamped cold from 2 mm hot rolled sheet steel conforming to AASHTO M 160 and shall be bent cold to form a circular, corrugated, sharp-toothed band a shall have an overall Pressed Steel Type. from mild steel conf flange around the edi from one face only. Malleable Iron Type. in accordance with A\ with a flange aroun Projecting from one \d circle. All sizes, 51 mm, 67 mm, 86 mm and 102 mm diameters jepth of 24 mm and a depth of fillet of 64 mm. iv. Shear Plate Connectors ressed steel shear plates of 67 mm diameter shall be manufactured ming to AASHTO M 160. Each plate shall be a true circle with a je, extending at right angles to the face of the plate and extending lalleable iron shear-plate of 102 mm diameter shall be manufactured ASHTO M 160. Each casting shall consist of a perforated round plate the edge extending at right angles to the face of the plate and ce only. v. in Connectors Spike grid timber co! They shall consist of teeth which are held Circular grids of 83 the outer circumferer \ectors shall be manufactured in accordance with AASHTO M 106. Jour rows of opposing spikes forming of 105 mm square grid with 16 iin place by fillets. im diameter shall consist of 8 opposing spikes equally spaced around ice and held in place by connecting fillets around the outer diameter and radial fillets projecting to a central circular fillet which forms a bolt hole opening of 32 mm. 26.2. ROUND TIMBERS Round timbers used of this Section of thi in the structure shall conform in all respects with the relevant parts Specification. The selection of the particular species to be used will depend on its position in the structure and upon | cal availability, At least two weeks prior to the felling of any timber the Contractor shall submit for the consent of the Engin structure. The Cont round timbers for th ler the proposed timbers to be used and their locations in the finished actor shall make all necessary arrangements for the acquisition of structure and shall pay all fees and royalties due. 26.2.1. Grade Description Round timbers shall pockets of preliminay Logs shall be general or similar piles where be of sound wood and free from imperfections other than minor rot, and shall be suitable for their purpose in the structure. stripped free from bark after felling except in the case of Turpentine the Engineer may direct that bark shall be left on and that care shall BMS. Stndes Spnctton for Bie Consincnon «26 Jonny 1993 26-326. TIMBER BRIDGES be taken by the Contractor to protect the bark from damage. A ting of sound bark shall be left on logs for identification purposes but this shall be removed prior to incorporation into the Works. Where logs are not intended for treatment by an approved preservative forest-grown timber showing no more than the usual amount of sapwood shall be supplied. 26.2.2. Quality of Timber Timber shall be of best quality cut from well matured trees with defects being limited to the following: fa) tb) (c) dd) fe) 26.2.3. Single splits or shakes not exceeding 450 mm in length measured at the time of inspection at either end. Star splits or shakes not exceeding 300 mm in length measured at the time of inspection at either end A heart or pipe at the butt end only providing that it does not exceed one-sixth of the diameter of the butt. Knots in the centre half due to the removal of sound limbs which do not exceed one-sixth of the actual diameter of the log at the point where the knot occurs and knots in the end quarter due to the removal of sound limbs which do not exceed one-third of the actual diameter of the log at the point where knot occurs. Knot holes, other than open holes, connecting directly to a pipe or dozy heart which do not exceed one-twelfth of the specified log diameter and show no signs of rot. Dimensions Round timbers used in bridge works shall conform to the following dimensions unless otherwise shown in the Drawings: (a) Piles Crown diameter 310 mm minimum 360 mm maximum Butt diameter 450 mm maximum (o) Corbels Mid-diameter For bridge spans up to 6.0m: 480 mm minimum For bridge spans greater than 6.0m: 530 mm minimum 26-4 OMS8.S. stad Seectcatent fo ge Consiucton «26 Janay 1903tc) 26. TIMBER BRIDGES Stringers Mid-diameter For bridge|spans up to 6.0m: 530 mm minimum For bridge] spans greater than 6.0m: 580 mm minimum All diameters shall be Measured over the sapwood. 