February 27, 2014 Mr. Nicholas Fisco, P.E. TranSystems 55 Public Square, Suite 1900 Cleveland, Ohio 44113-1901 Reference: Materials Testing for the Hilliard Road Bridge 08.57 Condition Assessment / 25837 Lakewood and Rocky River, Cuyahoga County, Ohio Pro Geotech Inc. Project No. G13019T Dear Mr. Fisco: Enclosed, please find our Materials Testing Draft Report for the above referenced project. Our services included concrete coring and laboratory testing. It is important that the items under "Limitations" be precisely followed and complied with. We appreciate the opportunity of working with you on this project and we invite you to contact us at (440) 717-1415, when we can be of further assistance. Respectfully, PRO GEOTECH, INC. Frank Busher Project Manager Walid I. Najjar, P.E. Vice President Enclosure G13019trpt/SS
MATERIALS TESTING DRAFT REPORT FOR THE HILLIARD ROAD BRIDGE 08.57 CONDITION ASSESSMENT /25837 CUYAHOGA COUNTY, OHIO PRO GEOTECH, INC. PROJECT NO. G13019T PREPARED FOR: TRANSYSTEMS PREPARED BY: PRO GEOTECH, INC. FEBRUARY 27, 2014
TABLE OF CONTENTS 1.0 INTRODUCTION... 1 1.1 Project Description... 1 1.2 Scope of Services... 1 2.0 CORING AND TESTING... 2 2.1 Coring Operations... 2 2.2 Laboratory Testing Program....3 3.0 CORE INFORMATION....4 4.0 SAMPLE ANALYSIS... 5 4.1 Chloride Ion Testing... 5 4.2 Compressive Strength Testing... 6 4.3 Petrographic Analysis.... 6 4.4 Freeze-thaw Testing... 6 5.0 LIMITATIONS... 7 LIST OF TABLES Table 3.1 Core Sample Location.......................4 Site Location Map Bridge Deck Core Location Plan Core Logs with Photographs Chloride Content Test Results Compressive Strength of Concrete Test Results ASTM C 39 Cylindrical Core Break Diagram Petrographic Analysis Results Freeze-thaw Test Results APPENDIX
Hilliard Road Bridge 08.57 Condition Assessment / 25837 Lakewood & Rocky River, Cuyahoga County, Ohio Page 1 1.0 INTRODUCTION This report has been prepared for the proposed rehabilitation or replacement of the Hilliard Road Bridge 08.57 (SFN 1830147) over Rocky River located in the cities of Lakewood and Rocky River in Cuyahoga County, Ohio. This report represents the intent of TranSystems the design engineer, and Cuyahoga County, the owner, to evaluate the condition of the existing concrete of the bridge deck and supporting structures through field and laboratory testing performed by Pro Geotech, Inc. (PGI) personnel. Compressive strength, chloride ion content, petrographic analysis, and freeze-thaw tests were performed on representative concrete samples obtained at locations selected by TranSystems personnel in order to determine the condition of the structure. This report was prepared using English units. 1.1 Project Description This project involves the evaluation of the Hilliard Road Bridge 08.57, which is located in the cities of Lakewood on the east side and Rocky River on the west side of the bridge. The bridge carries four lanes of Hilliard Road over the Rocky River. The existing, multiple span open-spandrel reinforced concrete arch structure is 860 feet long and was originally constructed in 1925 and rehabilitated in 1983. PGI performed a field exploration program and laboratory testing to assist TranSystems personnel in determining whether sub-structure units of the existing bridge can be salvaged or need to be replaced. Visual inspection and testing were performed on representative concrete core samples obtained from the bridge substructure units in order to derive quantitative data to aid TranSystems in evaluating the condition of the substructures. The Site Location Map is located in the Appendix. 1.2 Scope of Services The scope of services to be provided by PGI for bridge deck and abutment concrete coring services was limited to the following phases: Phase I - Reconnaissance and Planning will primarily consist of reviewing the existing site conditions especially traffic and safety. The concrete core locations will be selected in the field by TranSystems personnel. Lifts and snooper, traffic control, and necessary permits will be provided by others before commencing coring. A plan of the existing structure will be provided to PGI to show on it the core locations. Pro Geotech, Inc. G13019Trpt/SS
Hilliard Road Bridge 08.57 Condition Assessment / 25837 Lakewood & Rocky River, Cuyahoga County, Ohio Page 2 Phase II Coring and Sampling Program consisted of field verification of the core locations and advancing the cores at the site and preparing field core logs. The coring was performed by PGI. A total of sixteen (16) concrete cores were to be obtained; fourteen (14) cores from the bridge structural members and two (2) cores from the bridge deck. These cores were to be advanced 16 to 18 inches or through the structural members, whichever is less. Phase III - Testing Program primarily consisted of performing engineering property tests on selected core samples. A total of twelve (12) compressive strength tests and twenty-four (24) chloride ion tests were performed on structure cores C-01 through C-08, C-13 and C-14 and on bridge deck cores C-15 and C-16. A total of two (2) petrographic analyses were performed on structure cores C-09 and C-11. A total of four (4) freeze-thaw tests were to be performed on bridge deck core C-15 and on structure cores C-01, C-10 and C-12, however only two freeze-thaw tests were performed. Phase IV - Technical Report: The technical report will be prepared in ENGLISH units and will include the following: Brief description of the project and our exploration methods Core logs with photographs Description of composition and condition of the cores Laboratory test results 2.0 CORING AND TESTING 2.1 Coring Operations In order to evaluate the concrete condition of the sub-structure units of the bridge, coring operations were performed in December 2013. A truck mounted snooper and self operated man lift were used to secure the core samples from the bridge. A total of sixteen (16) core samples were secured during the field operation for visual inspection and testing. Fourteen (14) core samples identified as C-01 through C-14 were secured from the bridge structure units and two (2) core samples identified as B-01/C-15 and C-16 were secured from the bridge deck. The core samples were secured from the bridge as follows: test core C-01 was secured from the south face of Pier No. 2, C-02 was secured from the north face of Arch Line A between Pier No. 2 and the west abutment, C-03 was secured from the north face of Arch Line C between Pier No. 2 and the west abutment, C-04 was secured from the south face of Arch Line D between Piers No. 1 and No. 2, C-05 was Pro Geotech, Inc. G13019Trpt/SS
