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r R WAY STRUCTURES

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Inspection Manualfor ighwayStructures

Volume :Inspectors andbook

London TS May 2 7Licensedcop

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Published by the Stationery Office and available from:Onlinewww.tsoshop.co.u kMaiI Telephone Fax & E-mailTSOPO ox 29 Norwich NR3 GNTelephone ordenlGeneral enquiries: 0870 600 5522Fax orders: 0870 600 5533E-mail: [email protected] 0870 240 370TSO ShopsI23 Kingsway London WCZB 6PQ020 7242 6393 Fax 020 7242 6394I 6 Ar thur St reet Belfast BT I 4GD02890238451 Fax02890235401 71Lothian Road Edinburgh EH3 9AZ0870 606 5566 Fax 0870 606 5588TSO@Blackwelland other Accredited Agents

Q Queen s Printer and Controllero Her Majesty s Stationery m c e , 2007Copyright in the typographical arrangement rests with the Queen s Printer andController of Her Majesty s Stationery Office, 2007This publication, excluding logos, may be reproduced fr of charge in anyformat or medium for research, private study or for internal circulation within anorgenisation. This s subject to it being reproduced accurately and not used in amisleading context. The material must be acknowledged as copyright of theQueen'sPrinter ndController of HMSO and the title of the publication s p e cWFor any other use of this material please apply in writing to The Licensing Division,Office for Public Sector Information, St Clments House,2-16Colegate NorwichNR3 1BaF a 01603 723000, or e-mail [email protected] is a value added publication which falls outside the s ope of the coreClick-Use Licence.ISBN978 0 11 552798 2Printed in Great Britain on material containing a minimum of 75 post-consumerwaste and the remainder ECF r TCF pulp.N5465216C15 05/07May 2007

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This Manual is supported endorsedand recom mended by

W YSG E N C Y

CountySurveyorsSociety

U K B R I D G E S u u n n u

TR NSPORTSCOTL ND

Llywodraeth Cyndiad CWNelsh AssemMv Government

Full details o the Project Sponso r the Technical Project Board and th eProject Team are provided in the Ackn owledgements section on page 8-63 .

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Forewordby Ginny Clarke Chief Highway Engineer Highways Agency

Inspections play a vital role in the effective management ofhighway structures ensuring that our highway assets are safefor use and fit for purpose. This document comprising twocomplementary Volumes has been produced to assistengineers and inspectors with this task and draws together awealth of experience and knowledge reflecting current bestpractice in the United Kingdom superseding the BridgeInspection Guide Yellow Book which has served us well formany years.The manual reflects a very successful collaboration with otherhighway authorities owners interested bodies and the supplychain and I would like to thank all those who have contributedto its drafting review and publication.Ginny ClarkeChief Highway Engineer Highways Agency

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Inspection Manual for Highway tructures Volume

ContentsForewordSummaryAcronyms and Abbreviations

Part A: Inspectors Guide1 Introduction1.11.2 Layout of Part A

Overview of the Inspection Process

2 Work PackagesGuidance and Cross References

Part B: Defect Photographs1 Introduction1.1 General1.2 Layout of Part B22.12.22.32.42.52.62.72.82.92.102.1 12.12

Structural Component DefectsScourSubstructure RotationfliltingSettlementCorroded BearingsBearings Close to End of TravelBearings: Seating DefectsElastomeric Bearings: Splitting DefectsBuried Expansion JointsAsphaltic Plug Joints: CracksAsphaltic Plug Joints: DebondingAsphaltic Plug Joints: Material LossAsphaltic Plug Joints: Tracking

ixxii

A- 1A-2A-2A-2A-4A-8

B- 18-28-28-38-4B-4B 7B-9B-11B-13B-14B-16B-17B-18B-19B-208-22

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2.1 32.1 42.12.1 62.1 72.182.192.20