26.2.4. Tolerances for Round Timber Round timbers shall bi (a) tb) te) id) te) (g) (hy Lenath - 7} ends on si supplied in accordance with the following tolerances: imber shall measure the full specified length when cut square at the je. They shall be delivered with an over length allowance of not less than 75 mm and not more than 300 mm for this purpose. ‘Sweep - The maximum sweep shall not be greater than 25 mm per 150 mm of actual deviation mid-point Stringers id-diameter. Sweeps shall be measured at the point of maximum rom a straight line lying between the mid-point at the crown and the it the butt hall in addition conform to the following tolerances on diameter. Mid-diamelter - Where the cross section at the mid-point of the stringer is circular th Drawings mid-diameter shall be not less than the diameter as shown on the lor in the Special Specifications. For non circular sections the smallest djameter shall be not less than 25 mm under the specified diameter and the mi than the 5 an of any two diameters measured at right angles shall be not less specified diameter. Crown diameter - The least diameter measured at the crown shall not be less than the Specificat| stringers mid-diameter as shown on the Drawings or in the Special lons by more than 90 mm for 7.5 m stringers nor 75 mm for 6.0 m nd proportionally for other lengths. Butt diameter - The greatest diameter measured at the butt shall not exceed the mid-di more tha Proportion meter as shown on the Drawings or in the Special Specifications by 150 mm for 7.5 m stringers nor 125 mm for 6.0 stringers and lly for other lengths. Insect Holbs - Isolated holes, free from insect life and decay, less than 6 mm in diamet timber is and not in groups will be tolerated provided the density of the jot unduly affected. Gum Vein - Gum veins will be accepted provided they are clean tight gum veins as dj are not cl Branches Istinct from gum pockets or cavities, free from decayed tissue, and ser together than 40 mm Stringers with branches will be accepted provided that there is only one branch, that at its junction with the tree this branch has a diameter less than 125 Im and that the branch does not occur within 1.5 m of the centre Jor Grdge Consvucton 26 Jarvey 1989 26-526. TIMBER BRIDGES 26.2.5. Protection As soon as practicable after cutting, the ends of all timbers shall be coated with a liberal application of hot petroleum jelly or similar approved moisture repellant coating. Petroleum jelly shall not be applied to wet timber. The jelly shall be heated until it becomes fluid and is easily workable with a brush. Care must be taken to avoid overheating the jelly. The ends of any timbers sawn off to the correct lengths in the finished works shall be re- treated. If required by the Engineer the Contractor shall supply and fit steel bands to the ends of all timbers delivered to the works to prevent the formation of splits. Details of the steel bands shall be submitted to the Engineer by the Contractor for his consent. Banding shall be carried out as soon as possible after application of the jelly. 26.3. SAWN TIMBER 26.3.1. Species Sawn timber to be used in the bridgework shall conform with the relevant part of this Specification unless otherwise consented to by the Engineer. Selection of the particular species to be used will be dependent on its position in the structure and upon local availability. Only one species of timber shall be used in bridge decking unless the bridge is over 20 metres in length, and then all planks of the same species shall be placed together. 26.3.2. Quality Sawn timber shall conform to AASHTO M 168 ‘Wood Products’and ASTM D 245 ‘Visually Stress Graded Timber for Structural Purposes’. All decking shall be backsawn. 26.3.3. Tolerances for Sawn Timber Insect Holes - Clean holes which are isolated and not in groups, free from insect life and decay, and less than 6 mm in diameter will be tolerated provided the density of the timber is not unduly affected, . Gum veins - These will be accepted provided they are clean tight gum veins (as distinct from gum pockets or cavities), free from decayed tissues, and are not closer together than 40 mm. Waney edaes'- Sapwood on the comer of a piece of sawn timber shall not be cause for rejection unless it exceeds 12 mm on either face of the piece. Knots - Sound, tight knots, provided they are less than 50 mm diameter and not excessive in number, will be accepted except in handrail timber. Shrinkage - The size shown the Drawings are nominal sizes, and the timber shall have excess size to the extent of 1 mm per 15 mm in both transverse directions. No shrinkage allowance is required in the longitudinal direction 26-6 n+ 26 Jowey 1999,26. TIMBER BRIDGES. 