Bridge Inspection Manual FOR INVENTORY AND APPRAISAL OF ALABAMA BRIDGES ALABAMA DEPARTMENT OF TRANSPORTATION MAINTENANCE BUREAU 1409 COLISEUM BLVD MONTGOMERY, ALABAMA 36110 December 2017 Alabama Department of Transportation Maintenance Bureau Bridge Inspection Manual Table of Contents Chapter 1: Introduction and Purpose ........................................................................................... 1-1 Chapter 2: BI-1 - Bridge Identification Assignment .................................................................... 2-1 Chapter 3: BI-4 - Streambed Cross Sections ............................................................................... 3-1 Chapter 4: BI-5 - Bridge Inspection Condition Report ................................................................ 4-1 Bridge Deck Commentary: ................................................................................................. 4-6 Superstructure Commentary ............................................................................................... 4-8 Substructure Commentary ................................................................................................ 4-18 Channel and Channel Protection Commentary ................................................................. 4-29 Culvert Commentary ......................................................................................................... 4-32 Guidelines for Element Condition States .......................................................................... 4-41 Inspector Information........................................................................................................ 4-56 Chapter 5: New Inspection Task .................................................................................................. 5-1 Chapter 6: BI-6 - Structure Appraisal and Inventory................................................................... 6-1 Appraisal Task .................................................................................................................... 6-2 Inventory - Admin Subtask ............................................................................................... 6-25 Inventory - Design Subtask ............................................................................................... 6-39 Inventory - Roads Subtask ................................................................................................ 6-50 Inventory - Identification Subtask .................................................................................... 6-69 Inventory - State Items Subtask ........................................................................................ 6-92 Inspection Summary and Bridge Replacement Task ...................................................... 6-103 Chapter 7: Schedule Task ............................................................................................................ 7-1 i Chapter 8: BI-9 – Bridge Maintnenance Needed ......................................................................... 8-1 Chapter 9: BI-13 – General Narrative Form ................................................................................ 9-1 Chapter 10: Underwater Inspection of Bridges ......................................................................... 10-1 Chapter 11: Scour ...................................................................................................................... 11-1 Chapter 12: Fracture Critical Members and Fracture Critical Bridges ...................................... 12-1 Appendices ................................................................................................................. Appendices -1 Appendix A: Region / Area and District Maps ..................................................Appendix A-1 Appendix B: FIPS Place Codes ......................................................................... Appendix B-1 Appendix C: County Codes ............................................................................... Appendix C-1 Appendix D:Bridge Inspection Forms ...............................................................Appendix D-1 BI-1 ...............................................................................................................Appendix D-1 BI-4 ..............................................................................................................Appendix D-2 BI-5 ...............................................................................................................Appendix D-4 BI-6 ...............................................................................................................Appendix D-7 BI-9 .............................................................................................................Appendix D-16 