Hilliard Road Bridge 08.57 Condition Assessment / 25837 Lakewood & Rocky River, Cuyahoga County, Ohio Page 3 secured from the north face of Arch Line B between Piers No. 1 and No. 2, C-06 was secured from the east face of the Floor Beam between Arch Lines C and D, C-07 was secured from the west face of the Interior Jack Arch (Row 3), C-08 was secured from the north face of the North Jack Arch (Row 1), C-09 was secured from the north face of Arch Line A between Pier No. 1 and the east abutment, C-10 was secured from the south face of Arch Line C between Pier No. 1 and the east abutment, C-11 was secured from the north face of Arch Line B between Pier No. 1 and the east abutment, C-12 was secured from the west face of the Floor Beam between Arch Lines A and B, C-13 was secured from the north face of Arch Line A between Pier No. 2 the west abutment, C-14 was secured from the south face of Arch Line D between Pier No. 2 and the west abutment, test core C-15 was secured from the Bridge Deck Westbound Lane, and C-16 was secured from the Bridge Deck Eastbound Lane. These sub-structure test core locations were selected by TranSystems personnel. All coring operations were performed in accordance with ASTM procedures. The core samples were removed from the bridge abutments and piers using a 4.25-inch outside diameter core barrel. The bridge cores consisted entirely of concrete. All of the cores were terminated at depths ranging from approximately 12.5 to 19.5 inches from the surface of the concrete. All test core holes were backfilled immediately upon completion with Set 45 non-shrink grout. 2.2 Laboratory Testing Program All concrete core samples obtained during the field operations were returned to PGI s materials testing laboratory for examination and testing. Upon arrival, the samples were photographed, visually examined, and logged for matrix, aggregate types and sizes, voids, uniformity, cracks, delaminations, reinforcement, overall condition, and any other unusual features. The attached core logs containing detailed information and photographs of each core sample are included in the Appendix. Chloride Ion Content, Petrographic Analysis, Freeze/thaw Cycles test, and Compressive Strength testing was performed on core samples selected by TranSystems personnel. All laboratory tests were performed in accordance with the ASTM or other standards listed in "Laboratory Test Standards" located in the Appendix. The results of the laboratory tests are also included in the Appendix. Upon completion of the laboratory testing, all samples were placed in storage at PGI s Cleveland facility. Pro Geotech, Inc. G13019Trpt/SS
Hilliard Road Bridge 08.57 Condition Assessment / 25837 Lakewood & Rocky River, Cuyahoga County, Ohio Page 4 3.0 CORE INFORMATION The following information is based on the core samples obtained from the bridge during our field work and the physical measurements of the core samples during coring operations and in the laboratory. A total of sixteen (16) concrete core samples were secured during the field operation. The approximate thickness of the core samples ranged from 12.5 inches to 19.5 inches with an average thickness of 16.5 inches. All of the concrete core samples consisted of cement matrix with angular to round aggregate. The aggregate encountered in the bridge structure units consisted of limestone with washed sand and gravel. The largest aggregate size ranged from 1.5 to 2.0 inches in diameter. A concrete overlay was encountered in the bridge deck cores and measured 3.0 inches thick in C-15 and 3.5 inches thick in C-16. Aggregate encountered in the overlay consisted of angular to subround limestone with the largest size aggregate 0.5 inches in diameter. Bridge deck concrete below the overlay contained limestone with washed sand and gravel aggregate. Rebar (0.5 diameter) was encountered in three (3) of the structural concrete core samples. Rebar (0.75 diameter) was encountered in both of the bridge deck core samples. The rebar appeared to be in good condition with no rust. The core sample locations were selected by TranSystems personnel and are presented in Table 3.1. Complete core information, including core logs located in the Appendix. Table 3.1 Core Sample Locations Core No. Structure Unit Face Total Core Thickness C-01 Pier No. 2 South 16.0 C-02 Arch Line A between Pier No. 2 and West Abutment North 17.75 C-03 Arch Line C between Pier No. 2 and West Abutment North 18.25 C-04 Arch Line D between Piers No. 1 and No. 2 South 18.25 C-05 Arch Line B between Piers No. 1 and No. 2 North 19.5 C-06 Floor Beam between Arch Lines C and D East 13.0 C-07 Interior Jack Arch (Row 3) West 18.75 C-08 North Jack Arch (Row 1) North 18.0 C-09 Arch Line A between Pier No. 1 and East Abutment North 12.5 C-10 Arch Line C between Pier No. 1 and East Abutment South 18.0 C-11 Arch Line B between Pier No. 1 and East Abutment North 12.5 Pro Geotech, Inc. G13019Trpt/SS
Hilliard Road Bridge 08.57 Condition Assessment / 25837 Lakewood & Rocky River, Cuyahoga County, Ohio Page 5 Core No. Structure Unit Face Total Core Thickness C-12 Floor Beam between Arch Lines A and B West 18.0 C-13 Arch Line A between Pier No. 2 and West Abutment North 18.0 C-14 Arch Line D between Pier No. 2 and West Abutment South 16.75 C-15 Bridge Deck WB Lane -- 12.75 C-16 Bridge Deck EB Lane -- 16.5 All coring operations were performed in accordance with ASTM procedures. The core samples were removed from the bridge abutment using a 4.25-inch outside diameter core barrel. All test core holes were backfilled immediately upon completion with Set 45 non-shrink grout. All concrete core samples obtained during the field operations were returned to PGI s materials testing laboratory in Cleveland, Ohio for examination and testing. Upon arrival, the samples were photographed, visually examined, and logged for matrix, aggregate types and sizes, voids, uniformity, cracks, delaminations, reinforcement, overall condition, and any other unusual features. The attached core logs containing detailed information and photographs of each core sample are included in the Appendix. 