1. 2013 Northcentral Region Construction Conference
WisDOT - Bureau of Structures
Brandan Burger & Dave Kiekbusch

2. Contact BOS – When & Why?
Anything “structural” – change in loading, structural capacity, pile locations
If in doubt, call us!
See Structures
Contacts Handout
Remind Contractor to go thru Construction Staff for answers

3. Contractor Staking
Measure Twice… Cut Once!

4. Removal Issues

5. Steel Shop Drawings & Fabrication
Send electronic files via to:
Craig Wehrle: Girders, rails, exp. joints, bearings, etc.
Steel fabrication
Who inspects?:
BOS Structures Maintenance
BOS hired Consultants

6. Shop Inspection Prestressed Concrete Girders
Plant has one Quality Verification (QV) inspector
Weekly plant - QV reports
QV reports with girder acceptance recommendations are sent to region materials staff and forwarded to project personnel.
Issues from the fabrication plant should NOT be re-visited at the job site.
 Final approval is made by project engineer at job site - any shipping or erection damage.
Managed by Bureau of Technical Services
Each plant has one Quality Verification (QV) inspector who is a consultant under contract to WisDOT.
Approval at plant is weekly via QV inspection reports. 
QV reports with girder acceptance recommendations are sent to region materials staff and forwarded to project personnel.
Issues from the fabrication plant should not be re-visited at the job site.
 Final approval is made by project engineers when girders are received at job site, which accounts for any shipping or erection damage.

7. Prestressed Girder Sweep
Initial sweep is critical
Fabricator’s responsibility
Measured at the plant
Long term sweep only a concern IF intermediate diaphragms don’t fit.
Initial sweep is critical, is under the control of the fabricator, and is the fabricator’s responsibility.
Measurements should be made just after form stripping and strand release in a “plant controlled” environment (no influence from temperature).
If measured on bed, girder should be lifted and reset to free the ends.
Measure sweep at the web mid-point utilizing a cotton or nylon string tied to the girder ends with sufficient tension and a conventional tape measure or ruler.

8. Exterior Girder Rotation
Mostly occurs w/ steel & wide flange (>4’) prestressed girders
Contractor’s responsibility
Strapping top flanges & bracing bottom flanges
NO welding to top flange of steel girders or prestressed girder rebar!

10. Strip Seal Joints Proper rebar clearance
Release joint straps ASAP – before set

11. Anchor Bolt Projection
Anchorage for Steel Railings
Hold anchor bolts up – thread connection

12. Erosion/Grading @ Wings
Plan details for fill at wing tips
Proper Fill = Minimize Future Erosion

13. MSE Walls What to look for:
Materials
Backfill – Material, Compaction
Reinforcement – Strap Placement
Panels – Damage, Filter Fabric
Construction – Obstructions
Drainage
If designed and built correctly = Quality Product

16. Ancillary Structures
Overhead sign supports, sign bridges, traffic signal monotubes, high mast lighting poles
Contractor’s responsibility
Anchor bolt tensioning: DT each structure
Submit to the engineer - permanent project records
Engineer’s responsibility
Contact region traffic or maintenance - set up inspection as soon as each structure is complete
Overhead sign supports, sign bridges, traffic signal monotubes, high mast lighting poles
Contractor must complete anchor bolt tensioning form DT2321 for each structure, submit to the engineer for inclusion in the permanent project records.
Engineer should contact region traffic or maintenance individual responsible for setting up inspections as soon as each structure is complete

17. Ancillary Structures FOUNDATIONS: Too Low/Buried Too Low/Buried
Removal of Excess Formwork
Shaft/Bar Cage Not Plumb or Centered
Missing Rodent Screen
FOUNDATIONS:
Too Low/Buried
Removal of Excess Formwork
Shaft/Bar Cage Not Plumb
Missing Rodent Screen

18. Ancillary Structures ANCHOR BOLTS: Use of Lock Washer
Out of Plumb
Leveling Nuts
Improper Tensioning
ANCHOR BOLTS:
Use of Lock Washer
Out of Plumb
Leveling Nuts
Improper Tensioning

19. Ancillary Structures Bolted Connections: Missing Bolts on Truss
Loose Bolts on Splice
Prepped Splice Plates
FOUNDATIONS:
Missing Bolts on Truss – All bolts must be installed on the ground before uplift up to the towers
Loose Bolts on Splice – 3 out of 8 bolts not tightening
Prepped Splice Plates – Last photo shows dirt in between the splice plate. The plates should be clean and free of dirt

20. Ancillary Structures Bolted Connections: Faying Surface Gap
Use of Lock Washer
Incorrect Bolt Size/Length
Bolted Connections:
Faying Surface Gap – Friction Connection place oversized washer or filler plate in gap
Use of Lock Washer – Shown harden Flat washer is O.K.
Incorrect Bolt Size/Length

21. Ancillary Structures Sign Connections: Approved Hardware
Oversized and slotted hole
Over Tensioning
Blank Signs and cover
Bolted Connections:
Approved Hardware – Photos 1 & 3 show inappropriate hardwares
Oversized and Slotted Hole – Not allowed
Over Tensioning - last photo shows cracked aluminum casting with over tensioning. Also shown uncoated bolts & Nut
Blank Signs and Cover – Blank signs must be used per plan notes when permanent sign is not available. Permanent signs should be covered when they are not in use.