26.4. STACKING OF TIMBER 26.4.1. General| Immediately on deliver} ' at the bridge site all timber shall be stacked clear of the ground and ‘supported at regular intervals. Round timber shall be stacked so that each log will be separated from adjacent timber by at least 75 mm. Squared timber may be stacked as for round timber and in s| with a minimum of timber separated by timber stacked at the| damaged or unsuitabli expense. The ends of| immediately after sta Timbers of length gr member does not suf acceptable and timbe| Untreated material sh: surface to avoid absor stacked as to permit ich @ manner as to prevent warping. Sawn timber shall be stacked 5 mm thick battens between layers and with individual pieces of minimum of 25 mm to allow proper ventilation for seasoning. All site shall be effectively protected and should such timber become it will be rejected and shall be replaced by the Contractor at his own both round and sawn timber shall be coated with hot petroleum jelly king ater than 6 m shall be lifted using slings located such that the jer any damage. The practice of ‘barring’ timbers off trucks is not 's so handled may be rejected. Il be open-stacked on supports at least 0.3 metres above the ground iption of ground moisture and permit air circulation and it shall be so ree circulation of ai 26.4.2. Special Requirements for Treated Timber - Handling Treated timber shall bruising, or penetratis hooks, peaveys, pike} 26.5. TIMBER This Clause covers thi lengths shown on the squaring of ends shall 26.5.1. Preparat All piles shall be point on the Drawings or in 1 Wing piles shall be poi The Contractor shall central to prevent the Pile heads shall be pro not less than 75 mm being prepared for dri intervals. e carefully handied without dropping, breaking of outer fibres, }g the surface with tools. It shali be handled with rope slings. Cant or hooks shall not be used. PILES installation of driven timber piles, potted piles and silled piles. Pile [Drawings include a one metre cut-off length. An allowance for the be added to the specified lengths. jon for Driving Timber Piles id as shown in the Drawings and shall be shod with shoes as shown 1@ Special Specifications. Shoes shall be firmly attached to the toes. inted only and not shod. jake care when pointing the piles to ensure that the pile point is piles tending to wander off line when being driven. fected during driving with either a suitable helmet or mild steel ring Jeep and 50 mm thick and fitting tightly but not shouldered. After ing piles shall have the length from the toe marked at 250 mm ONS6-S Stasis Spnstcstane Bdge Cenetactan «26 Janay 1989 26-726. TIMBER BRIDGES 26.5.2. Equipment for Driving Timber Piles At least 14 days prior to the commencement of driving operations the Contractor shall submit to the Engineer, for his consent, details of the equipment and procedure proposed for driving the piles. Piles may be driven by drop hammers or diesel hammer. Drop hammers shall be of masses approximately the weights of piles but shall not be less than 1.5 tonnes. The drop used shall vary according to the length of the pile being driven and shall be as shown on the Drawings or as directed by the Engineer but in no case shall the drop exceed 4.5 metres. Diesel hammers shall have an energy per blow of not less than 3 tonne-metres for piles with lengths up to 15 metres and of not less than 5.5 tonnes-metres for piles in excess of 15 metres. 26.5.3. Pile Bearing Values Timber piles shall either be driven to a final set (mm per blow) or until a specified bearing value is achieved. If the latter is to be used to determine when driving is to be stopped then the one of the methods of Section 5 Piles Driven (subclause ‘Capacity of Driven is to be used for calculating the ultimate bearing capacity of the pile. 26.5.4. Driving Timber Piles Piles shall be pitched accurately in position prior to the commencement of driving. The Contractor shall give the Engineer not less than 14 days notice of his intention to carry out pile driving. The final ’sets’ shall be taken in the presence of the Engineer and the Contractor shall provide all necessary facilities for the Engineer to check pile sets and take records he may require. Piles shall not be sprung into place