3.13.23.33.43.53.63.73.83.93.103.1 13.1 23.13.1 444.14.24.34.44.54.64.7

Expansion Joints: Nosing Defects 8-23Elastomeric Expansion Joints 8-24Fragmented Surfacing Adjacent to Expansion Joints 8-27Half JointsParapets and Safety Fences: Impact DamageParapets and Safety Fences: CorrosionParapets: Corroded or Cracked WeldsDrainage

oncrete DefectsPlastic Shrinkage CracksDrying Shrinkage CracksCrazingPoor Compaction: HoneycombingReinforcement Corrosion Cracking: ChloridesMap cracking and Alkali Silica ReactionIncipient SpallSpallingScaling due to frost damage)EfflorescenceRust StainingLeakage Through DeckThaumasite Sulphate AttackShuttering Left in PlaceSteel DefectsLoss of Section due to CorrosionCorrosion of Welded ConnectionsCorrosion of Bolted or Riveted ConnectionsDeformation of Plates due to CorrosionPaint: BlisteringPaint: FlakingFire Damage

8-288-298-328-348-358-378-378-388-398-408-41B-428-448-458-478-488-508-538-548-558-568-568-588-598-608-618-628-64

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Inspection M anual for Highway Structures Volume 2

5.15.25.35.45.55.65.75.866.16.26.36.46.56.67

Masonry DefectsWater PercolationErosionFreeZenhaw Dam ageMissing MasonryCracks Through MortarCrack s Through MasonryCorrosion of Embedded MetalworkMortar ossMiscellaneous Materials DefectsCast Iron: Cracking and FractureCast Iron: BlowholesCast Iron: CorrosionWrought Iron: CorrosionWrought Iron: Delam inationTimberReferences for Part B

Acknowledgements

8 658 658 668 678 698 718 728 738 748 758 758 768 778 788 808 818 828 83

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SummaryIt is widely recognised that a well managed transportinfrastructure is vital to the economic stability growth andsocial well being of a country. Bridges and other highwaystructures are fundamental to the transport infrastructurebecause they form essential links in the highway network.They are relied upon to remain in service year after yearcarrying ever-increasing traffic flows while being managed in amanner that ensures they are Safe for Use and Fit for Purpose.The majority of highway structures are managed andmaintained at public expense. It is therefore important that theirmanagement minimises disruption risk and consequentialcosts to road users and makes economic and efficient use ofresources. Fundamental to effective management is aninspection regime that provides timely accurate andappropriately detailed information on asset condition andperformance. The overall purpose of inspection testing andmonitoring is to check that highway structures are Safe forUse and Fit for Purpose and to provide the data required tosupport effective maintenance management and planning.The purpose of this Inspection Manual is to provide guidance onthe inspection process for all staff involved in the managementof highway structures. It is also considered that this Manualprovides a sound basis for the development of formalinspector training courses.This Manual aims to ensure that inspections are carried outefficiently uniformly and to a high standard. The Manual isintended for use as guidance outlining typical procedures anddefining the normal requirements for the various categories ofinspection. It is not intended to provide the definitive solutionin all situations as the party best able to decide on theappropriate course of action is the inspector or engineerundertaking the work.

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Inspection Manual for Highway Structures Volume

The Manual is divided into two separate but complementaryVolumes. Each of the two Volumes is sub-divided into severalParts that provide guidance on a wide range of issues aslisted below.

Volume 1: Reference Manual covers all aspects ofhighway structures inspection that both inspectors andengineers should be aware of.

Part A Introduction and Im@ementation:Provides anoverview of the Manual; includes an introduction to therole and need for the Manual describes the purposeobjectives and scope of the Manual and how it should beimplemented. It also offers an overview of the inspectionregime and summarises the general competence andtraining requirements for inspection staff.Part B Behaviour of Structures: Provides inspectorswith an overview of the engineering topics that theyshould be aware of and offers a consistent basis forinspector knowledge development and training. Itcontains a summary of topics such as structuralmechanics structural materials and their propertiescommon types of highway structures and structuralelements. It aims to provide organisations with a checklist of criteria they should include on training coursesbut does not provide detailed coverage of the topics.Part C The InsDection Process: Provides generalinformation on scheduling inspections planning andpreparing for inspections access considerations healthand safety aspects and advice on performing inspectionson differing types of structures.Part D Defect DescriDtions and Causes: Providesbackground information and guidance on describingand categorising defects. It describes the principaldefects that are likely to be encountered in concretestructures metal and metal/concrete compositestructures masonry structures and structures builtfrom other materials with the emphasis placed onidentification and likely causes.

