Abu Dhabi, United Arab Emirates. STANDARD CONSTRUCTION SPECIFICATIONS (PART 2 - ROAD STRUCTURES, 2020)

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Painting system shall consist of all coating system materials, including primers, intermediate or top
coats, and other materials applied as surface treatment of concrete.

24.7.1

General Requirements for Concrete Painting

All materials shall be from a specialized manufacturer whose products have proven to be highly
satisfactory in similar works. The concrete protection system shall have a valid British Board of
Agreement (BBA) Certificate (or equally recognized certification).

The paint system shall be recommended by the manufacturer for the specific use intended and it
shall be applied in full accordance with the manufacturer's instructions.

The paint manufacturer shall provide evidence, in the form of relevant, independent test certification
prior to approval, that proposed coatings are sufficiently durable against temperature, humidity,
ultraviolet (UV) light, and salt exposure. The manufacturer shall retest the coats to verify durability if
found necessary and requested by the Engineer.

The concrete protection system shall have a minimum 10 year warranty for both the coating and its
application provided to the satisfaction of the Engineer.

The Contractor, when submitting for approval of the Paint proposed to be used, shall enclose also a
list of works, executed in the Gulf Region, in which the same make of paint was successfully used.

Consequently the following Specifications are meant to give the necessary information which shall
enable the Contractor to identify the works to be carried out and the material and equipment to be
proposed for the Engineer's approval.

The  paint  shall  be  applied  by  an  applicator  approved  by  the  manufacturer.  The  Contractor  shall
submit to the Engineer for approval the name of the proposed paint applicator and evidence that the
applicator  has  successfully  completed  similar  structural  painting  and  coating  projects  over  the
preceding  five  years.  The  applicator  shall  verify  this  experience  by  citing  at  least  two  projects
comparable to the Project that have been successfully accomplished. The approved applicator shall
prepare a method statement for substrate preparation, including covering materials and methods,
coating  application,  quality  assurance  (QA),  and  quality  control  (QC).  The  material  manufacturer
shall endorse this method statement.

The manufacturer or supplier shall provide technical representative as an expert supervisor of all
painting work undertaken.

Prior to applying the system in the works, trial applications shall be carried out on trial panels made
by  the  Contractor.  The  trials  shall  demonstrate  the  method  proposed  for  applying  the  system,
coverage,  coating  thickness,  colour  and  final  appearance  of  the  coating.  Representatives  of  the
coating manufacturers shall be present at the trials and the surface preparation and application of
the coatings shall be carried out in accordance with their recommendations. The Contractor shall, at
his own expense, surface coat as many panels as required to satisfy the Engineer that the panel,
when accepted, will form the standard against which the corresponding coating in the works will be
judged.  No  application  of  the  coating  in  the  works  shall  be  undertaken  until  trials  have  been
completed to the Engineer's satisfaction.

The Contractor shall not proceed with the surface finish or making good concrete surfaces until he
has received the Engineer's permission to do so and he shall not apply cement slurry or mortar or
any other coating to the concrete surfaces from which the shuttering has been struck until the
concrete has been inspected and approved by the Engineer.

The Contractor shall, on the written instruction of the Engineer, remove and reconstruct any such
portion of the work which, in the opinion of the Engineer, is unsatisfactory as regards quality of
concrete, incorrect dimension of the cast portion, badly placed or insufficient reinforcement,
honeycombing or other such cause as shall render the construction not up to the standard required
and which, in the opinion of the Engineer, may prejudicially affect the strength or durability of the
construction.

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To protect passing traffic and adjacent surfaces from unintentional paint application, the Contractor
shall provide protective shields, drop cloths, masking, and other protective covering devices. These
devices shall protect surfaces that are not to be painted and shall meet the approval of the Engineer.
Misapplied paint on unspecified surfaces shall be completely removed using compounds that are
recommended by the paint manufacturer.

Bearing devices, painted steel surfaces, exposed bituminous materials and joint sealants adjacent
to members to be painted shall be masked off. All masking shall be removed following completion of
painting process.

24.7.2

Paint Test Areas for the Engineer’s Approval

The Contractor shall furnish a coat color conform to FED-STD-595B or Classic RAL System as
approved by the Owner. The Contractor shall provide the Engineer with color chips from the paint
supplier. Based on the Owner selection of colours the manufacturer shall prepare test areas for
inspection an

d final approval by the Owner. The Owner’s acceptance of colours, tones, glosses, and

aesthetic appearance shall be based on observing samples of varying colours, tones, and glosses.

The Contractor shall prepare and paint test areas of at least 5 square metres in at least four
inconspicuous locations on the structure to be painted, as directed by the Engineer. The Contractor
shall use these test areas to determine absorption rates, achieve colour uniformity, and prove the
suitability of the application technique. The Contractor shall conduct tests under the direct
supervision of a technical representative who is familiar with appropriate application techniques for
the specific coating being applied.

The Engineer's approval must be obtained prior to applying the coating system in the works. Before
approval is given, the Engineer will need to be satisfied as to the following:

a. All construction work in the immediate vicinity of the structure to be coated has been

completed.

b. The surface preparation of the structure has been completed.
c. The whole of the structure can be coated in a continuous operation with paint from the same

batch.

d. Adequate measures have been taken to protect the property of third parties, including

vehicles from coating splatters.

e. The weather conditions are in accordance with the coating manufacturer's directions for

coating applications.

f. The timing of all coating operations.

24.7.3

Project and Weather Conditions

All materials shall be delivered to the jobsite in original, new, and unopened packages and containers
bearing the following information:

•

Manufacturer's name and label

•

Name of the material

•

Stock number

•

Date of manufacture

•

Contents by volume for major constituents

•

Thinning and application instructions

•

Colour number and name

Paints shall be applied only when surface temperatures and the surrounding air temperatures are
between 10° C and 32° C, unless otherwise permitted by the paint manufacturer in printed
instructions.

Unless a paint manufacture’s printed instructions permit painting in such conditions and the Engineer
approves such activity, the Contractor shall not apply paint under any of the following conditions:

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•

In rain, fog, or mist

•

When the relative humidity exceeds 85%

•

When surfaces to be painted are damp or wet.

At  the  time  of  applying  paint,  the  concrete  surface  must  be  dry  as  per  ASTM  D4263  -  83(2012).
However, a  moisture level  of  2.5%  or  less may be acceptable by the Engineer  depending on the
paint manufacturer's specification. In this case, the Contractor shall use the radio frequency method
to measure the moisture content in concrete, with other non-destructive measurement technique as
approved by the Engineer. The results shall be compared for accuracy and submitted to the Engineer
for approval.

24.7.4

Surface Preparation and Application

The Contractor shall prepare surfaces and paint the

structure’s exposed surfaces in compliance with

the Contract plans, the specifications in this chapter, and any directions from the Engineer.

On concrete surfaces that extend into earth, concrete paint shall extend at least 150 mm below the
finished grade. The Contractor must also propose a proper paint termination edge protection to the
Engineer for approval.

The Contractor, who shall perform all work to complete painting, must provide all necessary
materials, labour, tools, equipment, and appurtenances.

The surface cracks, if any, need to be verified to determine if the cracks are wet or dry cracks and
the repair methodology shall be to suit the crack criteria as approved by the Engineer. Horizontal
and vertical cracks are to be treated with specific method statements/ITP (Inspection and Test Plan)
all as approved by the Engineer.

Conditions deemed detrimental to the proper and timely completion of the work by the Contractor
shall be reported to the Engineer, in writing. Work shall not proceed until the Contractor has corrected
unsatisfactory conditions in a manner that is acceptable to the Engineer.

Before  painting,  the  Contractor  shall  prepare  and  clean  all  surfaces  in  strict  accordance  with  the
manufacturer’s  instructions  and  as  specified  herein.  Preparation  and  cleaning  of  surfaces  shall
include,  but  not  be  limited  to,  the  removal  of  dust,  dirt,  rust,  scale,  oil,  and  grease  by  manual  or
mechanical methods. Prior to any paint application, surfaces shall be inspected by the Contractor
and the Engineer to ensure that they are free of any cracks that could be detrimental to the structural
member and that they are suitable for the formation of a durable paint film.

All hardware, hardware accessories, machined surfaces, plates, and similar items shall be covered
to protect them from the painting operation. Details for protection shall be submitted to the Engineer
for approval prior to application.

Painting and cleaning operations shall be scheduled to prevent contaminates from the cleaning
process from falling onto wet or newly painted surfaces.

All paints shall be applied in accordance with the manufacturer’s directions.

All paints shall be applied using rollers. Spray painting shall not be permitted. The first-coat
application shall be applied to the cleaned, pretreated or otherwise prepared surface, as soon as
practical after the preparation, and before subsequent surface deterioration.

Where there is evidence of defects or unsealed areas in the first application, the surfaces shall be
repaired, grouted, and resealed or primed again to the satisfaction of the Engineer.

A prime coat of material shall be applied by the Contractor to all surfaces that are required to be
painted or finished, and that have not been prime-coated by an earlier application.

Additional coats of paint shall be applied when undercoats, stains, or other conditions show through
the final coat of paint.

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The Contractor shall ensure that all surfaces, including edges, corners, and crevices receive a dry
film thickness equivalent to that of the flat surface.