during or after driving but shall be effectively guided and held in true position. Should any pile crack or split during driving or become damaged in any way or swerve out of position in excess of the tolerances given in Clause 26.5.11 it shall be withdrawn and replaced by a sound pile or an additional pile driven as directed by the Engineer and at the Contractor's expense. The Contractor shall take all measures necessary to ensure that the piles are driven to the tolerances specified in Clause 26.5.11 and shall maintain a continuous check on pile alignment during driving Cutoffs shall be accurately made to ensure satisfactory bearing between the cap and piles. 26.5.5. Penetration and Set Piles shall be driven until the minimum penetration and the final set as shown on the Drawings (or ultimate capacity as calculated in Clause 26.5.3 above) have both been achieved unless the resistance to driving as indicated by the penetration per blow is such that in the opinion of the Engineer further driving would damage the piles. Should the specified set not be achieved at the specified minimum penetration dri cease and the Engineer shall determine whether splicing is necessary. ing shall 26-8 MSE. - Stndia Spuctcaon for Budge Contucton = 26 Jewry 1989.26.5.6. Potting Where specified pile shown on the Dra excavated such tha Position. All loose ai and the floor of the hk 26. TIMBER BRIDGES iS shall be potted into solid rock. The depth of the pot shall be as ings or as otherwise directed by the Engineer. The rock shall be there is at least 150 mm clearance around the pile after it is in \d fractured rock and debris and water shall be removed from the hole le brought to a uniform surface square with the axis of the pile using @ bedding of mortar in accordance with the requirements of Section 34 of this Specification. All sapwood shall bf concrete. The mini approval of the fount backfilled to the surf for drainage. The c| (200 kg/cm?) Potted piles shall be to satisfactorily sup) Not less than 72 ho the rock surface shall least the same densi 26.5.7. Silling Where shown on the installed at levels sh sill shall be in one le} neatly mortised to t bearing to the shoul horizontal surface wi In earth the base of th sill and shall be cor excavation to avoid below foundation le: the Engineer. For sil all loose and decom; After approval of t minimum thickness shall have a minimu to the seating as sh rock with a cement Specification. Earth excavated to evenly on all sides i surrounding naturall removed from the area of the pile which will be in contact with um diameter remaining after such removal shall be 30 mm. After fation by the Engineer the pile shall be placed upright in the hole and }ce of the rock with concrete which shall be sloped away from the pile crete shall have a minimum 28 day cylinder strength of 20 MPa \dequately braced until the concrete has reached sufficient strength jort the pile. rs after the concrete has been placed the earth excavated to reach be backfilled around the pile and compacted in 300 mm layers to at 'y as the surrounding naturally occurring material. [Drawings or in the Special Specifications piles shall be silled with sills wn on the Drawings or as otherwise directed by the Engineer. The \gth of a size as shown in the Drawings. The top surface shall be ke the pile tenons and shall be dressed so as to provide uniform lers of tenons. The underside of the sill shall be dressed to provide a ith a minimum width of 175 mm. 1@ excavation shall be dressed to provide a horizontal seating for the pacted as directed by the Engineer. Care shall be taken during jisturbing material below foundation level. All soft material occurring jel shall be removed and replaced or further excavated as directed by ing on rock the base shall be excavated to a horizontal bed free from josed material and clean-cut to a firm surface at the required level. le foundation by the Engineer a seating of mass concrete with a f 50 mm shall be constructed to provide a level bed. The concrete 28 day cylinder strength of 20 MPa. The sill shall be firmly bolted wn on the Drawings, Bolts shall be grouted into holes drilled in the grout in accordance with the requirements of Section 34 of this jonstruct silled piers or abutments shail be backfilled around the sill 300 mm layers and compacted to at least the same density as the occurring material. BMS. - Stance Spuctcnon tor Bnage Constucton » 26 Janay 1983, 26-9