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PartE. lnvestiaation and Testing: Summarises a widerange of testing methods available for highway structures,including tests for material properties, defects andcauses of defects. This aims to make inspection staffaware of the tests that may be used to informmanagement.

- PartE A.DDendices: Contains a selectiono informationwhich collectively support the guidance provided inPartsA to E

Volume : Inspector sHandbook acts as a quickreference for inspectors on site.- PartA Insoector s Guide: Highlights the key points

from Volume 1 that inspectors should be aware ofbefore, during and after undertaking inspections.Cross-references to Volume 1 are provided, enablinginspectors to quickly look up more detailed advice orguidance as and when required.

- PartB Defect Photoara-phs:Providesa library ofphotographs illustrating the different types of defectsthat are likely to be encountered on highway structures.

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Inspection Manual for Highway Structures Volume

Acronyms andAbbreviationsDM

MEWP Mobile Elevating Work PlatformPPE Personal Protective Equipment

The Construction Design and Management)Regulations

TSn

Thaumasite Sulphate AttackSection@)Paragraph s)

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PartAInspectors uideThis Part highlights and cross-references the key points fromVolume that inspectors should be aware of before duringand after undertaking nspections. Cross-re erences t Volumeare provided t enable inspectors to quickly look up moredetailed advice or guidance as and when required.

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Inspection Manual for HighwayStructures Volume 2, Part AI 1 Introduction1.11.1.1

OVERVIEW OF THE INSPECTION PROCESSThe overall purpose of inspection, testing andmonitoring is to check that highway structures aresafe for use and fit for purpose and to provide thedata required to support effective maintenancemanagement and planning see Volume 1: Part A:Section 1.2 . In order to achieve this, a rational fivestep approach, illustrated in Figure A.1, isrecommended for the development and deliveryof a robust inspection regime.

1

FigureA The inspection process

1.1.2

1 21.2.1

It is unlikely that inspectors will be involved in allparts of the process illustrated in Figure A.l ;however they should have a sound understanding ofthe overall process.LAYOUT OF PARTThis Part of the Manual seeks to provide a conciseoverview of the inspection process, containingcross-references to Volume 1 that enable inspectorsto look up more detailed advice or guidance as andwhen required. This is provided in the form of twsummary tables:

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Section 1 ntroduction

1 2 2

Section : Work Packages divides theinspection process into a number o distinct butinterrelated work packages.Section 3: Guidance and Cross-referencesprovides high level guidance for each for theWork Packages and cross-references o moredetailed guidance in Volume 1.

The guidance provided in this handbook does notprovide sufficient detail to enable inspection staff toundertake safe effective and efficient inspections.This handbook must be used in conjunction withVolume 1 and supplemented by appropriateinspector training.

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Inspection Manual for Highway Structures Volume 2 Part A

2 1 1

Work PackagesThe following table presents the typical packagesofwork that make up the inspection process. Theorder in which the Work Packages are presented isconsidered to represent a logical and practicalapproach for the inspection process; however thisshould be reviewed by authorities and whereappropriate tailored to their specific working practicesand requirements. The ID column refers to theguidance and cross-references given in Section 3

MethodStatement

Health andSafety

RiskAssessment

method statement that 1-5summarises the safest methodof working should be prepared.ll other relevant informationshould also be prepared andagreed before undertaking an

inspection.Due consideration should begiven to minimising health andsafety risks to people includingthe public and others who maybe affected by the work activitiesas well s hose actually carryingout the work.

risk assessment that identifies 19-23and records the measures to betaken to eliminate or reduce risksto inspection personnel and tothe public during the proposedactivity should be carried out.