4.0 SAMPLE ANALYSIS 4.1 Chloride Ion Testing It should be noted that the chloride contents at shallow depths (relative to the face of the core) within a core sample are generally indicative of chloride penetration from external sources such as road salt, airborne pollutants, or pollutants present in the soil. In comparison, the chloride contents at deeper locations in a core sample may be more indicative of the as-built chloride content of the concrete. Based on Section 412.1 of the Ohio Bridge Design Manual dated January 2007, active corrosion is assumed to be taking place if a chloride ion content greater than 2.0 lb/yd 3 is present in the concrete. In general accordance with PGI s proposal, chloride content determination tests were performed on a total of twelve (12) core samples, nine (9) of the core samples identified as C-02 through C-08, C-13, and C-14 from substructure units and two (2) core samples identified as C-15 and C-16 from the bridge deck. The chloride content was determined at both a shallow depth (0.5 to 1.5 ) and at a deeper depth (12.5 to 18 ) from the face of the core samples. The chloride contents of the tested abutment core samples ranged from 0.42 lb/yd 3 to 5.91 lb/yd 3. Nine (9) of the twelve core samples tested, contained chloride contents at the shallow depth in excess of the ODOT maximum specification listed above. Core Pro Geotech, Inc. G13019Trpt/SS
Hilliard Road Bridge 08.57 Condition Assessment / 25837 Lakewood & Rocky River, Cuyahoga County, Ohio Page 6 sample C-03 contained a chloride content in excess of the ODOT maximum in both the shallow and deeper depths. Usually chloride contents of core samples are higher near the face of each core, as in the case of all of the cores tested. Refer to the attached Chloride Content Test Table for the chloride content test results found in the Appendix. 4.2 Compressive Strength Testing Compressive strength testing was performed on ten (10) of the structural core samples and two (2) of the bridge deck core samples obtained from this structure. Compressive strength testing was performed on the same core samples that Chloride Ion Content testing was performed. The compressive strength of the tested structural core samples ranged from 2,737 to 10,154 psi and the tested bridge deck core samples were 10,478 and 10,949 psi. Note that all of the core samples tested with the exception of C-01 exceeded 4,000 psi, which at present is generally considered the minimum strength standard for structural concrete. The compressive strength of the concrete core samples may or may not indicate potential strength problems at the tested locations. Refer to the Compressive Strength of Concrete Table found in the Appendix for the compressive strength test results. Upon completion of the laboratory testing, the remaining portions of the core samples will be discarded with the approval of TranSystems personnel. 4.3 Petrographic Analysis Petrographic Analysis was performed on two of the structural core samples (C-09 and C-11) by The Rock Doctor, Inc. Concrete Petrography. Based on The Rock Doctor report, core sample C-09 is deemed to be in fair general condition and core sample C-11 is deemed to be in poor-fair condition. The complete petrographic report prepared by The Rock Doctor, Inc. is included in the Appendix. 4.4 Freeze-thaw Freeze-thaw tests were performed on two (2) of the structural core samples; C-10 and C-12 by Bowser- Morner, Inc. Core samples C-01 and C-15 were also submitted for testing, however they were deemed nontestable. Core samples C-01 and C-15 were returned to PGI for compressive strength and chloride ion testing. The complete freeze-thaw report prepared by Bowser-Morner, Inc. is included in the appendix. Note that the testing was terminated early due to deterioration of the specimens. Pro Geotech, Inc. G13019Trpt/SS
Hilliard Road Bridge 08.57 Condition Assessment / 25837 Lakewood & Rocky River, Cuyahoga County, Ohio Page 7 5.0 LIMITATIONS This report is subject to the following conditions and limitations: 1. The results of the chloride ion, compressive strength, petrographic analysis, and freeze-thaw testing are indicative only of conditions at the tested locations of the core samples. Interpolation and correlation of these results to other locations within the structure should be performed by a qualified bridge engineer. Test results at specific locations may not be indicative of concrete conditions at similar locations throughout the structure. 2. It should be noted that the appearance and visual description of all concrete core samples in this report may vary from the actual condition of the cores. The actual condition of the concrete cores may be better determined by additional physical and/or chemical testing. 3. PGI personnel performed chloride ion content and compressive strength tests on twelve (12) core samples. Freeze-thaw testing on four (4) core samples, and petrographic analysis on two core samples was performed by others. These core samples may not be representative of the entire structure. It is possible that the actual condition of the structure may be better or worse than revealed by these core samples. The data contained in this report should be used in conjunction with a detailed visual inspection by a qualified bridge engineer. Design and rehabilitation recommendations should not be base solely on this report. Pro Geotech, Inc. G13019Trpt/SS
PROJECT No.: G13019T PROJECT: Hilliard Rd. Bridge 08.57 Condition Assessment / 25837 COMPRESSIVE STRENGTH OF CONCRETE (ASTM C 39) CORE LENGTH DIAMETER DENSITY LOAD AT CORRECTION COMPRESSIVE TYPE OF NUMBER OF CORE OF CORE OF CORE FAILURE FACTOR STRENGTH FRACTURE* (in) (mm) (in) (mm) (pcf) (tons/cu.m) (lbs) (kg) (psi) (MPa) C-15 8.03 204 3.60 91 142.0 2.274 114280 51837 0.97 10478 72.246 3 C-01 8.03 204 3.60 91 146.3 2.344 29460 13363 1.00 2737 18.872 3 C-02 8.03 204 3.60 91 143.5 2.299 61454 27875 1.00 5694 39.260 3 C-03 8.06 205 3.71 94 146.6 2.348 82306 37333 1.00 7622 52.553 2 C-04 7.83 199 3.72 94 145.2 2.325 62076 28157 1.00 5736 39.551 2 C-05 3.89 99 3.72 94 145.8 2.336 67293 30524 1.00 6232 42.967 3 C-06 7.83 199 3.71 94 139.5 2.234 109648 49736 1.00 10154 70.011 3 C-07 8.07 205 3.70 94 141.2 2.262 54641 24785 1.00 5068 34.945 3 C-08 7.93 201 3.70 94 143.2 2.293 62924 28542 1.00 5836 40.242 3 C-13 7.87 200 3.71 94 142.6 2.285 58542 26554 1.00 5421 37.379 3 C-14 8.05 204 3.72 94 145.0 2.322 44789 20316 1.00 4150 28.613 2 C-16 8.05 204 3.72 94 139.8 2.240 116137 52679 1.00 10949 75.492 3 Pro Geotech, Inc. 3201 E. Royalton Rd. Cleveland, OH 44147 Note: (1) Refer to locations in Appendix (2) 11 of 12 core tests pass the strength requirements as per ACI 301-17.3. (3) * Refer to ASTM C-39.