Sufficient time between successive coats shall be allowed by the Contractor to permit drying.
Previous coats shall have dried to a state where it feels firm, does not deform or feel sticky under
moderate thumb pressure, and when the application of another coat of paint will not cause lifting or
loss of adhesion of the undercoat.

24.7.5

Paint Materials

Materials for painting shall be as specified herein. Thinners, driers, and colour pigments shall be
manufactured, finished, or approved by the accepted manufacturer for use with his products.

Paint materials shall be handled, stored, mixed, and applied in compliance with the
recommendations of the manufacturer. In the event it appears that conflicts exist between such
recommendations and the Contract documents, the Contractor shall refer the matter to the Engineer
for clarification.

The following are the specifications for the coating systems for use on concrete surfaces on the
Project.

If any cracks observed have no structural significance, and would allow for any thermal cracks etc.
in the future, a suitable crack bridging surface coating conforming to BS EN 1504-9:2008 shall be
used as approved by the Engineer. This will safeguard the structure in unnoticed durability issues.

24.7.5.1

Exposed Concrete Surfaces

The coatings shall be pigmented water based, aliphatic acrylic polymer based elastomeric coatings
providing a barrier to water, carbon dioxide, oxygen, airborne acidic gases, chloride ions and
sulphates but with the ability to allow the outward passage of water vapour which may otherwise
become entrapped. The coating shall be completely opaque, and shall have very high U.V.
resistance. Solvent based coating may be used with proper justification if approved by the Engineer.

The minimum physical properties of the coating system shall be:

•

Weight per litre: 1.23 kg.

•

Solids by weight:

64%

•

Solids by volume: 50%

•

The total dry film thickness of the coating shall not be less than 250 microns for aboveground

structures, and 300 microns for belowground structures. The Coating shall be applied in two
coats on a Silane/Siloxane, impregnating, internal-membrane forming, concrete clear sealant
primer.

The minimum performance test requirements for the coating system and primer shall be as shown
in Table 24-12 and Table 24-13.

Table 24-12: Pigmented elastomeric aliphatic acrylic coating for exposed concrete surfaces

Property

Value

Method

diffusion resistance (DIN

53122-1 (2001-08))

– Equivalent

Air Layer Thickness

> 175 metres

Taywood method

CO2 diffusion resistance -
Equivalent thickness of 30MPa
concrete.

> 500 mm

Taywood method

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Property

Value

Method

Water vapour diffusion resistance

Sd Value = 1.0m at 200
microns DFT

BS 3177:1959, Taywood
method

Chloride ion diffusion coefficient

No chloride ion diffusion after
600 days immersion

BS 3177:1959, Taywood
method

Reduction in Water Absorption



82 percent

ASTM C642 - 06

Colour Retention

No Visible colour change after
2,500 hour of accelerated
weathering of sample

Taywood method

Reduction in Chloride Ion
Penetration



92 percent

AASHTO T 277-07 (2011)
(ASTM C1202

– 12)

Adhesion



2 N/mm

on concrete or 90%

failure in concrete surface

ASTM D4541 - 09e1

Abrasion Resistance



25 mg/1,000 cycle

ASTM D4060 - 10

Tear resistance



15N/mm

ASTM D624 - 00(2012)

Tensile Strength

5 MPa

ASTM D412 - 06a(2013)

Crack Bridging



2 mm (at 40°C)

BRE method

Freeze-Thaw Salt Scaling, 50
cycles (ASTM C672)

Unaffected

ASTM C672 / C672M - 12

Resistance to Salt, Alkalis, and
Acids

Resistant

Application Method

Roller

Table 24-13: Silane/Siloxane primer for exposed concrete surfaces

Property

Value

Method

Nonvolatile Content (Vol.)

5% to 10%

Reduction in Absorption



80%

BS 1881-122:2011

Moisture-Vapour Transmission



220 g/m

/ Day



Reduction in Cl ion Penetration



90%

BS 1881-124:1988

Reduction in absorption for the whole system shall be equal to or better than 95%. Adhesion of the
whole system to concrete shall be ≥ 2 MPa or 90% failure in concrete surface.

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24.7.5.2

Concrete Surfaces in Splash Zones

The coatings shall be pigmented water based, aliphatic acrylic polymer based elastomeric coatings
conforming to the requirements of Article 24.7.5.1. Solvent based coating may be used with proper
justification if approved by the Engineer.

The total dry film thickness of the coating shall be 350 microns applied in two coats on a
Silane/Siloxane, impregnating, internal-membrane forming, concrete clear sealant primer
conforming to the performance test requirement of Table 24-13.

Adhesion of the whole system to concrete after 500 hours in salt water shall be ≥ 2 MPa as per
ASTM D4541 - 09e1or 90% failure in concrete surface. The whole system shall have no blistering,
peeling or disbonding when immersed in deionised water for 30 days at 24°C. Reduction in Water
Absorption shall be 99% as per ASTM C642

– 06. Reduction in Chloride Ion Penetration shall be

97% as per AASHTO T 277-07 (2011) (ASTM C1202

– 12).

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NDEX

adjacent property, 24-2
Adjacent surfaces, 24-2
aluminium, 24-1, 24-4, 24-32, 24-33
blast cleaning, 24-3, 24-19, 24-21, 24-26
bottle brushes, 24-4
Brush application, 24-25
calibration, 24-28
chromium, 24-1, 24-10
cleaning products, 24-2
coat color, 24-10, 24-14, 24-15, 24-35
coating systems, 24-10, 24-12, 24-17, 24-29,

24-30, 24-37

cold weather, 24-3
condensation, 24-15, 24-24, 24-27
contamination, 24-2, 24-13, 24-23, 24-27
corrosion, 24-1, 24-12, 24-17, 24-19, 24-21,

24-33

Cyclic exposure, 24-16
dehumidification, 24-3
deleterious material, 24-2, 24-30
deterioration, 24-1, 24-22, 24-36
disfigurement, 24-2, 24-9
engineering controls, 24-3
galvanized, 24-1, 24-13, 24-14, 24-16, 24-18,

24-30

gravity convection oven, 24-22
H and Pipe pilings, 24-31
hazardous material, 24-1, 24-2
incompatibility, 24-17
independent test laboratory, 24-2
ingredients, 24-23, 24-25
lead, 24-1, 24-10, 24-24, 24-25, 24-33
Machine-finished, 24-26

Magnetic Gages, 24-27, 24-28
mechanical methods, 24-23, 24-36
notarized statement, 24-31
outdoor exposure testing, 24-10
paint debris, 24-2
paint manufacturer, 24-3, 24-10, 24-24, 24-32,

24-34, 24-35

painting operations, 24-1, 24-2
Painting services, 24-1
pressurized water, 24-19
Protective devices, 24-1
regulations, 24-1, 24-10, 24-19
removed material, 24-2
Salt fog, 24-16
sheepskin daubers, 24-4
Shop painting, 24-26
site hazards, 24-2
solvent cleaning, 24-19
spray application, 24-25
spray equipment, 24-3
steel sheet, 24-31
structural iron and steel, 24-1, 24-9, 24-12, 24-

17, 24-18

surface preparation, 24-2, 24-3, 24-17, 24-22,

24-26, 24-34, 24-35

surface temperatures, 24-35
test area, 24-17
Thinning, 24-23, 24-35
volatile organic compounds, 24-10
waste materials, 24-1
water based, 24-37, 24-39
workers, 24-2

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25.4.13.5

Tolerances ................................................................................................... 25-22

25.5

Fabrication of Bearing Devices .................................................................................. 25-22

25.5.1

Elastomeric Bearings Tolerance ......................................................................... 25-23

25.5.2

Other Fabrication Tolerances.............................................................................. 25-23

25.6

Testing and Acceptance of Bearing Devices .............................................................. 25-26

25.6.1

Bearing Device Testing Terminology .................................................................. 25-26

25.6.1.1

Adapter Plates and Attachments .................................................................. 25-26

25.6.2

Bearing Device Tests .......................................................................................... 25-26

25.6.2.1

Material Certification Tests .......................................................................... 25-27

25.6.2.2

Material Friction Test (Sliding Surfaces Only) .............................................. 25-27

25.6.2.3

Dimension Check for Bearing Devices ......................................................... 25-27

25.6.2.4

Clearance Test for Bearing Devices............................................................. 25-27

25.6.2.5

Short-term Compression Proof Load Test for Bearing Devices .................... 25-28

25.6.2.6

Long-term Compression Proof Load Test for Bearing Devices..................... 25-28

25.6.2.7

Bearing Friction Test (Sliding Surfaces Only) ............................................... 25-28

25.6.2.8

Long-term Deterioration Test for Bearing Devices ....................................... 25-28

25.6.2.9

Bearing Horizontal Force Capacity (Fixed or Guided Bearings Only) ........... 25-29

25.6.3

Performance Criteria for Bearing Devices ........................................................... 25-29

25.6.4

Special Testing Requirements for Bearing Devices ............................................ 25-29

25.6.4.1

Testing Elastomeric Bearings ...................................................................... 25-29

25.6.4.2

Testing Pot and Disc Bearings ..................................................................... 25-31