6-18

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Section Work Packages

Methods ofAccessEquipmentNeeded

StructureRecords

Testing

InspectionStaff

WorkNotification

Careful thought should be givento how access will be gained tothe required partsof the structureIt is essential that the inspectoris appropriately equipped forthe type of inspection to beundertaken and that theequipment required is availableand is functioning correctly.The number and type of recordsto be reviewed would dependon availability and the nature ofthe inspection but shouldgenerally cover the appropriaterecords held in the Health andSafety File.If site testing is required as partof the inspection then a suitableprogramme of testing should bedeveloped.

ll inspections should beUndertaken by personnel thatare judged by the SupervisingEngineer to satisfy the minimumhealth experience and whereappropriate qualificationrequirements or the particularinspection type.There may be a need to notifyother parties and in somecases obtain their approval forthe proposed inspection.

?4 35

36 46

17 48

19 53

54 57

58 62

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inspection Manual for Highway Structures -Volu m e 2 Part A

A-6

EnvironmentalImpacts

Arrival on Site

BeforeCommencingWork

UndertakingInspections

RecordingInspectionFindings

Before Leavingthe Site

Consideration should be givento whether the work is likely tohave any environmental impactsand i so seek expert advice toidentify and implement theappropriate working practicesand/or mitigation measures.The team leader should brief theinspection team. Attention shouldbe paid to avoid inspecting thewrong structure by mistake.t is advisable to check and

ensure that the required safetytraffic management and accessarrangements are in place andoperate satisfactorily.Inspections should be carriedout in a logical and systematicmanner to the full requirementsof the specific inspection briefbut without compromising safetyAny observed defects alongwith their associated severityand extent should be recordedon an appropriate inspectionpro-forma.The inspection team shouldverify that all the informationrequired has been captured andthat the site is thoroughly clearof all inspection equipmentand materials

63 72

73 77

78 84

85 94

95 96

97 100

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Section 2 -Work Packages

The principal informationob tained from all inspectionsshould b e appropriately storedfor example on a computerisedsystem. The inspection findingsshould b e evaluated to identifyurgent actions and futuremaintenance needs .

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Inspection Manu al for Highway Structures -Volum e 2 Part A

3.1.1

3.1.2

uidance andCross-ReferencesThe following table provides guidance on theconsiderations and activities related to each WorkPackage outlined in Section 2. Cross-references toVolume 1 are provided against each item, enablingmore detailed advice or guidance to be looked-upas and when required. The following symbols areused to summarise the actions required:

m-Document reviewDocument preparation

- Document storageSeek agreemenuadvice from the

If expertise is lacking, seek agreement or

Specialist support or advice may be

Third party notification/agreement

Supervising Engineer

advice from the authoritys Safety Officer

required

m quipment required- Equipment serviceability checked. Information or WarningThe following abbreviations are also used:

Section s)paragraph@)

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Section 3 Guidance and Cross References

3.1.3 Authorities may wish to use the following as a genericchecklist of activities that should be undertakenduring the inspection process. However, it is importantto tailor the following to reflect any authority specificworking practices and to be proportional o the scope,detail and needs of the particular inspection andstructure type.

1 Consult the inspectionschedule to find outwhat type of inspectionis required.

2 Prepare a draft methodstatement in conjunctionwith a risk assessment)that details the safestmethod of working.

3 Review and agree thedraft method statement.Retain a copy of themethod statement in thestructure Health andSafety file.

4

Ensure that the entireinspection team isfamiliar with the agreedmethod statement.

Part C: 2

Part C 3.2:3.2.1

Part C 3.2:l 3.2.1

Part C 3.2:rn3.2.3

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Inspection Manualfor Highway Structures Volume 2, Part A

Review the structureHealth and Safety File.

7 Check whether the workfalls within the scope ofCDM regulations.

8 Review the AsbestosManagement Plan.

9 Consider personal safetymatters andor reviewpersonal safety checklist.

0 Assess the benefits ofnight-time working todecide whether it is asafe and practicableoption.If work will be carriedout in or near water or inconfined spaces, ensurethat the entire inspectionteam is warned of thedangers of LeptospirosisWeils Disease) and isfamiliar with the relevantcontrol measures.