BI-13 ...........................................................................................................Appendix D-17 Appendix E: Bridge Inspection Program Compliance ....................................... Appendix E-1 Appendix F: Underwater Inspection Field Reference ....................................... Appendix F-1 Appendix G: ALDOT Guidelines for Operation ...............................................Appendix G-1 Appendix H: Element Inspection Definitions ....................................................Appendix H-1 Appendix I: Load Rating .................................................................................... Appendix I-1 Appendix J: State Structures Underwater Inspection Frequency Exception ...... Appendix J-1 ii LIST OF FIGURES FIGURE CAPTION PAGE Figure 1 BI-1 Form – Bin Assignment Card 2-1 Figure 2 BI-4 Form - Streambed Cross Sections 3-1 Figure 3 BI-5 Form – Inspection Report 4-1 Figure 4 Joint with Deck 4-7 Figure 5 No Joint with Deck 4-7 Figure 6 Girder and Truss Type Bridges 4-11 Figure 7 Other Bridge Types 4-12 Figure 8 Types of Abutments 4-19 Figure 9 Abutment Checklist Items 4-20 Figure 10 Types of Piers 4-22 Figure 11 Types of Piers 4-23 Figure 12 Types of Piers 4-24 Figure 13 Concrete Pier and Bent Checklist Items 4-27 Figure 14 BI-5 Form – Element Conditions 4-41 Figure 15 Condition States – Reinforced Concrete 4-44 Figure 16 Condition States – Prestressed Concrete 4-45 Figure 17 Condition States – Steel 4-46 Figure 18 Condition States – Timber 4-47 Figure 19 Condition States – Masonry 4-48 Figure 20 Condition States – Other 4-49 Figure 21 Condition States – Joints 4-50 Figure 22 Condition States – Bearings 4-51 Figure 23 Condition States – Wearing Surface 4-52 Figure 24 Condition States – Steel Protective Coating 4-53 Figure 25 Condition States – Concrete Reinf. St. Prot. Coating 4-54 Figure 26 Condition States – Concrete Protective Coating 4-55 Figure 27 BI-5 Form – Inspector Information 4-56 Figure 28 New Inspection Task 5-1 Figure 29 Appraisal Task 6-2 Figure 30 Example Minimum Vertical Under Clearance 6-16 Figure 31 Example Right and Left Under Clearance 6-18 Figure 32 Admin Subtask 6-25 Figure 33 Examples of Measurement of Item 112 6-34 Figure 34 Examples of Measurement of Item 112 6-35 Figure 35 Examples for Item 101-Parallel Structure Designation 6-36 Figure 36 Design Subtask 6-39 Figure 37 Examples for Items 50, 51 and 52 6-42 Figure 38 Examples for Items 50, 51 and 52 6-43 Figure 39 Example for Item 33 6-45 Figure 40 Roads Subtask 6-50 Figure 41 Roads Subtask Continued 6-61 iii LIST OF FIGURES FIGURE CAPTION PAGE Figure 42 Example Inventory Route, Total Horizontal Clearances 6-63 Figure 43 Example for Item 32 6-64 Figure 44 Example for Item 32 6-64 Figure 45 Example for Item 51 6-65 Figure 46 Example for Items 51 and 52 6-66 Figure 47 Example for 19 - Detour Length 6-68 Figure 48 Example for Item 19 - Detour Length 6-68 Figure 49 Identification Subtask 6-69 Figure 50 Identification Subtask Continued 6-80 Figure 51 State Items Subtask 6-92 Figure 52 Inspection Summary and Bridge Replacement Task 6-103 Figure 53 Schedule Task 7-1 Figure 54 BI-9 Form 8-1 Figure 55 BI-13 Form - General Narrative 9-1 Figure 56 Representative Pier Types 10-6 Figure 57 Types of Abutments 10-7 iv LIST OF TABLES TABLE TITLE PAGE Table 1 Rating by Comparison of Item 29 and Item 66 6-8 Table 2A & 2B Rating by Comparison of Item 29 and Item 51 6-10 Table 2C & 2D Rating by Comparison of Item 28 and Item 51 6-11 Table 2E Rating by Comparison of Item 53 and Item 26 6-12 Table 3A Rating by Comparison of Item 54 and Item 26 6-13 Table 3B Rating by Comparison of Items 55 & 56 and Item 26 6-14 Table 4 Maintenance Activity Codes, Descriptions, and Units 8-3 Table 5 Assessing the Scour Potential at Bridges 11-7 Table 6 Examples of Alabama Fracture-Critical Bridges 12-5 v Alabama Department of Transportation Maintenance Bureau Bridge Inspection Manual Chapter 1: Introduction and Purpose General Purpose This manual has been prepared by the Alabama Department of Transportation (hereafter called ALDOT or the Department) to outline the general policies, practices, and procedures which are used to carry out the bridge inspection program in this state. It outlines and explains, in as simple a manner as possible, the complex series of regulations and instructions which govern the periodic inspection, data collection, and documentation of bridge structure information. Useful information for bridge inspection personnel is also found in several other federal, state, and independent manuals, available from a variety of sources. No attempt has been made to include in this Bridge Inspection Manual all information contained in those manuals, which is pertinent to bridge inspection operations. However, certain