25.6.4.3

Testing Rocker and Roller Bearing .............................................................. 25-33

25.6.4.4

Testing Polytetrafluorethylene Surfaces for Bearings ................................... 25-33

25.6.4.5

Testing Bronze or Copper-alloyed Plates for Bearings ................................. 25-34

25.6.4.6

Testing for Curved Sliding Bearing .............................................................. 25-34

25.6.5

Use of Tested Bearings in a Structure ................................................................ 25-34

25.7

Packaging, Handling, and Storing Bearing Devices ................................................... 25-34

25.8

Installing Bearing Devices .......................................................................................... 25-35

25.8.1

Installing Elastomeric Bearings ........................................................................... 25-35

25.8.1.1

Stress Relieving of Elastomeric Expansion Bearings ................................... 25-36

25.8.2

Installing Pot and Disc Bearings ......................................................................... 25-36

25.8.3

Installing Rocker and Roller Bearings ................................................................. 25-37

25.8.4

Installing Spherical Bearings ............................................................................... 25-37

25.8.5

Installing Bronze or Copper-alloyed Plates for Bearings ..................................... 25-37

25.8.5.1

Bronze Bearing and Expansion Plates ......................................................... 25-37

25.8.5.2

Rolled Copper-alloy Bearings and Expansion Plates ................................... 25-37

25.8.6

Installing Masonry, Sole, and Shim Plates for Bearings ...................................... 25-38

25.8.7

Installing Polytetrafluorethylene Surfaces for Bearings ....................................... 25-38

25.8.7.1

Attachment of Polytetrafluorethylene Material .............................................. 25-38

25.8.7.2

Stainless Steel Mating Surface .................................................................... 25-38

25.8.7.3

Lubrication for Polytetrafluorethylene Surfaces ............................................ 25-39

25.8.7.4

Installation of Polytetrafluorethylene Surfaces ............................................. 25-39

25.8.8

Installing Anchor Bolts for Bearing Devices ......................................................... 25-39

25.8.9

Installing Load Plates for Bearing Devices .......................................................... 25-39

25.8.10

Installing Guides for Bearing Devices ................................................................. 25-39

25.8.11

Installing Guide-ways and Restraints for Bearing Devices .................................. 25-39

25.8.12

Installing Seismic Buffer Blocks .......................................................................... 25-40

25.8.13

Installing Seismic Restraint Cables ..................................................................... 25-40

25.8.14

Installing Shear Transfer Units at Abutments ...................................................... 25-40

25.8.15

Load Cells ........................................................................................................... 25-40

25.9

Bearing Replacement ................................................................................................ 25-40

25.10

Warranty and Maintenance for Bearing Devices ........................................................ 25-41

25.11

Documentation for Bearing Devices ........................................................................... 25-41

Index 25-42

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BEARING DEVICES

This chapter outlines standards and requirements for furnishing and installing bridge bearings and
the bedding of materials used under masonry plates for the Project.

Bearing  construction  shall  conform  to  the  details  shown  in  the  Contract  documents.  When  the
Contract documents do not provide complete details, bearings shall conform to the limited details
shown and shall support all required loads, movements, and specified performance characteristics.
The Contractor shall design, supply, and install bearings, in compliance with these specifications,
AASHTO LRFD Bridge Design Specifications, and  Road Structures Design Manual (ADQCC TR-
516). Bearing devices shall suit limitations on space and access and shall meet the requirements for
transfer of bearing loads into the primary structure. The Contractor shall obtain approval from the
Engineer  for  bearing  designs.  The  Owner  requires  a  certificate  of  compliance  from  the  bearing
Manufacturer.

The Owner approves the use of bearings of the following types:

a.  Elastomeric pad bearings
b.  Rocker bearings
c.  Roller bearings
d.  Pot bearings
e.  Spherical bearings
f.  Disc bearings
g.  Sliding plate bearings

The Owner may approve the use of other types of bearings if proven suitable to the Project.

Bearing components include the following:

•

Masonry

•

Sole and shim plates

•

Bronze or copper-alloyed bearing and expansion plates

•

Anchor bolts

•

Guide devices

•

Polytetrafluorethylene (PTFE) sheets or surfacing

•

Lubricants

•

Adhesives

25.1

Reference Standards and Codes

Standards and codes shall be as specified in these specifications, in the Contract documents, if any,
and the following, in their latest edition:

AASHTO LRFD

American Association of State Highway and Transportation Officials -
load and resistance factor design, Bridge Construction Specifications;

AASHTO LRFD

American Association of State Highway and Transportation Officials -
load and resistance factor design, Bridge Design Specifications;

AASHTO

Standard Specifications for Transportation Materials and Methods of
Sampling and Testing;

AASHTO

Guide Specifications for Seismic Isolation Design, 3rd Edition;

AASHTO/AWS

Bridge Welding Code;

D1.5M/D1.5:2010

ADQCC (TR-516)

Road Structures Design Manual;

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ASME

American Society of Mechanical Engineers;

ASME B46.1-2009:

Surface Texture (Surface Roughness, Waviness, and Lay);

ASTM

American Society for Testing and Materials;

British Standards;

BS EN

European Standards;

DIN

German Institute for Standardization;

ISO

International Organization for Standardization;

ISO 9001:2008

Quality management systems

– Requirements;

UK (DFT)

Department for Transport, Manual of Contract Documents for Highway
Works, Volume 3 - Highway Construction Details.

Table 25-1 and Table 25-2 presents American Association of State Highway and Transportation
Officials (AASHTO), American Society for Testing and Materials (ASTM), British (BS), European (BS
EN), and German (DIN) Standards that are related to materials for bearing devices. It also includes
designations and titles.

Table 25-1: Designations and titles for AASHTO and ASTM standards that apply to bearing

devices

AASHTO
Designation

ASTM

Designation

Title

AASHTO M
270M/M 270-12

ASTM A709 /
A709M - 11

Standard Specification for Structural Steel for Bridges

ASTM A802 /
A802M -
95(2010)e1

Standard Practice for Steel Castings, Surface
Acceptance Standards, Visual Examination

ASTM A1011 /
A1011M - 12a

Standard Specification for Steel, Sheet and Strip, Hot-
Rolled, Carbon, Structural, High-Strength Low-Alloy,
High-Strength Low-Alloy with Improved Formability, and
Ultra-High Strength

ASTM A788 /
A788M - 11

Standard Specification for Steel Forgings, General
Requirements

ASTM A167 -
99(2009)

Standard Specification for Stainless and Heat-Resisting
Chromium-Nickel Steel Plate, Sheet, and Strip

ASTM A240 /
A240M - 12

Standard Specification for Chromium and Chromium-
Nickel Stainless Steel Plate, Sheet, and Strip for
Pressure Vessels and for General Applications

ASTM D2240 -
05(2010)

Standard Test Method for Rubber Property

—Durometer

Hardness

ASTM D412 -
06ae2

Standard Test Methods for Vulcanized Rubber and
Thermoplastic Elastomers

—Tension

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AASHTO
Designation

ASTM

Designation

Title

ASTM D573 -
04(2010)

Standard Test Method for Rubber

—Deterioration in an

Air Oven

ASTM D395 -
03(2008)

Standard Test Methods for Rubber Property

—

Compression Set

ASTM D1149 -
07(2012)

Standard Test Methods for Rubber Deterioration-
Cracking in an Ozone Controlled Environment

ASTM D746 -
07

Standard Test Method for Brittleness Temperature of
Plastics and Elastomers by Impact

ASTM D1043 -
10

Standard Test Method for Stiffness Properties of Plastics
as a Function of Temperature by Means of a Torsion
Test

ASTM D429 -
08

Standard Test Methods for Rubber Property

—Adhesion

to Rigid Substrates

AASHTO M 251-
06 (R2011)

ASTM D4014 -
03(2007)

Standard Specification for Plain and Steel-Laminated
Elastomeric Bearings for Bridges

ASTM B36 /
B36M - 08a

Standard Specification for Brass Plate, Sheet, Strip, And
Rolled Bar

ASTM B121 /
B121M - 11

Standard Specification for Leaded Brass Plate, Sheet,
Strip, and Rolled Bar

ASTM D4895 -
10

Standard Specification for Polytetrafluoroethylene
(PTFE) resin produced from dispersion

AASHTO M
235M/M 235-
2003(R2007)

ASTM C881 /
C881M - 10

Standard Specification for Epoxy-Resin-Base Bonding
Systems for Concrete

ASTM D2256 /
D2256M - 10e1

Standard Test Method for Tensile Properties of Yarns by
the Single-Strand Method

ASTM D638 -
10

Standard Test Method for Tensile Properties of Plastics

ASTM D792 -
08

Standard Test Methods for Density and Specific Gravity
(Relative Density) of Plastics by Displacement

ASTM D5977 -
03(2007)

Standard Specification for High Load Rotational
Spherical Bearings for Bridges and Structures

AASHTO M 108-
09

ASTM B100 - 08

Standard Specification for Wrought Copper-Alloy
Bearing and Expansion Plates and Sheets for Bridge
and Other Structural Use