12 A supply of soap, waterand disposable papertowels is advised, incase there is contactwith ditty surfaces.

Part C: Q 3.3:13.3.6

Part C: Q 3.3:3.3.7 3.3.8

Part C: Q 3.3: ~Part F:AppendixPart C: Q 3.5:

3.3.9 3.3.20

3.5.55 3.5.61

Part C: Q 3.3: m m

Part C: Q 3.3:3.3.13

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Section Guidance and Cross References

A first aid kit appropriatefor the number of staffand nature of likelyinjuries should be madeavailableEnsure that the entireinspection team is awareof the procedures to befollowed and people tocontact in the event ofan accidentEnsure that any electricalequipment attached tostructures is isolated ordisconnected beforecarrying out inspectionsin the vicinity and notethe locations of anynearby overhead linesConsider the coverageof the inspectors mobilephone if the inspectioninvolves enteringremote areasEnsure that excavationwork is not undertakenwithout first checking forthe presenceof cablesor otherburiedapparatusConsider the safety ofthe public and otherthird parties

Part c: 3.3:3.3.13

Part C: 3.3:.3.20

Part C: 3.3:3.3.22 3.3.23

Dart C: 3.5:13.5.20

>artC: 3.3:3.3.24

Part C: 3.3:Part C: 3.5:3.3.26 3.3.293.5.44

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9 Prepare a draft riskassessment identifyinghazards and mitigationor control measures.

Inspection Manual for Highway Structures Volume 2 art A

A 12

20 If appropriate combinethe risk assessment withother documents suchas the health and safetyplanwmethodstaternent

21 Review and agree thedraft risk assessment.Retain a copy of the riskassessment in thestructure Health andSafety file.

23 Ensure that the entireinspection team isfamiliar with the agreedrisk assessment.

24

st

~

If work will be carriedout on or near ahighway provide trafficmanagement and ifnecessary diversionaryroutes for pedestrians.

traffic management on aroad owned by anotherauthority consult theowner.

Part C: Q3.4PartC:Q 3.5:3.5.39, .5.513.5.571 .5.1 i,3.5.32,

Part C: Q 3.4:3.4.11 Ea

I-PartC: Q 3.2:13.2.2

PartC: 3.2:3.2.3 rn

Part C: Q 3.5:3.5.4-3.5.15

Partc:. 3.5:3 5 7

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Section 3 - Guidanc e and Cross References

out off the highway seekpermission for accessfrom landowners oroccupiers

27

28

If work will becarriedoutoff the highway take intoaccount the requirementsof vehicles pedestriansand livestock that mayuse the area.If work will be carriedout on or over railwaysadhere to the proceduresof the relevant railwayauthority.

9 workw will becarriedoutin or over water ensurethat it is undertaken bysuitably experienced andqualied st ff or specialistfirms as appropriate.

3

31

If work will be carriedout underwater reviewall available informationconcerning underwaterparts of the structure.Unless an underwaterinspection is requiredurgently consider timingit to coincide withfavourable conditionssuch as low spring tidesor low river flow.

PartC 53.5:3.5.16-3.5.19

PartC 3.5:.5.17

PartC 3.5:3.5.21 3.5.22

Part c: 3.5:3.5.23-3.5.30

Part C: 53 5:.5.31 3.5.33

Part C: 5 3.5:13.5.34

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32

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34

35

If an underwaternspection is required2onsider lowering thewater level or divertingthe watercourse but donot disregard theassociated environmentalimplications.

If diving operations willbe required ensure thatthese are carried out bysuitably qualified andexperienced personnel.If diving contractors willbeemployed to undertakeunderwater inspectorsensure that a job specificdiving plan and aseparate risk assessmentfor non-diving operationsare prepared.If work will be carriedout in a confined spaceprepare a permit toworwenter system.

I

3artC: 3.5:3.5.33 3.3.41

Dart C: 3.5:3.5.39

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Section 3 Guidanceand Cross References

36

r

___ _Determine what type ofaccess equipment isrequired, how theequipment will betransported to and fromthe site and whetherthere are any restrictionsor obstructions.