PROJECT No.: G13019G PROJECT: Hilliard Rd. Bridge 08.57 Condition Assessment / 25837 CHLORIDE CONTENT TEST (ASTM C-1152 / AASHTO T260) CORE DEPTH DENSITY CHLORIDE CHLORIDE NUMBER FROM FACE OF CORE CONTENT CONTENT (in) (mm) (lb/cu.ft) (tons/cu.m) (%) (lb/cu. yd) (kg/cu. m) C-15 0.5 12.7 142 2.274 0.063 2.42 1.433 C-15 12.0 304.8 142 2.274 0.006 0.23 0.136 C-01 1.0 25.4 146.3 2.344 0.047 1.86 1.101 C-01 7.1 180.3 146.3 2.344 0.02 0.79 0.469 C-02 1.0 25.4 143.5 2.299 0.073 2.83 1.678 C-02 17.0 431.8 143.5 2.299 0.032 1.24 0.736 C-03 1.5 38.1 146.6 2.348 0.060 2.37 1.409 C-03 17.0 431.8 146.6 2.348 0.051 2.02 1.198 C-04 1.0 25.4 145.2 2.326 0.068 2.67 1.582 C-04 17.0 431.8 145.2 2.326 0.022 0.86 0.512 C-05 1.0 25.4 145.8 2.335 0.074 2.91 1.728 C-05 18.5 469.9 145.8 2.335 0.019 0.75 0.444 C-06 1.0 25.4 139.5 2.235 0.157 5.91 3.508 C-06 12.5 317.5 139.5 2.235 0.010 0.38 0.223 C-07 1.0 25.4 141.2 2.262 0.137 5.22 3.099 C-07 17.5 444.5 141.2 2.262 0.032 1.22 0.724 C-08 1.0 25.4 143.2 2.294 0.030 1.16 0.688 C-08 17.5 444.5 143.2 2.294 0.012 0.46 0.275 C-13 1.0 25.4 142.6 2.284 0.068 2.62 1.553 C-13 16.5 419.1 142.6 2.284 0.015 0.58 0.343 C-14 1.0 25.4 145.0 2.323 0.047 1.84 1.092 C-14 15.5 393.7 145.0 2.323 0.025 0.98 0.581 C-16 0.5 12.7 139.8 2.239 0.131 4.94 2.934 C-16 15.5 393.7 139.8 2.239 0.011 0.42 0.246 Pro Geotech, Inc. 3201 E. Royalton Rd. Cleveland, OH 44147
Core Location: C-01 CORE LOG Hilliard Road Bridge 08.57 over Rocky River Core obtained from the south face of Pier No. 2 Project: Hilliard Rd. Bridge Condition Assessment / 25837 Date: Location: Lakewood & Rocky River, OH Core Type / Alignment: Client: TranSystems Coring Crew: Core Barrel Size (O.D.): 4.00" Hole Patched w/: 12/2/2013 Structure / Horizontal PGI - SP / DH Set 45 Non-shrink grout Photograph and Core Depth Description and Noted Features of Core Sample FACE OF THE CORE IS AT ZERO Cement matrix with subround to angular limestone aggregate with washed sand and gravel. The largest size aggregate is 1.5" in diameter. Few very small voids. @3.5"; 0.5" Rebar and mechanical break during removal. @ 9.0"; Mechanical break during removal. Total Core Recovery = 16.0" Abbreviations and Notes Note: Due to the angle at which the photographs were taken, the description to the right of the above core may appear to be slightly above or below the actual feature being described.
C-02 CORE LOG Core Location: Hilliard Road Bridge 08.57 over Rocky River Core obtained from the north face of Arch Line A between Pier No. 2 and the west abutment. Project: Hilliard Rd. Bridge Condition Assessment / 25837 Date: 12/3/2013 Location: Lakewood & Rocky River, OH Core Type / Alignment: Structure / Horizontal Client: TranSystems Coring Crew: PGI - JR / MN Core Barrel Size (O.D.): 4.00" Hole Patched w/: Set 45 Non-shrink grout Photograph and Core Depth Description and Noted Features of Core Sample FACE OF THE CORE IS AT ZERO Cement matrix with subround to angular limestone aggregate with washed sand and gravel. The largest size aggregate is 1.25" in diameter. Few very small voids. Density of core = 143.5 pcf Compressive strength = 5694 psi @15.0"; Mechanical break during removal. Total Core Recovery = 18.75" Abbreviations and Notes Note: Due to the angle at which the photographs were taken, the description to the right of the above core may appear to be slightly above or below the actual feature being described.
C-03 CORE LOG Core Location: Hilliard Road Bridge 08.57 over Rocky River Core obtained from the north face of Arch Line C between Pier No. 2 and the west abutment. Project: Hilliard Rd. Bridge Condition Assessment / 25837 Date: 12/5/2013 Location: Lakewood & Rocky River, OH Core Type / Alignment: Structure / Horizontal Client: TranSystems Coring Crew: PGI - JR / MN Core Barrel Size (O.D.): 4.00" Hole Patched w/: Set 45 Non-shrink grout Photograph and Core Depth Description and Noted Features of Core Sample FACE OF THE CORE IS AT ZERO Cement matrix with subround to angular limestone aggregate with washed sand and gravel. The largest size aggregate is 2.0" in diameter. Few very small voids. Density of core = 146.6 pcf Compressive strength = 7622 psi @12.75"; Mechanical break during removal. Total Core Recovery = 18.75" Abbreviations and Notes Note: Due to the angle at which the photographs were taken, the description to the right of the above core may appear to be slightly above or below the actual feature being described.
Core Location: C-04 CORE LOG Hilliard Road Bridge 08.57 over Rocky River Core obtained from the south face of Arch Line D between Piers No. 1 and No. 2 Project: Hilliard Rd. Bridge Condition Assessment / 25837 Date: Location: Lakewood & Rocky River, OH Core Type / Alignment: Client: TranSystems Coring Crew: Core Barrel Size (O.D.): 4.00" Hole Patched w/: 12/4/2013 Structure / Horizontal PGI - JR / MN Set 45 Non-shrink grout Photograph and Core Depth Description and Noted Features of Core Sample FACE OF THE CORE IS AT ZERO Cement matrix with subround to angular limestone aggregate with washed sand and gravel. The largest size aggregate is 1.5" in diameter. Few very small voids. Minor surface fractures. Density of core = 145.2 pcf Compressive strength = 5736 psi @14.5"; Mechanical break during removal. Total Core Recovery = 19.0" Abbreviations and Notes Note: Due to the angle at which the photographs were taken, the description to the right of the above core may appear to be slightly above or below the actual feature being described.