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AASHTO
Designation

ASTM

Designation

Title

ASTM B103 /
B103M - 10

Standard Specification for Phosphor Bronze Plate,
Sheet, Strip, and Rolled Bar

ASTM A307 - 10

Standard Specification for Carbon Steel Bolts and Studs,
60 000 PSI Tensile Strength

ASTM B29 -
03(2009)

Standard Specification for Refined Lead

ASTM C920 -
11

Standard Specification for Elastomeric Joint Sealants

AASHTO M 107-
09

ASTM B22 -
09e2

Standard Specification for Bronze Castings for Bridges
and Turntables

ASTM D4894 -
07(2012)

Standard Specification for Polytetrafluoroethylene
(PTFE) Granular Molding and Ram Extrusion Materials

ASTM C939 -
10

Standard Test Method for Flow of Grout for Preplaced-
Aggregate Concrete (Flow Cone Method)

ASTM C827 /
C827M - 10

Standard Test Method for Change in Height at Early
Ages of Cylindrical Specimens of Cementitious Mixtures

ASTM C413 -
01(2012)

Standard Test Method for Absorption of Chemical-
Resistant Mortars, Grouts, Monolithic Surfacings, and
Polymer Concretes

AASHTO M 85-12

ASTM C150 /
C150M - 12

Standard Specification for Portland Cement

Table 25-2: Designations and titles for BS, BS EN, and DIN standards that apply to bearing

devices

BS
Designation

BS EN

Designation

DIN
Designation

Title

BS EN 197-
1:2011

Cement. Composition, specifications and
conformity criteria for common cements

BS EN 12390-
1:2000

Testing hardened concrete. Shape,
dimensions and other requirements for
specimens and moulds

BS EN 12390-
2:2009

Testing hardened concrete. Making and
curing specimens for strength tests

BS EN 12390-
3:2009

Testing hardened concrete. Compressive
strength of test specimens

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BS
Designation

BS EN

Designation

DIN
Designation

Title

BS 6319-
1:1983

Testing of resin and polymer/cement
compositions for use in construction. Method
for preparation of test specimens

BS 6319-
2:1983

Testing of resin and polymer/cement
compositions for use in construction. Method
for measurement of compressive strength

The Contractor shall manufacture and test bearings devises in accordance with these specifications
and in compliance with AASHTO/ASTM standards. Where bridge bearings are manufactured and
tested by standards other than AASHTO/ASTM, products conforming to equivalent or higher
standards will be acceptable if proven to be suitable.

25.2

Working Drawings for Bearing Devices

The Contractor shall prepare and submit working drawings for bearings. Such drawings shall show
all details of the bearings and of the materials proposed for use, including bearing assembly. They
shall also include an installation procedure and procedures for the access, maintenance, and
replacement of the bearings during the operational life of the bridge.

The  proposed  bearing  Manufacturer  shall  submit  evidence  of  the  successful  installation  and
operation of comparable bearings to the  Engineer to get approval for use. Such evidence  should
demonstrate  the  suitability  of  the  proposed  systems  and  materials  for  heavy  traffic  and  high
temperatures. Bearings shall be dispatched only upon approval from accredited independent testing
lab.

Working drawings shall be approved by the Engineer before the fabrication of the bearings. Such
approval shall not relieve the Contractor of any responsibility under the Contract documents for the
successful completion of the work.

Working documents shall specify the following details:

a. Total quantity of each kind of bearing required (fixed, guided expansion, or non-guided

expansion), grouped first according to type (load range), then by actual design capacity

b. A plan view and section elevation view that show all relative dimensions for each type of

bearing

c. Location of base and upper part of the bearings drawn in a plan and in elevation on the deck

soffit and on the support showing edge distances and thickness of any grout pads, shim
plates, or adapter plates

d.  A maximum design coefficient of friction, as noted in the Contract documents
e.  Types of materials for all bearing elements
f.  If  applicable,  a  clear  description  and  details  for  any  welding  process  used  in  the  bearing

manufacture that does not conform to the approved processes of the current version of the

AASHTO/AWS D1.5M/D1.5:2010

Bridge Welding Code.

g.  Vertical and horizontal load, rotation, and movement capacity
h.  Painting or coating requirements
i.  Alignment plans showing bearing orientation with respect to the point  of zero temperature

movement of the bridge deck or to other points of reference as appropriate.

j. Installation scheme
k. Complete design calculations that verify conformance with the requirements in this chapter,

if the Engineer requires such calculations

l. Anchorage details
m. Bearing preset details, if applicable

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25.3

Special Design Requirements for Bearing Devices

All bearings shall include components and materials that ensure operation without any maintenance
other than external painting over a bridge

’s 100 year design life. Internal components shall be

corrosion resistant, stable, and appropriate for long life in the intended environment concerned. All
moving components shall ensure low wear.

25.3.1

Horizontal Restraint for Bearing Devices

A design may require that some primary bearings can resist a proportion of horizontal seismic loads.
Where so required, these loads shall be included in the extreme limit state load combination, as
given on the bearing schedule from the Contract documents.

Such primary bearings shall include guides that transmit longitudinal and transverse loads, as
indicated on the bearing schedule, for all combinations of service and strength loads.

Where primary bearings do not include required transverse and longitudinal restraints, transverse
and longitudinal loads will be resisted by rigid fuse link devices that separate under extreme condition
earthquakes.

Under extreme earthquake conditions, in which the horizontal load exceeds the capacity of the
primary bearings or fuse links, viscous seismic dampers shall resist seismic loads. A single device
may combine both the fuse link and viscous damping functions.

The Contractor shall design and detail such guides and their connections to main bearing plates so
that, when horizontal load guides are subjected to loads up to the extreme limit, they fail in a ductile
manner to minimize damage to other parts of the bearings. The Contractor shall demonstrate to the
E

ngineer’s satisfaction that the actual failure load of a guide does not exceed the extreme limit

designated on the bearing schedule by more than 10%.

Seismic restraint devices and fuse links shall provide the basic force, displacement, and velocity
characteristics and peak design loads, as shown on the bearings schedule. When designing seismic
restraint devices and fuse links, a supplier shall develop further details of their force, displacement,
and velocity characteristics and submit these details to the Engineer for approval.

25.3.2

Characteristic Requirements for Fuse Links

Fuse  links  shall  deform  less  than  2  mm  overall  in  an  elastic  mode  (in  which  deflections  are  fully
recoverable on unloading) for all service condition loads. Each link shall separate in a ductile manner
with complete loss of resistance between 110% and 130% of specified strength condition loads. After
extreme  loads  separate  a  link,  it  shall  allow  further  cyclic  displacement  of  the  structure  without
interference or damage to other components. Links shall be double acting (supporting both tension
or compression), unless the Engineer approves otherwise.

Transverse  fuse  links  shall  be  adjustable  so  that  any  parasitic  effects  caused  by  pre-stress,
shrinkage, or creep can be relieved during construction. As necessary, immediately after applying
pre-stresses  and  at  the  end  of  construction,  the  Contractor  shall  adjust  these  links  to  support  a
minimal locked in-construction load.

25.3.3

Lift-off Tolerance of Primary Bearings

Certain primary bearings, as indicated on the Contract plans or working drawings, may be subject to
temporary lift-off in extreme conditions. By design, rather than resisting tension, such bearings shall
separate temporarily then reconnect without damaging or dislocating the bearing or its sliding
surface.

25.3.4

Characteristic Requirements for Viscous Dampers

A basic characteristic of bearing devices is tensile or compressive force. Equation 25-1 shows the
calculation.

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F = {K} (x) + {C}(v)

Equation 25-1: Tensile or compressive force

Where:

(x) is the relative displacement of the connection points of the device [m]

(v) is the relative velocity of the connection points of the device [m/s]

{K} is the stiffness of the device which shall satisfy the minimum requirements of the

AASHTO Guide

Specifications for Seismic Isolation Design, 3rd Edition

[kN/m]

{C} is the damping coefficient [kN/(m/s) ]

0.15

Characteristics in Equation 25-1 act in parallel (these forces are additive). Although all devices shall
have some stiffness in series with the damping force (deflections are additive), the Contractor shall
ensure that such stiffness is sufficient to render any associated extra deflections insignificant.

25.3.5

Pot Type Bearings - Guided Expansion and Fixed Bearings

The Contractor shall furnish and install pot type, guided expansion and fixed bridge bearings of the
sizes specified at the locations shown on the Contract plans. The bearing assemblies shall be
complete and ready for installation.

Pot expansion bearings shall have sliding surfaces as indicated in the Contract plans and shall
comply with the specifications in this chapter. Fixed bearings shall be rotational fixed units as shown
on the Contract plans, and purchased from an approved manufacturer.

When specified, Polytetrafluoroethylene (PTFE) sliding surfaces shall be designed by the Contractor
to translate or rotate by sliding of a self-lubricating PTFE surface across a smooth and hard stainless
steel mating surface.

Expansion bearings with sliding PTFE surfaces shall provide for rotation or equalization of the stress
on the PTFE sliding surface. Rotation shall be considered the sum of live load rotation, changes in
camber during construction, and misalignment of the bearing seats due to construction tolerances.
Rotational capability shall not be less than 1:50. Design, materials and construction of the means of
equalizing the stress or provision for rotation in the bearing shall comply with the specifications in
this chapter and on the Contract plans.

