Do It Right! Lessons from the field not to be repeated
Rehab work
- Don’t allow the contractor to use over 60 pound jackhammers when removing the deck over the beams — or the beams may get damaged!
- These concrete beams were supposed to be left in place, and a new deck poured on top of them.
- The contractor thought they could just repair them with the deck pour.
- We had to make the contractor provide new beams, so a large delay was incurred.
Haste makes waste
- These beams were supposed to be reused after the deck was removed. There is no way to repair this much damage to prestressed concrete beams.
- The DNR would rather we don’t attempt to neutralize the effects of acid rain with the liberal application of concrete dust!
- We now require the concrete saws to have a stream of water be directed at the area being cut, and the milling to be performed in such a manner as to prevent visible dust to be liberated.
- Try not to remove more concrete than is shown in the plan.
- Quite a bit of sound concrete was removed and a lot of rebar was damaged because of the speed at which this joint was removed.
- Remove only what was called to be removed in the Plans.
- In this case, the barrier dowels were cut off to make it easier to replace the Expansion joint.
- What will hold the barrier on the deck now?
- Try to remove only what is shown in the plans, as long as the in-place concrete is sound.
- Don’t cut epoxy coated reinforcement with a torch!
- All damage to portions of the structure to remain in place that is due to the contractor's operations shall be repaired at the contractor’s expense.
- What happens if the barrier takes a hit at this location now?
- Try to prevent damage to sound concrete when performing repairs!
- Sure, maybe they saved some time removing the expansion joint with a backhoe-mounted hammer . . . but how much time will they need to spend repairing the damage?
- And how much damage will not get repaired?
Shotcrete Repairs
- Shotcrete is thirsty! Make sure that all repairs area are cleaned and saturated 24 hours prior to shotcreting, and re‐wetted prior to shooting.
- And . . . make sure that it gets a full three-day wet cure.
- Form new top flange monolithically with new expansion joint.
- This repair does not meet the criteria for beam repair, as only spalls less than 3 inches deep are permitted to be poured with the deck. Obtain Bridge Office approval for exceptions!
- Form top flange monolithically with expansion joint to repair damage to top flange of beam (removal of entire portion on left side of web). Excess damage caused!