Core Location: C-05 CORE LOG Hilliard Road Bridge 08.57 over Rocky River Core obtained from the north face of Arch Line B between Piers No. 1 and No. 2 Project: Hilliard Rd. Bridge Condition Assessment / 25837 Date: Location: Lakewood & Rocky River, OH Core Type / Alignment: Client: TranSystems Coring Crew: Core Barrel Size (O.D.): 4.00" Hole Patched w/: 12/4/2013 Structure / Horizontal PGI - JR / MN Set 45 Non-shrink grout Photograph and Core Depth Description and Noted Features of Core Sample FACE OF THE CORE IS AT ZERO Cement matrix with subround to angular limestone aggregate with washed sand and gravel. The largest size aggregate is 1.5" in diameter. Few very small voids. Density of core = 145.8 pcf Compressive strength = 6232 psi @15.0"; Mechanical break during removal. Total Core Recovery = 20.0" Abbreviations and Notes Note: Due to the angle at which the photographs were taken, the description to the right of the above core may appear to be slightly above or below the actual feature being described.
Core Location: C-06 CORE LOG Hilliard Road Bridge 08.57 over Rocky River Core obtained from the east face of the Floor Beam between Arch Lines C and D Project: Hilliard Rd. Bridge Condition Assessment / 25837 Date: Location: Lakewood & Rocky River, OH Core Type / Alignment: Client: TranSystems Coring Crew: Core Barrel Size (O.D.): 4.00" Hole Patched w/: 12/3/2013 Structure / Horizontal PGI - JR / MN Set 45 Non-shrink grout Photograph and Core Depth Description and Noted Features of Core Sample FACE OF THE CORE IS AT ZERO Cement matrix with subround to angular limestone aggregate with washed sand and gravel. The largest size aggregate is 1.5" in diameter. Few very small voids. @2.75"; 0.5" Rebar Density of core = 139.5 pcf Compressive strength = 10154 psi Total Core Recovery = 13.25" Abbreviations and Notes Note: Due to the angle at which the photographs were taken, the description to the right of the above core may appear to be slightly above or below the actual feature being described.
Core Location: C-07 CORE LOG Hilliard Road Bridge 08.57 over Rocky River Core obtained from the west face of the Interior Jack Arch (Row 3) Project: Hilliard Rd. Bridge Condition Assessment / 25837 Date: Location: Lakewood & Rocky River, OH Core Type / Alignment: Client: TranSystems Coring Crew: Core Barrel Size (O.D.): 4.00" Hole Patched w/: 12/4/2013 Structure / Horizontal PGI - JR / MN Set 45 Non-shrink grout Photograph and Core Depth Description and Noted Features of Core Sample FACE OF THE CORE IS AT ZERO Cement matrix with subround to subangular limestone aggregate with washed sand and gravel. The largest size aggregate is 1.5" in diameter. Few very small voids. Density of core = 141.2 pcf Compressive strength = 5068 psi @14.75"; Mechanical break during removal. Total Core Recovery = 19.25" Abbreviations and Notes Note: Due to the angle at which the photographs were taken, the description to the right of the above core may appear to be slightly above or below the actual feature being described.
C-08 CORE LOG Core Location: Hilliard Road Bridge 08.57 over Rocky River Core obtained from the north face of the North Jack Arch (Row 1) north end and 8" from the top of the abutment. Project: Hilliard Rd. Bridge Condition Assessment / 25837 Date: 12/4/2013 Location: Lakewood & Rocky River, OH Core Type / Alignment: Structure / Horizontal Client: TranSystems Coring Crew: PGI - JR / MN Core Barrel Size (O.D.): 4.00" Hole Patched w/: Set 45 Non-shrink grout Photograph and Core Depth Description and Noted Features of Core Sample FACE OF THE CORE IS AT ZERO Cement matrix with round to angular limestone aggregate with washed sand and gravel. The largest size aggregate is 2.0" in diameter. Few very small voids. Density of core = 143.2 pcf Compressive strength = 5836 psi @15.0"; Mechanical break during removal. Cored completely through the North Jack Arch Total Core Recovery = 18.0" Abbreviations and Notes Note: Due to the angle at which the photographs were taken, the description to the right of the above core may appear to be slightly above or below the actual feature being described.
C-09 CORE LOG Core Location: Hilliard Road Bridge 08.57 over Rocky River Core obtained from the north face of Arch Line A between Pier No. 1 and the east abutment. Project: Hilliard Rd. Bridge Condition Assessment / 25837 Date: 12/3/2013 Location: Lakewood & Rocky River, OH Core Type / Alignment: Structure / Horizontal Client: TranSystems Coring Crew: PGI - JR / MN Core Barrel Size (O.D.): 4.00" Hole Patched w/: Set 45 Non-shrink grout Photograph and Core Depth Description and Noted Features of Core Sample FACE OF THE CORE IS AT ZERO Cement matrix with round to angular limestone aggregate with washed sand and gravel. The largest size aggregate is 1.25" in diameter. Few very small voids. @14.75"; Mechanical break during removal. Total Core Recovery = 19.5" Abbreviations and Notes Note: Due to the angle at which the photographs were taken, the description to the right of the above core may appear to be slightly above or below the actual feature being described.
C-10 CORE LOG Core Location: Hilliard Road Bridge 08.57 over Rocky River Core obtained from the south face of Arch Line C between Pier No. 1 and the east abutment. Project: Hilliard Rd. Bridge Condition Assessment / 25837 Date: 12/4/2013 Location: Lakewood & Rocky River, OH Core Type / Alignment: Structure / Horizontal Client: TranSystems Coring Crew: PGI - JR / MN Core Barrel Size (O.D.): 4.00" Hole Patched w/: Set 45 Non-shrink grout Photograph and Core Depth Description and Noted Features of Core Sample FACE OF THE CORE IS AT ZERO Cement matrix with subround to angular limestone aggregate with washed sand and gravel. The largest size aggregate is 1.25" in diameter. Few very small voids. @15.0"; Mechanical break during removal. Total Core Recovery = 18.25" Abbreviations and Notes Note: Due to the angle at which the photographs were taken, the description to the right of the above core may appear to be slightly above or below the actual feature being described.