22. Reinforcement 505.3.4 Placing and Fastening
Plastic chairs – support bottom mat of rebar
Continuous chairs – support top mat of rebar off bottom mat
NOT ALLOWED – individual plastic chairs to support top mat of rebar
Reminder: Hardware incorporated in deck must be galvanized, epoxy coated, stainless steel, etc.
Welding is not permitted on epoxy steel.
Placing and Fastening
The contractor may use recycled plastic supports for a bottom layer of steel reinforcement which in turn supports upper layers on continuous bar chairs; but do not use individual plastic chairs to directly support upper layers.
Reminder: Hardware incorporated in deck must be galvanized, epoxy coated, stainless steel, etc.
Welding is not permitted on epoxy steel.

25. Driven Piles
New Section 550: similar to STSP used for the last few years.
Modified Gates – Required Driving Resistance
Specification Covers:
Steel, Cast in Place & Precast Concrete Piles
Pile Points
Providing test piles
Driving piles
Determining required driving resistance
Preboring
Pile redriving
New Section 550: piling specifications that use a modified Gates formula to determine the required driving resistance
Describes providing steel piles, cast in place concrete piles, and precast concrete piles; providing test piles; driving piles; determining required driving resistance; describes preboring or redriving.

26. Pile Splices
Weld splices conforming to the AWS D1.1/D1.1M Structural Welding Code-Steel.

27. Pile Splices
Contractor certifies the quality of field welds as follows:
Designate who inspects welding.
Must be an AWS certified welding inspector (CWI) or a department-approved individual.
Evaluate field welding at suitable intervals.
Complete DT2320 for each structure
Submit form to the engineer - permanent project record.
Certify the quality of field welds as follows:
1. Designate who will visually inspect the contractor’s welding. Must be an AWS certified welding inspector (CWI) or a department-approved individual.
2. Designated inspector must evaluate the field welding at suitable intervals.
3. Designated inspector must complete department form DT2320 for each structure and submit the form to the engineer for inclusion in the permanent project record.

28. Pile Splices
If piles drive longer than plan length, pay for field splice
Current policy: Splices paid as equivalent to the contract price for:
HP piles = 9 feet per pile spliced
Other piles = 6 feet per pile spliced
ONE payment per pile.
Possible revision for 2014
Additional payment under the Pile Splices administrative item for piles spliced in the field if the required driving resistance cannot be achieved in the length the plans show.
Pay an amount equivalent to the contract price for 9 feet of piling for each HP pile spliced and for 6 feet of piling for each pile for other pile types. ONE payment per pile.
Possible revision for 2014.

29. Painting Exposed Piling
Section Painting:
See the department’s approved product list “Paint Systems for Exposed Piling”

30. Temporary Structures
Inspect temporary structures before opening to traffic
Conform to NBIS & department’s structure inspection manual
Guidance in CMM: Chapter 5 Structures
Contractor’s Responsibility
Included in ASP 6
Submit DT2007 to the engineer & BOS Maintenance Section
Inspector must be department-certified active team leader
List online – see CMM
Included in ASP 6
Inspect temporary structures conforming to the National Bridge Inspection Standards and the department’s structure inspection manual before opening to traffic.
Submit inspection reports on department form DT2007 to the engineer and electronic copies to the department's bureau of structures maintenance section.
Ensure that a department-certified active team leader, listed online in the department's highway structures information system (HSIS), performs the inspections.
Construction and Materials Manual: Chapter 5 – Structures, Section 65 – Temporary Structures

31. Bridge Approaches New Structural Approach Slabs
US Highways & Interstates

32. Accelerated Bridge Construction
Every Day Counts – FHWA Initiative
Bridge Manual – ABC chapter
Completed WisDOT projects: Precast deck panels, abutments & pier caps; Inverted T girders; Superstructure lateral slides; Geosynthetic reinforced soil (GRS) abutments

33. Accelerated Bridge Construction
Upcoming WisDOT projects: Self-Propelled Modular Transporter (SPMT), precast columns and pier cap, precast inverted T
WisDOT continues to look for projects where ABC provides clear benefits.

34. Conclusion Call us with Questions
We look forward to another great year of bridge construction!

35. Any Questions?