Unfilled or filled PTFE sliding surfaces shall be at least 1.6 mm thick, but not more than 4.8 mm thick.

The PTFE sliding surface shall be bonded under factory-controlled conditions to a rigid back-up
material (steel substrate) that can resist any bending stresses to which the sliding surface may be
subjected, and shall be recessed for half its thickness into the back-up material. The bonding shall
be performed at the factory of the bearing manufacturer of the expansion bearings under controlled
conditions and in accordance with the written instructions of the manufacturer of the approved
adhesive system. After completion of the bonding operation, the PTFE surface shall be smooth and
free from bubbles. Filled PTFE surfaces shall then be polished.

The mating  stainless steel surface to the PTFE shall be accurate and flat  in accordance with  the
design. Such surfaces shall have a minimum Brinell hardness of 125 and a surface finish of less
than  0.5  micron  rms  (root  mean  square).  The  mating  surface  shall  completely  cover  the  PTFE
surface  in  all  of  the

bearing’s operating positions, and shall be seal welded around the entire

perimeter to the back-up material.

Average bearing pressure on the PTFE sliding surface, from all loads, shall not exceed the following
values:

•

Filled PTFE: 24.13 MPa

•

Unfilled PTFE (Recessed): 24.13 MPa

•

Unfilled PTFE (Not Recessed): 13.73 MPa

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The expansion bearing shall be manufactured to the dimensions, and the requirements of the
method of fastening to the structure as shown on the Contract plans. Guide bar to bearing clearance
of 3 mm maximum shall be maintained on all guided bearings.

25.4

Materials for Bearing Devices

All bearing materials for which the Contract documents do not define specific requirements shall
comply with the requirements for applicable materials that are outlined in this section and the
following specifications:

•

Chapter 4, Concrete Works, of these

Standard Specifications

•

Chapter 21, Concrete Structures, of these

Standard Specifications.

•

Chapter 23, Steel Structures, of these

Standard Specifications.

25.4.1

Rolled Steel for Bearing Devices

Rolled steel shall be of the type specified in the Contract documents and shall satisfy the testing
requirements of the standard to which it conforms. Unless otherwise specified, steel shall be grade
36 that conforms to AASHTO M 270M/M 270-12 or grade 250 that conforms to ASTM A709 / A709M
- 11. Such steel shall cause no adverse electrolytic or chemical reaction with other components of a
bearing and shall be free of all rust and mill scale.

25.4.2

Steel Laminates for Bearing Devices

Steel laminates shall meet the requirements of AASHTO M 251-06 (R2011). Unless otherwise
specified in the Contract documents, steel laminates used for reinforcement shall be grade 36 rolled
mild steel that conforms to AASHTO M 270M/M 270-12, grade 250 rolled mild steel that conforms to
ASTM A709 / A709M - 11, steel that conforms to ASTM A1011 / A1011M - 12a, or an equivalent.
Laminates shall have a nominal thickness of at least 3 mm. Laminate edges shall be deburred or
otherwise rounded prior to moulding the bearings. Holes through the laminated elastomeric bearings
for shear pins shall not be permitted.

25.4.3

Cast Steel for Bearing Devices

Cast steel shall satisfy the requirements of ASTM A802 / A802M - 95(2010)e1 and shall not have
any blow-holes and impurities larger than 3.2 mm. Interior walls for pot in pot bearings and contact
surfaces for metal rocker or roller bearings shall have neither blow holes nor impurities of any size.

25.4.4

Forged Steel for Bearing Devices

Forged steel shall satisfy the requirements of ASTM A788 / A788M - 11.

25.4.5

Stainless Steel for Bearing Devices

Stainless steel for bearing devices shall be type 304 that conforms to the requirements of ASTM
A167 - 99(2009) or ASTM A240 / A240M - 12. Stainless steel be at least 0.91 mm thick. A

bearing’s

surface finish shall equal or exceed

0.2 μm. Stainless steel in contact with PTFE sheet shall be

polished to a finish no less than 0.50 μm.

25.4.6

Elastomeric Bearings

Elastomeric bearings shall include unreinforced pads that consist of elastomer only (plain pads) or
reinforced bearings with steel or fabric laminates (laminated bearing). The minimum and maximum
thicknesses of the elastomeric bearings shall be in accordance with the following.

1. Plain elastomeric pads shall have a minimum nominal thickness of 19 mm.
2. Cover layer of laminated bearings shall have a minimum nominal thickness of 3 mm, and a

maximum nominal thickness of 6 mm.

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3. Interior layers of laminated bearings shall have a minimum nominal thickness of 10 mm, and

a maximum nominal thickness of 16 mm.

All material used in the manufacture of bearing assemblies shall be new and unused with no
reclaimed material. All bonding of components shall be done under heat and pressure during the
vulcanizing process. Each bond shall be continuous throughout, with no voids or air spaces greater
than 0.25 mm within the bonding material. Bearing assemblies shall be furnished as complete units
from one manufacturing source.

Elastomeric bearings shall be furnished with the dimensions, material properties, elastomer grade,
and type of laminates specified in the Contract documents. The Contractor shall test the bearings to
verify that they comply with the design loads specified in the Contract documents. The Contractor
shall conduct load testing on such bearings as specified in this chapter. Unless the Contract
documents specify otherwise, bearings shall be steel-reinforced Grade 3, 60-durometer elastomer.

25.4.6.1

Properties of Elastomeric Bearings

Raw elastomer shall be either virgin Neoprene (polychloroprene) or virgin natural rubber
(polyisoprene). An elastomer compound shall be classified as being of low-temperature Grade 0, 2,
3, 4, or 5. Grades are defined by the testing requirements in Table 25-3 and Table 25-4. A higher
grade of elastomer may be substituted for a lower one.

The  elastomer  compound  shall  meet  the  minimum  requirements  shown  in  Table  25-3  and  Table
25-4,  except  as  otherwise  specified  by  the  Engineer.  Test  requirements  may  be  interpolated  for
intermediate hardness. If a material is specified by its shear modulus, its measured shear modulus
shall be within fifteen percent (15%) of the specified value. A consistent value of hardness shall also
be  supplied  for  the  purpose  of  defining  limits  for  the  tests  in  Table  25-3  and  Table  25-4.  If  the
hardness is specified, the measured shear modulus shall comply with Section 14 of the AASHTO
LRFD Bridge Design Specifications and AASHTO M 251-06 (R2011). When test specimens are cut
from the finished product, physical properties may vary from those specified in Table 25-3 and Table
25-4  by  ten  percent  (10%).  All  material  tests  shall  be  carried  out  at  23

Celsius plus or minus 2

Celsius, unless the Contract documents note otherwise. When conducting shear modulus tests, the
manufacturer shall use the apparatus and procedure described in Annex A of ASTM D4014 -
03(2007).

Table 25-3: Polychloroprene (neoprene) quality-control tests based on hardness (AASHTO

M 251-06 (R2011))

ASTM test
method

Physical properties

ASTM D2240 -
05(2010)

Hardness (shore A
durometer)

50+5

60+5

70+5

ASTM D412 -
06ae2

Tensile strength,
minimum MPa

15.5

Ultimate elongation,
minimum %

400

350

300

Heat resistance

ASTM D573 -
04(2010), 70
hours at 100° C

Change in durometer
hardness, maximum
points

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ASTM test
method

Physical properties

Change in tensile
strength, maximum %

-15

Change in ultimate
elongation, maximum
%

-40

Compression set

ASTM D395 -
03(2008),
Method B

22 hours at 100° C,
maximum %

Ozone

ASTM D1149 -
07(2012)

100 pphm ozone in air
by volume, 20% strain
38° C ± 1° C 100
hours mounting
procedure D 518,
procedure A

No cracks

Low-temperature
brittleness

ASTM D746 -
07, Procedure B

Grades 0 and 2

No tests required

Grade 3-brittleness at -
40° C

Pass

Grade 4-brittleness at -
48° C

Grade 5-brittleness at -
56.5° C

Instantaneous thermal stiffening

ASTM D1043 -
10

Grades 0 and 2-tested
at -32°C

Stiffness at test temperature shall not exceed four
times stiffness measured at 23° C

Grade 3-tested at -40°
C

Grade 4-tested at -
45.5° C

Grade 5-tested at -34°
C

Low-temperature crystallization

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ASTM test
method

Physical properties

Quad shear test
as described in
Annex

ASTM D4014 -
03(2007)

Grade 0 (No test
required)

Stiffness at test time and temperature shall not exceed
four  times  stiffness  measured  at  23°  C  with  no  time
delay. Stiffness shall be measured with a quad shear
test  rig  in  an  enclosed  freezer  unit.  Test  specimens
shall  be  taken  from  a  randomly  selected  bearing.  A
±25% strain cycle shall be used and a complete cycle
of strain shall be applied with a period of 100 seconds.
First  0.75  cycle  of  strain  shall  be  discarded  and  the
stiffness  shall  be  determined  by  slope  of  force
deflection curve for next 0.25 cycle of loading.

