DIVISION 500 - BRIDGES AND STRUCTURES

SECTION 501 - CONCRETE STRUCTURES

501.16 Concrete Deck Surface Requirements.

A. Permissible Surface Variations. The surface of concrete bridge deck slabs will be tested with a rolling Straightedge that automatically marks, in colored dye, the length of deck surface variations which exceed a tolerance of 3 millimeters in 3 meters.

Deck slabs which are required to be struck and finished with a self-propelled finishing machine shall be so constructed that, when tested in accordance with Subpart C below, the measured length of lot exceeding the specified 3 millimeters in 3 meters tolerance shall not exceed 8.9 percent as specified in Subpart E, Table 501-2, Schedule A below.

When manual strike-off and finishing is permitted and the option for manual methods is used, the deck slab shall be so constructed that the measured length of lot exceeding the specified 3-millimeter tolerance shall not exceed 19.9 percent as specified in Subpart E, Table 501-2, Subschedule B1 below.

If the option to use a self‑propelled finishing machine is selected when manual strike-off and finishing is permitted, the deck slab shall be so constructed that the measured length of lot exceeding the specified 3 millimeters tolerance shall not exceed 13.9 percent as specified in Subpart E, Table 501-2, Subschedule B2 below.

B. Control Testing. Deck slab surfaces shall be systematically checked during placement to correct surface irregularities while the concrete is in a workable condition.

Such systematic control testing shall be performed as follows:

1. After the intended final pass with the finishing machine or other strike-off, the deck surface shall be checked with a metal Straightedge operated parallel to the centerline of the bridge. Surface variations from the testing face of the Straightedge shall be corrected before the concrete sets. Major deviations shall be corrected by the finishing machine or other strike-off, while minor deviations may be corrected by the use of a straightedge or float. The addition of water to the surface of the concrete to assist in finishing operations will not be permitted.

2. The specific conduct of the control testing, including the number and location of Straightedge checks, shall be entirely the province of the Contractor. However, it is suggested that the checking operation progress in successive 1.5-meter longitudinal increments, with at least one full‑slab length straightedge check being made within the transverse limits of each of the designated lanes of traffic.

C. Acceptance Testing. Conformance to the surface tolerance for concrete deck slabs will be determined in lots, each lot being equal to the number of cubic meters of deck concrete placed in the designated lanes of traffic in each production day. Such lot quantity will be calculated using the specified nominal deck thickness and excludes the quantity of concrete placed in haunches, end dams, and diaphragms. For the second course of the two-course deck slab construction, such lot quantity will be calculated using the specified nominal thickness of the latex modified concrete.

The acceptance of a lot is based on the percentage of the total length of the lot having surface variation exceeding 3 millimeters in 3 meters, this percent noncompliance being defined as the Lot Percent Defective Length. Lot percent defective length is computed by adding the lengths of individual surface defects exceeding the specified tolerance, dividing this sum by the total length tested, and multiplying by 100 to convert to percent.

The full extent of the lot will be tested in the longitudinal direction. The transverse location of the test generally is in the wheelpaths of vehicle travel, defined as the two imaginary lines located approximately 915 millimeters on each side of the centerline of the lane and extending for the full length of the lane.

The minimum number of full‑length tests required to determine the lot percent defective length is equal to the total number of wheelpaths in the lot. The number of tests performed beyond this minimum, if any, and their location, are at the option of the Engineer.

When the lot percent defective length of a deck slab exceeds the value specified in the applicable paragraph of Subpart A above but is less than 25 in the case of a machine‑finished deck or 35 in the case of a manually finished deck, and if the slab is not removed and replaced, the lot may be accepted upon written request provided that payment for the lot is adjusted in accordance with Subpart E, Table 501-2 below.

If the lot percent defective length equals or exceeds 25 on any machine finished deck (irrespective of whether such machine finishing was required or optional) or 35 on a manually struck and finished deck, the Engineer may order any or all of the concrete in the lot to be removed, replaced, and retested for acceptance. If the Engineer allows the concrete to remain in place, payment for the lot will be reduced by 15 percent.

Subpart E, Table 501-2 does not apply to the second course of two-course deck slab construction. If the lot percent defective length equals or exceeds 20 on the finished second courses deck slab, the Engineer may order any or all of the concrete in the lot to be removed, replaced, and retested for acceptance. If the Engineer allows the concrete to remain in place, payment for the lot will be reduced by 15 percent.

D. Cessation of Deck Concreting. The Resident Engineer reserves the right to reject bridge deck construction methods or equipment which do not result in surfaces which are in substantial conformity with the 3 millimeters in 3 meters surface tolerance. The deck will be considered in substantial conformity with the required surface tolerance only if the lot percent defective length does not exceed the value specified in the applicable paragraph of Subpart A above.

The continued use of methods and equipment which result in a lot percent defective length of 20 or more on any machine finished deck slab or 35 or more on any manually struck and finished deck will not be permitted. If these limitations are exceeded, deck placement and finishing shall be discontinued until other methods or equipment are proposed for trial and submitted in writing for approval. Approval of this revised plan of operations does not relieve responsibility for the satisfactory performance of the revised method or equipment.

Additional compensation, extension of Contract Time or other concession will not be granted because of revised methods or equipment necessary to produce deck slabs in substantial conformity with the 3 millimeters in 3 meters surface tolerance.

E. Surface Remedial Measures. Regardless of the overall surface conformity of a lot of bridge deck concrete, if surface deviations have a detrimental effect on deck drainage or reinforcement steel cover, the Engineer may require appropriate remedial measures to restore any or all of the deck slab surface to the required grades and surface tolerance. When such remedial procedures are ordered by the Engineer, a plan shall be submitted, setting forth the intended limits of the surface restoration and a complete description of the methods, equipment and materials proposed for use.

Following satisfactory completion of the surface restoration measures to the bridge slab, the lot containing the affected area shall be retested.

Additional compensation, extension of Contract Time or other concessions will not be granted for any surface restorations ordered.

Table 501-2 Reduction Per Lot of Deck Slab Concrete Due to

Nonconformance with Surface Requirements

Schedule A Machine Finishing Required		Schedule B Machine Finishing Optional
		Subschedule B1 Manual Finishing		Subschedule B2 Machine Finishing
Lot Percent Defective Length	Reduction Per Lot, Percent	Lot Percent Defective Length	Reduction Per Lot, Percent	Lot Percent Defective Length	Reduction Per Lot, Percent
0-8.9	none	0-19.9	none	0-13.9	none
9.0-13.9	1.0	20.0-27.0	2.5
14.0-24.9	7.0	27.1-34.9	7.0	14.0-24.0	7.0

Remedial measures will not be required for the surface of the first course construction for high spots which do not exceed the prescribed grade by more than 6 millimeters in 3 meters.