C-11 CORE LOG Core Location: Hilliard Road Bridge 08.57 over Rocky River Core obtained from the north face of Arch Line B between Pier No. 1 and the east abutment. Project: Hilliard Rd. Bridge Condition Assessment / 25837 Date: 12/3/2013 Location: Lakewood & Rocky River, OH Core Type / Alignment: Structure / Horizontal Client: TranSystems Coring Crew: PGI - JR / MN Core Barrel Size (O.D.): 4.00" Hole Patched w/: Set 45 Non-shrink grout Photograph and Core Depth Description and Noted Features of Core Sample FACE OF THE CORE IS AT ZERO Cement matrix with subround to angular limestone aggregate with washed sand and gravel. The largest size aggregate is 1.75" in diameter. Few very small voids. @8.0"; 0.5" Rebar @14.0"; Mechanical break during removal. Total Core Recovery = 20.5" Abbreviations and Notes Note: Due to the angle at which the photographs were taken, the description to the right of the above core may appear to be slightly above or below the actual feature being described.
Core Location: C-12 CORE LOG Hilliard Road Bridge 08.57 over Rocky River Core obtained from the west face of the Floor Beam between Arch Lines A and B Project: Hilliard Rd. Bridge Condition Assessment / 25837 Date: Location: Lakewood & Rocky River, OH Core Type / Alignment: Client: TranSystems Coring Crew: Core Barrel Size (O.D.): 4.00" Hole Patched w/: 12/4/2013 Structure / Horizontal PGI - JR / MN Set 45 Non-shrink grout Photograph and Core Depth Description and Noted Features of Core Sample FACE OF THE CORE IS AT ZERO Cement matrix with round to angular limestone aggregate with washed sand and gravel. The largest size aggregate is 1.5" in diameter. Few very small voids. @15.0"; Mechanical break during removal. Total Core Recovery = 18.5" Abbreviations and Notes Note: Due to the angle at which the photographs were taken, the description to the right of the above core may appear to be slightly above or below the actual feature being described.
Core Location: C-13 CORE LOG Hilliard Road Bridge 08.57 over Rocky River Core obtained from the north face of Arch Line A between Pier No. 2 the west abutment Project: Hilliard Rd. Bridge Condition Assessment / 25837 Date: Location: Lakewood & Rocky River, OH Core Type / Alignment: Client: TranSystems Coring Crew: Core Barrel Size (O.D.): 4.00" Hole Patched w/: 12/4/2013 Structure / Horizontal PGI - JR / MN Set 45 Non-shrink grout Photograph and Core Depth Description and Noted Features of Core Sample FACE OF THE CORE IS AT ZERO Cement matrix with round to angular limestone aggregate with washed sand and gravel. The largest size aggregate is 1.5" in diameter. Few very small voids. Density of core = 142.6 pcf Compressive strength = 5421 psi @14.0"; Mechanical break during removal. Total Core Recovery = 18.25" Abbreviations and Notes Note: Due to the angle at which the photographs were taken, the description to the right of the above core may appear to be slightly above or below the actual feature being described.
C-14 CORE LOG Core Location: Hilliard Road Bridge 08.57 over Rocky River Core obtained from the south face of Arch Line D between Pier No. 2 and the west abutment. Project: Hilliard Rd. Bridge Condition Assessment / 25837 Date: 12/3/2013 Location: Lakewood & Rocky River, OH Core Type / Alignment: Structure / Horizontal Client: TranSystems Coring Crew: PGI - JR / MN Core Barrel Size (O.D.): 4.00" Hole Patched w/: Set 45 Non-shrink grout Photograph and Core Depth Description and Noted Features of Core Sample FACE OF THE CORE IS AT ZERO Cement matrix with round to angular limestone aggregate with washed sand and gravel. The largest size aggregate is 1.5" in diameter. Few very small voids. @4.5"; 0.5" Rebar Density of core = 145.0 pcf Compressive strength = 4150 psi @15.0"; Mechanical break during removal. Total Core Recovery = 16.75" Abbreviations and Notes Note: Due to the angle at which the photographs were taken, the description to the right of the above core may appear to be slightly above or below the actual feature being described.
Core Location: C-15 CORE LOG Hilliard Road Bridge 08.57 over Rocky River Core obtained from the Bridge Deck Westbound Lane Project: Hilliard Rd. Bridge Condition Assessment / 25837 Date: Location: Lakewood & Rocky River, OH Core Type / Alignment: Client: TranSystems Coring Crew: Core Barrel Size (O.D.): 4.00" Hole Patched w/: 12/2/2013 Bridge Deck / Vertical PGI - SP / DH Set 45 Non-shrink grout Photograph and Core Depth Description and Noted Features of Core Sample FACE OF THE CORE IS AT ZERO 3.0" Overlay - Cement matrix with subround to angular limestone aggregate. The largest size aggregate is 0.5" in diameter. @3.0"; Mechanical break during removal. Cement matrix with subround to angular limestone aggregate with washed sand and gravel. The largest size aggregate is 1.5" in diameter. Few very small voids. @ 6.0" and 10.0"; 0.75" Rebar @10.0"; Mechanical break during removal. Total Core Recovery = 12.75" Abbreviations and Notes Note: Due to the angle at which the photographs were taken, the description to the right of the above core may appear to be slightly above or below the actual feature being described.