Grade 2-7 days at -
18° C

Grade 3-14 days at -
26° C

Grade 4-21 days at -
37° C

Grade 5-28 days at -
37° C

Table 25-4: Polyisoprene (natural rubber) quality-control tests based on hardness (AASHTO

M 251-06 (R2011))

ASTM test
method

Physical properties

ASTM D2240 -
05(2010)

Hardness (shore A
durometer)

50+5

60+5

70+5

ASTM D412 -
06ae2

Tensile strength,
minimum MPa

15.5

Ultimate elongation,
minimum %

450

400

300

Heat resistance

ASTM D573 -
04(2010), 70
hours at 100° C

Change in durometer
hardness, maximum
points

Change in tensile
strength, maximum %

-25

Change in ultimate
elongation, maximum
%

-25

Compression set

ASTM D395 -
03(2008),
Method B

22 hours at 100° C,
maximum %

Ozone

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ASTM test
method

Physical properties

ASTM D1149 -
07(2012)

25 pphm ozone in air
by volume, 20% strain
38°C ± 1° C 48 hours
mounting procedure D
518, procedure A

No cracks

Low-temperature
brittleness

ASTM D746 -
07, Procedure
B

Grades 0 and 2

No tests required

Grade 3-brittleness at
-40° C

Pass

Grade 4-brittleness at
-48° C

Grade 5-brittleness at
-56.5° C

Instantaneous thermal stiffening

ASTM D1043 -
10

Grades 0 and 2-tested
at -32°C

Stiffness at test temperature shall not exceed four
times the stiffness measured at 23° C

Grade 3-tested at -40°
C

Grade 4-tested at -
45.5° C

Grade 5-tested at -34°
C

Low-temperature crystallization

Quad shear test
as described in
Annex A of
ASTM D4014 -
03(2007)

Grade 0 (No test
required)

Stiffness at test time and temperature shall not
exceed four times the stiffness measured at 23° C
with no time delay. Stiffness shall be measured with
a quad shear test rig in an enclosed freezer unit. Test
specimens shall be taken from a randomly selected
bearing. A ±25% strain cycle shall be used and a
complete cycle of strain shall be applied with a period
of 100 seconds. First 0.75 cycle of strain shall be
discarded and the stiffness shall be determined by
the slope of the force deflection curve for the next
0.25 cycle of loading.

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25.4.6.2

Fabric Reinforcement for Elastomeric Bearings

Fabric reinforcement for elastomeric bearings shall be woven from 100% continuous E type
fibreglass yarn. Each thread in either direction shall have at least one thread per mm. Such fabric
shall have either a crowfoot or an 8 hardness satin weave. Each ply of fabric shall have a minimum
breaking strength of 140 N/mm of width in each thread direction. Unless the Contract documents
specify otherwise, fabric reinforcement for elastomeric bearings shall not have holes.

25.4.6.3

Bond for Elastomeric Bearings

Vulcanized bonds between fabric and reinforcement shall have a minimum peel strength of 5.3
N/mm. Steel laminated bearings shall have a minimum peel strength of 7.0 N/mm. The Contractor
shall perform peel strength tests in accordance with method B of ASTM D429 - 08.

25.4.7

Pot and Disc Bearings

Pot and disc bearings shall be adequate for the design loads and movements shown or specified in
the Contract documents. The Contractor shall test pot and disc bearings to the appropriate level in
accordance with Article 25.6.4.2.

All materials shall be new and unused, with no reclaimed material incorporated in the finished
bearing.

25.4.7.1

Steel for Pot and Disc Bearings

All steel for pot and disc bearings, except stainless steel components, shall conform to the
requirements outlined in Section 23.4.1 of Chapter 23, Steel Structures, for carbon steel or for high-
strength, low-alloy structural steel for welding.

25.4.7.2

Stainless Steel for Pot and Disc Bearings

Stainless steel shall conform to the requirements outlined in Section 25.4.5.

25.4.7.3

Elastomeric Rotational Element for Pot Bearings

Elastomeric rotational elements used in pot bearings shall contain only virgin, crystallization-resistant
polychloroprene (Neoprene) that conforms to AASHTO M 251-06 (R2011) (ASTM D4014 - 03(2007))
or virgin natural polyisoprene (natural rubber) that conforms with AASHTO M 251-06 (R2011) as the
raw polymer. Physical properties of Neoprene and natural rubber shall conform to the specifications
outlined in this chapter with the following modifications:

•

Shore A Durometer hardness shall be 50+10 points.

•

Samples for compression set tests shall be prepared using a Type 2 die.

25.4.7.4

Lubricating Elastomer for Pot Bearings

The manufacturer shall lubricate the elastomer between the steel pot and the top steel bearing plate
with a silicon grease that does not react chemically with the elastomer and does not alter its
properties when subjected to the expected environmental conditions for the Project site or as
recommended by the Manufacturer.

25.4.7.5

Sealing Rings for Pot Bearings

Sealing rings between the

pot bearing’s steel piston and its elastomeric rotational element shall be

brass that conforms to ASTM B36 / B36M - 08a for rings of rectangular cross-section and to ASTM
B121 / B121M - 11 for circular sections. The Engineer, at their discretion, may approve other sealing
ring materials if tests provide evidence that such materials conform to AASHTO LRFD Bridge Design
Specifications and Abu Dhabi Road Structures Design Manual (AD-D-06).

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25.4.7.6

Polytetrafluorethylene Sheets & Strips for Pot and Disc
Bearings

Polytetrafluorethylene (PTFE) sheet and strip requirements for pot and disc bearings shall conform
to the provisions of Section 25.4.11.

25.4.7.7

Polyether urethane Structural Element for Disc Bearings

Polyether urethane structural elements in disc bearings shall be moulded from a monolithic polyether
urethane compound. Such polyether urethane shall have the physical properties listed in Table 25-5.

Table 25-5: Physical properties of polyether urethane

Physical properties

ASTM test method

Requirements

Hardness, type D durometer

ASTM

D2240

05(2010)

Tensile stress, MPa

At 100% elongation

At 200% elongation

ASTM D412 - 06ae2

Tensile strength, MPa

ASTM D412 - 06ae2

Ultimate elongation, %

ASTM D412 - 06ae2

350

285

220

Compression set, 22 hours at 70°
C, %

ASTM D395 - 03(2008)

25.4.8

Rocker and Roller Bearings

Steels in rocker and roller bearings shall be of the types and grades specified in the Contract
documents for the Project. Steel at a metal bear

ing’s contact surface may be hardened if, after

hardening, the steel satisfies the strength and ductility requirements of the Contract documents and
the material specifications.

The Contractor shall apply lubrication to all gear mechanisms and to all other components of roller
bearings for which lubrication is required. The Contractor shall comply with the Contract
specifications when selecting the type of lubricant and shall apply lubricant in accordance with its
Manufacturer's recommendations.

25.4.9

Spherical Bearings

Spherical bearings are most commonly utilized at locations where very high vertical loads and/or
large structural rotations are present.

Spherical bearings shall consist of a spherical rotational component, where typically stainless steel
convex surface slides against a concave steel plate covered with a lubricant or a maintenance-free
PTFE liner or other sliding material with suitable properties, as approved by the Engineer, to permit
angular rotation about a central point in two orthogonal directions within a specified angular limit
based on the bearing’s geometry. If the design of the other sliding material is not addressed in
AASHTO LRFD then the same shall be designed according to an internationally acceptable relevant
standard. Spherical bearings may have a locking feature in the axial direction.

The Contractor shall fabricate, test, and install spherical bearings as specified in the Contract
documents.

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25.4.10

Masonry, Sole, and Shim Plates for Bearings

Metal plates used in masonry, sole, and shim plates, unless otherwise specified in the Contract
documents, shall be grade 250 steel that conforms to AASHTO M 270M/M 270-12 or ASTM A709 /
A709M - 11. Bronze or copper alloy bearing and expansion plates shall conform to the requirements
outlined in Section 25.8.5.

During  bridge  construction,  bearings  may  require  shimming  to  allow  for  variability  in  assumed
material  parameters  and  the final  construction  sequence.  Shims  shall  consist  of  additional  plates
either  above  or  below  the  bearing  plates.  The  Contractor  shall  be  responsible  for  developing
proposals and methodologies for shimming bearings.

The Contractor shall include details of proposed jacking points and shall provide additional local
bursting reinforcement at jacking locations in permanent works.

25.4.11

Polytetrafluorethylene Surfaces for Bearings

Polytetrafluorethylene (PTFE) sheets and strips shall be one of the following materials:

a. Pure virgin (not reprocessed), unfilled PTFE resin
b. PTFE resin that is uniformly blended with either fifteen percent (15%) glass fibre or twenty-

five percent (25%) carbon (maximum filler, percent by weight)

c. Fabric that contains PTFE fibres

Horizontally installed PTFE sheet shall be bonded to and recessed into its steel substrate. Vertically
installed PTFE sheet shall be bonded to and recessed into or bonded to and mechanically fastened
to its steel substrate. PTFE sheet shall have a minimum thickness of 5 mm and shall be recessed
for at least one-half of its thickness into its steel substrate.

Finished PTFE sheets and strips shall have the following characteristics:

•

Resistant to all acids, alkalis, and petroleum products

•

Stable at temperatures up to 260° C

•

Non-flammable

•

Non water absorbent

Epoxy that bonds PTFE to its steel substrate shall be a heat cured high-temperature epoxy that can
withstand temperatures up to 260° C.

25.4.11.1 Polytetrafluorethylene Sheets and Strips

PTFE resin sheets, PTFE fabric, interlocked bronze and PTFE structures, PTFE perforated metal
composite, back-up materials, and all other parts of fixed or expansion bearings that contain PTFE
materials shall have the friction, mechanical, physical, and weathering properties specified in the
Contract documents.

25.4.11.2 Polytetrafluorethylene Resin

PTFE resin shall be 100% pure, new material that meets the requirements of ASTM D4894 -
07(2012) or ASTM D4895 - 10. PTFE resin shall satisfy the requirements outlined in Table 25-6. No
reclaimed material shall be used.

Any finished PTFE sheet, strip, or fabric shall have the following characteristics:

•

Resistant to acids, alkalis, and petroleum products

•

Stable at temperatures up to 260° C

•

Non-flammable

•

non water absorbent

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25.4.11.3 Filler Material for Polytetrafluorethylene Sliding Surfaces

Filler material, when used, shall be milled glass fibre, carbon fibre, or other approved filler material.
Such filler shall act compositely with PTFE and shall not have any chemical reaction with other
components or constituents.

25.4.11.4 Adhesive Material for Polytetrafluorethylene Sliding Surfaces

Adhesive material that bonds sheet PTFE shall be an epoxy resin that complies with the
requirements of AASHTO M 235M/M 235-2003(R2007) or ASTM C881 / C881M - 10, FEP film or an
equivalent, or some other adhesive that has been approved by the Engineer.

25.4.11.5 Unfilled Polytetrafluorethylene Sheets for Sliding Surfaces

Finished, unfilled PTFE sheets shall be made from virgin PTFE resin and shall conform to the
property requirements outlined in Table 25-6, with the exception that the ASTM test methods for
tensile strength and elongation shall conform to ASTM D2256 / D2256M - 10e1.

25.4.11.6 Filled Polytetrafluorethylene Sheets for Sliding Surfaces

Filled PTFE sheets shall be made from virgin PTFE resin that is uniformly blended with an approved
inert filler. Maximum filler content shall be fifteen percent (15%) for fibreglass and twenty-five percent
(25%) for carbon fibres. Maximum filler content for other materials shall be determined by the
Engineer.

Finished  filled  PTFE  sheets  that  contain  glass  fibre  or  carbon  shall  conform  to  the  requirements
outlined  in  Table  25-6,  with  the  exception  that  the  ASTM  test  methods  for  tensile  strength  and
elongation shall conform to ASTM D638 - 10.

Table 25-6: Filled polytetrafluorethylene sheet

Mechanical
property

ASTM method

Sheet
unfilled

Sheet

with

15%

glass

fibres

Sheet

with

25%

carbon

fibres

Woven
fabric

Tensile strength
minimum MPa

ASTM D638 - 10
or

ASTM D2256 /
D2256M - 10e1

19.3

13.78

8.96

16.54

Elongation
(minimum %)

ASTM D638 - 10
or

ASTM D2256 /
D2256M - 10e1

200

150

Specific gravity,
minimum

ASTM D792 - 08

623 ± 2

2.20 ± 0.03

2.10 ± 0.03

Melting point, °C

ASTM D4894 -
07(2012),

ASTM D4895 -
10 or

ASTM D5977 -
03(2007)

328 ± 2

328 ± 10

Values for intermediate filler contents may be obtained by interpolation.

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25.4.11.7 Fabric Containing Polytetrafluorethylene Fibres

Woven fabric PTFE shall be manufactured from oriented multi-filament PTFE fluorocarbon fibres or
from a mixture of PTFE fibres made from twisted, slit PTFE tape and other fibres as required by
proprietary designs. Typical physical properties of the PTFE fibres shall be taken from Table 25-6,
with the exception that the ASTM Test Methods for tensile strength and elongation shall conform to
ASTM D2256 / D2256M - 10e1.

25.4.11.8 Lubricants for Polytetrafluorethylene Sliding Surfaces

Lubricants, if used, shall consist of a combination of solids that does not react chemically or
electrolytically with the PTFE and its mating surface and that remains stable when subjected to the
environmental conditions expected at the bridge site.

25.4.11.9 Interlocked Bronze and Filled Polytetrafluorethylene

Structures

Interlocking bronze and filled PTFE structures shall consist of a phosphor bronze plate with a porous
bronze surface layer that is 0.25 mm thick into which a lead and PTFE compound has been
interjected. Such structures shall have an overlay of compounded PTFE that is at least 25 mm thick.
Phosphor bronze back plates shall conform to AASHTO M 108-09 or ASTM B100 - 08. Porous
bronze layers shall conform to ASTM B103 / B103M - 10.

25.4.11.10 Surface Treatment for Polytetrafluorethylene Sliding Surfaces

Where PTFE sheets are to be epoxy-bonded, one side of the PTFE sheet shall be factory-treated
by an approved Manufacturer using the sodium naphthalene or sodium ammonia process.

25.4.11.11 Stainless Steel Mating Surface for Polytetrafluorethylene

Sliding Surfaces

Stainless steel shall conform to the requirements outlined in Section 25.4.5.

25.4.12

Anchor Bolts for Bearing Devices

Anchor bolts shall meet the requirements of ASTM A307 - 10 or the Contract documents. Anchor
bolts shall include anchorage details that permit development of the full tensile strength of each bolt.
The Owner recommends that anchor bolts also include hooks or end plates.

25.4.13

Bedding of Masonry Plates for Bearing Devices

The Contractor shall place filler or fabric materials as bedding under masonry plates when the
Contract documents indicate such placement. Such material shall be of the type specified in the
Contract documents or as ordered or approved by the Engineer. The Contractor shall install such
materials to provide full bearing on contact areas.

Immediately before placing the bedding material and installing bearings or masonry plates, the
contact surfaces of the concrete and steel shall be thoroughly cleaned.

Preformed fabric  pads  used  as  bedding  shall  be  composed  of multiple  layers  of  2.7  N/m2  cotton
duck that has been impregnated and bonded with high-quality natural rubber. Alternately, such pads
may  be composed  of equivalent  and  equally  suitable  materials  that  are  compressed  into resilient
pads of uniform thickness. Each pad shall have a sufficient number of plies to produce the specified
thickness, after compression and vulcanizing. Finished pads shall withstand compression loads that
are  perpendicular  to  the  plane  of  the  laminations  of  not  less  than  70  MPa  with  no  detrimental
reduction in thickness or extrusion.

Sheet lead used as bedding shall be common, desilverized lead that conforms to ASTM B29 -
03(2009). Such sheets shall be of uniform thickness and shall be free from cracks, seams, slivers,

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scale, and other defects. Unless otherwise specified, lead sheets shall be 3 mm thick with a tolerance
of ±1 mm.

Epoxy resin bearing mortar shall be manufactured under factory conditions certified to comply with
the ISO 9001:2008 Quality Assurance and Quality Control (QA/QC) procedure. The Contractor shall
comply with all Manufacturer instructions when preparing, priming, mixing, and applying mortar to
surfaces. The Contractor shall conduct grouting trials on site to demonstrate, to the satisfaction of
the Engineer, that the Contractor’s proposed methods and materials will meet the Project
requirements and specifications.

Caulking material used as bedding shall be a non-sag polysulfide or type II polyurethane material
that conforms to the provisions of

ASTM’s Standard Specification for Elastomeric Joint Sealants

(ASTM C920 - 11).

Grout and mortar used for filling under masonry plates shall conform to Section 21.18 of Chapter 21,
Concrete Structures, and the following performance requirements:

Unless otherwise described on the Contract plans, bedding mortar shall have a cubical
compressive strength not less than 50 MPa when tested in accordance with Article 25.4.13.3.

ii.

The flow characteristics shall be such that the volume of the bed or plinth as shown on the
Contract plans is completely filled with homogeneous material when placed within the range
of ambient temperature between 5

C and 35

C, or as otherwise described on the Contract

plans.

iii.

The physical and chemical properties shall be compatible with those of the adjoining
surfaces.

The stress in the mortar shall not exceed that defined in the Contract documents or Contract plans.

Where the mortar is required to resist stress before attaining its 28-day strength the compressive
strength shall be confirmed by tests on mortar cubes stored under conditions that simulate the field
conditions or by a method approved by the Engineer. The assessment of the strength of the bedding
mortar and produced by the loads shall be subject to the agreement of the Engineer.

25.4.13.1 Materials for Bedding Mortar

The maximum aggregate size in bedding mortar shall be 2.36mm. Proprietary materials shall be
stored as follows:

The materials shall be stored in a dry environment at a temperature of between 10

C and 27

The containers shall be damp-proof, leak-proof and readily emptied of their contents. Containers
shall be marked with the batch reference number, component identification, manufacturer's name,
net weight and such warnings or precautions concerning the contents as are required.

The material shall not be removed from the store for use in the Works until immediately prior to
mixing.

Material shall not be used more than six months after the date of manufacture or any lesser period
specified by the Manufacture or Supplier.

The Contractor shall supply with each batch or part of a batch of the material delivered to the site,
certificates furnished by the Supplier or the Manufacturer stating the following:

•

The Manufacturer's name and address.