Core Location: C-16 CORE LOG Hilliard Road Bridge 08.57 over Rocky River Core obtained from the Bridge Deck Eastbound Lane Project: Hilliard Rd. Bridge Condition Assessment / 25837 Date: Location: Lakewood & Rocky River, OH Core Type / Alignment: Client: TranSystems Coring Crew: Core Barrel Size (O.D.): 4.00" Hole Patched w/: 12/2/2013 Bridge Deck / Vertical PGI - SP / DH Set 45 Non-shrink grout Photograph and Core Depth Description and Noted Features of Core Sample FACE OF THE CORE IS AT ZERO 3.5" Overlay - Cement matrix with subround to angular limestone aggregate. The largest size aggregate is 0.5" in diameter. @3.5"; Mechanical break during removal. Cement matrix with subround to angular limestone aggregate with washed sand and gravel. The largest size aggregate is 1.0" in diameter. @5.75"; 0.5" Rebar Few very small voids. @11.0"; Mechanical break during removal. Density of core = 139.8 pcf Compressive strength = 10948 psi @ 10.5" and 13.5"; 0.75" Rebar Total Core Recovery = 16.5" Abbreviations and Notes Note: Due to the angle at which the photographs were taken, the description to the right of the above core may appear to be slightly above or below the actual feature being described.
PETROGRAPHIC REPORT DATE: December 30, 2013 WORK ORDER: 13-12-20-01 CLIENT: Pro Geotech, Inc. Project #: G13019G / Hillard Rd. Bridge PREPARED BY: Jeffrey R. Varga, Concrete Petrographer, The Rock Doctor, Inc. INTRODUCTION We received two, 4-inch diameter X 6 inch length, cores of hardened concrete to determine the general condition. The cores were marked C-9 and C-11 and exhibited saw-cut bottom surfaces. It was reported that the submitted core samples represent exterior concrete placed within bridge arch and pier portions. Deterioration of the bridge structure was reported. The age of the concrete(s) was reported to circa 1925. It was reported that core samples tested from similar structure units within the bridge averaged 4785 psi. SAMPLE PREPARATION AND METHODS The submitted core samples were cut approximately in half with cut surfaces oriented perpendicular to the end surfaces. One half of each core sample was prepared for examination. The respective cut surfaces were prepared by grinding and lapping using water and progressively finer abrasive materials following our standard procedure. The air-void system parameters were determined following the guidelines of ASTM C 457-11 Standard Test Method for Microscopical Determination of Parameters of the Air-Void System in Hardened Concrete. The modified point count method was used at a magnification of 100 diameters. The prepared samples and sample trimmings were examined following the guidelines of ASTM C 856-11 Standard Practice for Petrographic Examination of Hardened Concrete. RESULTS OF PETROGRAPHIC EXAMINATION CORE C-9 GENERAL CONDITION: (See PLATES 1-8) The exposed, top surface was generally flat and exhibited numerous, partially exposed fine aggregate particles and an almost continuous coating of light brown-dull white, semi-rigid material. This coating material exhibited numerous air-void septa and numerous fine cracks in thicker portions. The exposed surface was moderate-slowly water absorptive. A few coarser aggregate particles and small amounts of paste/mortar were observed where no coating material was present at the exposed surface. In section, the upper portion of the sample, approx. 3/8 of an inch up to approx. 1-1/4 inches, exhibited a markedly lighter colored (light brown) paste as compared to the bulk paste. After staining with Rainbow indicator (a blend of ph sensitive phenolphthaleins), these lighter colored portions exhibited redorange (ph of 5) to yellow (ph of 7) to green (ph of 9) colorations as compared to the purple (ph of 11+) CONFIDENTIAL PAGE 1 12/30/13
color of the bulk paste. The observed colorations of paste after staining indicate carbonation. These paste portions also effervesced more strongly as compared to the bulk paste when dilute hydrochloric acid was applied. However, the carbonated paste portions exhibited similar hardness as compared to the bulk paste. The observed surface coating material ranged in thickness form zero (non-existent) up to approx. 0.50 mm at thickest portions. One, vertically oriented, fine crack was observed perpendicular to the exposed surface up to an observed depth of 1/2 of an inch. This cracks transected paste only. Many, small to large, irregularly shaped voids were present throughout the sample especially adjacent to aggregate peripheries. Several of these voids appeared to be interconnected. The bottom surface was a saw-cut surface. The core edges exhibited several, large, irregularly shaped voids. CEMENTITIOUS MATRIX: The color of the cement paste matrix in the upper portion was previously described. The bulk paste exhibited mottled appearance with color ranging from light gray to dull white. Both upper and lower pastes exhibited a very small amount of unhydrated cement particles. Both pastes were highly water absorptive and moderately hard. No fly ash, ground granulated blast furnace slag or other pozzolanic materials were microscopically observed. AIR-VOID CONTENT: The air-void system parameters are listed below in TABLE 1: TABLE 1 AIR-VOID SYSTEM PARAMETERS TRAVERSE PARAMETERS OF THE AIR-VOID SYSTEM Paste % Length, Air, % l α L Sample by vol. Points in. by vol. P/A n in. in. -1 in. C-9 21.05 1,986 98.60 4.63 4.55 2.3.0199 200.5.0221 The observed voids were inhomogeneously distributed and were mostly irregularly shaped and ranged in size from small to large. Fewer, smaller spherically shaped were present. Several voids were interconnected. No secondary, internal deposits were observed. COARSE AGGREGATE: The homogeneously distributed coarse aggregate was angular to subangular in shape with an observed topsize of 1-1/8 of an inch. The observed aggregate was composed of dolomitic limestone particles. No marked evidence of a cement alkali:aggregate reaction was observed. FINE AGGREGATE: The homogeneously distributed fine aggregate was angular-rounded in shape and was composed of quartz, sandstones, siltstones, limestones, feldspars, granites, microcrystalline quartz cherts and mica flakes. Some of the observed siltstones were water absorptive. Although cherts are considered to be, at least, potentially reactive with cement alkalis, after three days of partial immersion of the sample trimming in water, no evidence of a cement alkali:aggregate reaction was observed. CORE C-11 GENERAL CONDITION: (See PLATES 1, 2, 9-15) The exposed, top surface was composed of an approx. half, rough, flat surface and approx. half of a worn surface exhibiting loss of surface up to approx. 1/8 of an inch. The generally flat, rough surface exhibited numerous, partially exposed fine aggregate particles in a soft, easily scratched, slightly recessed cement paste matrix. The worn surface exhibiting loss of surface CONFIDENTIAL PAGE 2 12/30/13
exhibited exhibited numerous, partially exposed fine aggregate particles and a few, fractured, water absorptive fine aggregate particles in a soft, easily scratched, recessed cement paste matrix. Very thin, small, remnant amounts of dull gray colored coating material were observed on both exposed surfaces especially on exposed fine aggregate particle peripheries and higher relief portions of the surfaces. This coating material exhibited a few air-void septa. The exposed surfaces were highly water absorptive. In section, a discontinuous zone of carbonated paste was observed from a veneer up to approx. 1-5/8 of an inch depth. After staining with Rainbow indicator (a blend of ph sensitive phenolphthaleins), these carbonated paste portions exhibited red-orange (ph of 5) to yellow (ph of 7) to green (ph of 9) colorations as compared to the purple (ph of 11+) color of the bulk paste. The observed colorations of paste after staining indicate carbonation. These paste portions also effervesced more strongly as compared to the bulk paste when dilute hydrochloric acid was applied. However, the carbonated paste portions exhibited similar hardness as compared to the bulk paste. Numerous, small to large, irregularly shaped voids were present throughout the sample especially adjacent to aggregate peripheries. Several of these voids appeared to be interconnected. The bottom surface was a saw-cut surface. The core edges exhibited many, large, irregularly shaped voids. CEMENTITIOUS MATRIX: The color of the cement paste matrix was variegated from light brown-dull white in color pale gray-gray. The paste exhibited a very small amount of unhydrated cement particles. The paste was highly water absorptive and moderately soft-moderately hard. No fly ash, ground granulated blast furnace slag or other pozzolanic materials were microscopically observed. AIR-VOID CONTENT: The air-void system parameters are listed below in TABLE 2: TABLE 2 AIR-VOID SYSTEM PARAMETERS TRAVERSE PARAMETERS OF THE AIR-VOID SYSTEM Paste % Length, Air, % l α L Sample by vol. Points in. by vol. P/A n in. in. -1 in. C-11 17.53 2,014 100.00 3.67 4.78 1.4.0259 154.6.0293 The observed voids were inhomogeneously distributed and were mostly irregularly shaped and ranged in size from small to large. Fewer, smaller spherically shaped were present. Several voids were interconnected. Many sinuously shaped voids were present as well. No secondary, internal deposits were observed. COARSE AGGREGATE: The homogeneously distributed coarse aggregate was angular to subangular in shape with an observed topsize of 1-3/4 of an inch. The observed aggregate was composed of dolomitic limestone particles. No marked evidence of a cement alkali:aggregate reaction was observed. FINE AGGREGATE: The homogeneously distributed fine aggregate was angular-rounded in shape and was composed of quartz, limestones, sandstones, siltstones, feldspars, microcrystalline quartz cherts and water absorptive iron claystone particles. Some of the observed siltstones were water absorptive. Although cherts are considered to be, at least, potentially reactive with cement alkalis, after three days of partial immersion of the sample trimming in water, no evidence of a cement alkali:aggregate reaction was observed. CONFIDENTIAL PAGE 3 12/30/13
DISCUSSION We received two, 4-inch diameter X 6 inch length, cores of hardened concrete to determine the general condition. It was reported that the submitted core samples represent exterior concrete placed within bridge arch and pier portions. Deterioration of the bridge structure was reported. The age of the concrete(s) is unknown. No mix design, compressive strength testing results, placement details, etc. or other pertinent information was available as of this writing. According to ACI and PCA, durable concrete in a water saturated, cyclic freeze-thaw environment usually is air-entrained (air content of 3-7% by volume), manufactured with durable aggregates, exhibits a spacing factor, L, of 0.0080 inches or less, and attains an ultimate compressive strength of at least 4,000 psi. The examined samples were air-entrained however, the bulk of the voids were large and irregularly shaped. This strongly suggests that the samples were NOT intentionally air-entrained. The intended air content was unknown as of this writing. Overall, the aggregates appeared to be durable. The determined spacing factors (0.0221 and 0.0293 inches for Samples C-9 and C-11, respectively) was over the recommended industry standard limit of 0.0080 inches and are considered to be unacceptable for durability under water saturated, cyclic freeze-thaw conditions. Under similar exposure conditions, continued deterioration should be expected. It appears that Sample C-11 exhibited a higher degree of deterioration likely due to different exposure conditions. It should also be noted that Sample C-11 exhibited only remnants of coating material. The intended compressive strength of the concrete(s) represented by the samples and the actual compressive strengths of the in-place concrete(s) are unknown as of this writing. Carbonated paste portions were observed in both samples. However, the carbonated paste portions exhibited similar hardnesses as compared to the bulk pastes. All Portland cement based concretes will carbonate over time. The observed carbonation is likely a function of normal, expected carbonation over time. CONCLUSION Based on this examination, the general condition of Sample C-9 is deemed to be fair. The general condition of Sample C-11 is deemed to be poor-fair due to the greater degree of loss of surface and apparent higher degree of deterioration likely due to different exposure conditions. Both samples exhibited inadequate air-void systems that would predispose the concrete(s) to freeze-thaw distress in water-saturated, cyclic freezing environments. It must be noted that the intended compressive strength of the concrete(s) and the actual compressive strength of the in-place concrete are unknown as of this writing. J. R. Varga, Concrete Petrographer The Rock Doctor, Inc. CONFIDENTIAL PAGE 4 12/30/13
EXTERNAL RESOURCES American Concrete Institute ACI 201.2R-01 "Guide to Durable Concrete" CONFIDENTIAL PAGE 5 12/30/13
Summary of Results for the Freeze Thaw Tests Parameter C10 C12 Number of Cycles Completed 1: 116 23 Average Length Change at Termination, %: 1.504 0.356 Relative Dynamic Modulus of Elasticity, %: 6.4 20.5 Aggregate Durability Factor: 6.4 20.5 1. Average Length Change Many surrounding states have an expansion spec of 0.060% max. at 350 cycles. Both cores failed to pass the quality test for expansion 2. Relative Dynamic Modulus of Elasticity ODOT does not have a spec for Relative Dynamic Modulus nor for Durability Factor. Many USACE and FAA projects have a spec of at least >75% using C666 method A. The results of 6.4 and 20.5 scored way below the 75% target. Both cores fell apart during the test before reaching the 350 cycles intended. Based on information provided by the testing expert, the concrete core didn.t seem to be air entrained and the mortar base fell apart quickly