•

The Manufacturer's agent's name and address.

•

Description of material and brand name.

•

Batch reference number, size of batch and number of containers in the delivery order.

•

Date of manufacture.

•

The chloride ion content, expressed as percentage by mass of cement.

Calcium chloride or admixtures containing chloride salts shall not be used and the total chloride ion
content shall not exceed 0.1% of the mass of cement.

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Portland cement shall comply with Section 4.3.1 of Chapter 4, Concrete Works, and with BS EN 197-
1:2011 or AASHTO M 85-12.

The total acid-soluble sulfate content of the mix expressed as SO3 shall not exceed 4% of the mass
of cement in the mix. The sulfate content shall be calculated as the total from the various constituents
of the mix.

Water shall be in accordance with Section 4.3.8 of Chapter 4, Concrete Works.

Resinous bedding mortars shall be based on thermosetting organic polymers consisting of stable
fluid  and/or  solid  components  which  on  mixing  react  chemically  to  form  a  hardened  solid  mass.
Products shall be formulated from epoxide, polyester, polyurethane or acrylic resin systems or such
other  formulation  as  is  approved  by  the  Engineer.  Fillers  or  aggregates  to  be  incorporated  in
accordance  with  the  Manufacturer's  recommendations,  to  extend  or  modify  the  properties  of  the
resinous compositions, shall be pre-bagged, dry and factory proportioned. The addition of other fillers
or aggregates shall not be permitted.

25.4.13.2 Site Mixing, Placing and Curing for Bedding Mortar

Mixing, placing and curing proprietary bedding mortar shall be carried out in accordance with the
Manufacturer's written instructions together with the following:

The material shall not be mixed or placed in the Works at ambient temperatures of less than 5

C. If

for 24 hours before during or after placing, the ambient temperature falls below 5

C the Contractor

shall maintain the temperature of the substrate and other adjoining surfaces at not less than 5

C for

the duration of the curing period recommended by the Manufacturer.

For cementitious bedding mortars the water/cement ratio  shall not exceed 0.4. The water content
shall  be  confirmed  during  the  approval  tests,  and  maintained  within  ±  1  percent  of  the  quantity
approved by the Engineer in mortars placed in the Works.

Only full packs of mortar as supplied shall be mixed. On-site proportioning shall not be permitted.

The temperature of the mortar on completion of mixing shall be between 5

C and 25

C. For

cementitious bedding mortars, the substrate shall be flushed clean with water two hours before
placing and maintained wet until placing commences. Any free water on the surface of the substrate
shall be removed before placing the mortar. The underside of the base plate shall be clean and free
from loose rust and loose mill scale at the time of bedding. The mortar shall be placed in its final
position within 25 minutes of commencement of mixing. Immediately after casting, the mortar shall
be protected to prevent evaporation for at least three days.

For resinous bedding mortars the substrate shall be dry, free from loose dirt and dust and shall meet
the conditions specified by the Manufacturer. The underside of the base plate shall be clean and
free from loose rust and loose mill scale at the time of bedding. The mortar shall be placed in its final
position within one hour, or lesser period specified by the Manufacturer, of commencement of mixing.

The mortar shall be poured in one corner of the plinth. The addition of mortar to the sides of the
plinth shall only be permitted after the mortar has flowed completely under the plinth.

When the mix proportions have been approved by the Engineer no variations shall be made in the
manufacture, supply, mix proportions or method of mixing of the material without the consent of the
Engineer.

No internal metal shims shall be allowed to remain in the hardened bedding mortar except where
permitted by the Engineer. The Contractor shall submit his proposals for shims for approval by the
Engineer.

25.4.13.3 Laboratory Approval Tests for Bedding Mortar

Mortar shall not be used in the Works until it has been approved by the Engineer. Every batch of
mortar to be used in the Works shall be tested by the Contractor. Where more than one batch of

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mortar is to be used in the Works the elastic stability test may be omitted, with the consent of the
Engineer, from the testing regime subsequent to the initial laboratory approval tests.

The Contractor shall state the water content to be used, expressed as a percentage by weight of the
material. Mixing shall be carried out in accordance with the Manufacturer's written instructions.

a. Flow Cone Test, Calibration of Flow

The flow characteristics of the mortar shall be determined by the flow cone test method described in
ASTM C939 - 10.

Tests shall be conducted at ambient temperatures of 5

C and 20

C within 15 minutes of

commencement of mixing.

For the test at 5

C the temperature of the flow cone and the mixer shall be 5

C, the temperature of

the dry material 10

C, and the temperature of the water where required, 20

For the test at 20

C the temperature of the flow cone, the mixer, the dry material and the water

where required shall be 20

For each temperature at least two tests having times of efflux within ±5% shall be made and the
average time of the efflux to the nearest 0.2 second shall be reported.

b. Flow between Glass Plates

The  flow  characteristics  of  the  mortar  between  the  glass  plates  shall  be  determined  using  the
apparatus  shown  in  the  UK  (DFT)  Department  for  Transport,  Manual  of  Contract  Documents  for
Highway Works, Volume 3 - Highway Construction Details, Drawing Number K2.

Tests shall be conducted at ambient temperatures of 5

C and 20

The temperature of the apparatus, dry material and water for each test shall comply with the relevant
article of this section.

The mortar shall be poured in one corner of the apparatus commencing between 18 minutes and 20
minutes after commencement of mixing.

A satisfactory flow shall be achieved when the mortar flows under the glass plate and rises at least
10mm above the underside of the top plate at all positions, without signs of segregation, bleeding,
effervescence or air inclusions.

c. Compressive Strength (Cementitious)

The compressive strength of cementitious bedding mortars shall be carried out on six 70mm cubes
at an age of 28 days.

The temperature of the mixer, the dry material, the water and the moulds shall be 20

The  70mm  cube  moulds  shall  comply  with  BS  EN  12390-1:2000  and  BS  EN  12390-2:2009. Test
specimens  shall  be  made  by  filling  the  moulds  carefully  through  a  funnel  to  produce  a  void-free
mortar. The moulds shall be covered by a steel plate to prevent expansion of the mortar.

There shall be no compaction. Specimens shall be damp-cured for the first 24 hours, removed from
the moulds and then water cured. Curing shall comply with BS EN 12390-2:2009.

Testing shall comply with BS EN 12390-3:2009.

The strength requirement shall be satisfied if none of the compressive strengths obtained is lower
than 50 MPa and the difference between the highest and lowest values is not more than 20% of the
average. All results shall be reported.

d. Compressive Strength (Resinous)

The compressive strength for resinous bedding mortars shall be carried out on six 40mm cubes at
an age of 24 hours.

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The 40mm cube moulds shall comply with BS 6319-1:1983 and shall be carefully filled using a funnel
to ensure void-free cubes. There shall be no compaction.

Testing shall comply with BS 6319-2:1983.

e. Expansion Test

Short term expansion shall be determined by the method described in ASTM C827 / C827M - 10.
Results shall be determined from the mean of two tests.

The expansion of cementitious bedding mortars at 24 hours shall be less than 2.5% and greater than
0.25%.

The volume change of resinous bedding mortars at 24 hours shall be between -0.6% and +1.0%.

f. Water Absorption Test

Absorption of water by resinous bedding mortars shall be determined by the method described in
ASTM C413 - 01(2012). The absorption shall not be more than 0.4%.

g. Elastic Stability Tests (Cementitious)

For cementitious bedding mortar, the elastic stability tests shall be carried out on one set of three
cubes made at 20

C as described in the relevant articles of this section.

Curing shall comply with BS EN 12390-2:2009. After a minimum of 28 days, the cubes shall be
placed in water at 200

C heated at a uniform rate to 450

C in 24 hours.

Upon attaining 450

C the cubes shall be sealed in a plastic bag and then loaded at a compressive

stress of 30 MPa maintained for 6 hours at 450

C and the strain measured.

The total compressive strain shall not exceed 1% on each cube.

h. Elastic Stability Tests (Resinous)

For resinous bedding mortar, elastic stability tests shall be carried out on one set of two 40mm cubes
complying with BS 6319-1:1983.

On removing the cubes from the moulds after 24 hours they shall be heated at a uniform rate to 45

C in a further 24 hours.

Upon attaining 45

C the cubes shall be loaded at a compressive stress of 30 MPa maintained for 6

hours at 45

C and the strain measured.

The total compressive strain shall not exceed 1% on each cube.

25.4.13.4 Site Control Tests

a. Efflux Times

If the efflux times at 5

C and 20

C determined as described in the flow cone test of Article 25.4.13.3

are within 10% or 2 seconds of each other, whichever is the greater, then site control tests for flow
shall be carried out as described in (a) below. In other cases, when the air temperature is less than
10

C site control tests for flow shall be carried out as described in (b) below, and when the air

temperature is greater than 10

C site control tests for flow shall be carried out as described in (a)

below.

1. Each load of mortar mixed for placing in the Works shall be tested at ambient temperature

by the flow cone test method as described in Article 25.4.13.3. The results shall agree within

Abu Dhabi, United Arab Emirates. STANDARD CONSTRUCTION SPECIFICATIONS (PART 2 - ROAD STRUCTURES, 2020) - page 13