If scaffolding is used,ensure that it is erected,altered or dismantled byadequately trained andexperienced persons.Ensure that barriers orwarning devices areplaced around the baseof a scaffold to preventcollisioneither byvehicles or pedestrians.If MWPs are used, theyshould beoperated andchecked for serviceabilityby suitably experiencedand qualified personnel.If aMWP s used, en sur^that the work platform isfitted with clearly markecsafetyharnessattachmenlpoints that are sufficientfor th numberof personsthat will be carried.

art C: 9 3.6:3.6.1 3.6.27

Part C: 5 3.6:3.6.12

Part C: 3.6:3.6.12

Part C 9 3.6:q 3.6.1 6 3.6.18

Part C: 3.6:3.6.19 m

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nspection Manual for Highway Structures Volume 2 Part A

41 If abseiling is required itmust only be undertakenbyspecially trained andexperienced firms.Ensure that permanentlyinstalled accessequipment has beenappropriately maintainedand is safe for use.

42

3 If present do not usepermanently installedaccess equipment unlessappropriately experiencedand trained.

Part C: 3.6:3.6.26

Determine what PPE isrequired ensure it isavailable and that it hasbeen maintainedasrecommended by themanufacturers.

Part C: 3.6:3.6.m 3.6.3044

5 Part C: 3 43:3.6.31 3.6.34

Determine what type ofdata recording equipmentis required and ensure it isavailable and operational.Determine what type ofmeasuring equipment isrequired and ensure it isavailabte and operational.

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47

48

9

5

51

53

Section 3 Guidan ce and Cross References

Review the structurerecords to obtain athorough understandingof the characteristics ofthe structure and of anyfeatures or defects whichmay require specialattention.

PartC: 3.7

Particular attention should Part C: 3.7:be paid on records of fl 3.7.3the methods of accessand traffic managementpreviously used as hiswill eliminate the need toplan the work fromscratch.Determine whether there Part C: 3.8is a need for testing. Part E: 2.2Define and documentthe objectives of thetesting operations.Identify alternative

Part E: 2.22.2.3-2.2.4

~

Part E: 2.2testing options 2.2.5Appraise and compare Part E: 2.2the identified testing fl 2.2.6-2.2.8options and select themost appropriate solution.Plan testing operations Part C: 3.8i.e. the range and location Part E 2.2of tests and their extentand intensity to suit thespecific objectives.

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Inspection Manual for Highway Structures olume 2, Part A

I54

55

56

57

59

At least one experiencedinspector should alwaysbe present on siteduring an inspection.Inspectors should be insound health and have arealistic appreciation oftheir own limits ofeaerience and ability.Inspectors with limitedexperience should workunder the supervisionofexperienced staff.If work at night is planned,ensure that sufficientresources are providedto complete the work sothat the road can bereopenedby the due time.If access will be requiredto land under differentownership, at or adjacentto the highway structure,obtain access permissionfrom any landowners,tenants andor occupiers.If work will be carriedout on or over railways,consult with the relevantauthority to agree detailsof possessions and safeworking practices.

Part A: 4.2PartC: 3.9

PartA: 4.2PartC: 3.9

PartA: 4.2Part C: 3.9

Part C: 3.5:3.5.55 3.5.61

PartC: 3.5:PartC 3.10:.5.1 6 3.5.203.10.1

PartC: 3.5:PartC: 3.10:3.5.21 3.5.223.10.2

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Section Guidance and Cross References

60

1

6

63

If work will be carriedout adjacent to or overcanals or navigablewaterways consult therelevant authority to findout if there are anyspecial requirements.Establish the presenceof services in or near thehighway structure andconsult the serviceauthorities for details.Determine whetheradvanced publicity andorprior notification of theworks to the generalpublic will be required.

If work at night is plannednear residential propertiesor other sensitive areasconsult the environmentalhealth department of therelevant authority andobtain consent.If work will be carriedout on or near farmlandconsider the requirementsof livestock e.g. accesstiming straying etc.

Part C: 3.5:Part C: 3.10:3.5.293.10.2

PartC: 3.3:PartC: 3.1 :3.3.23-3.3.24fi 3.10.3Part C: 9 3.5:PartC: 3.10:PartC: 3.11:

n3.5.61

3.1 0.5-3.1 .63.1 .3-3.1 .4

Part C: 3.5:Part C: 3.10:Part C: 3.11:

q 3.5.613.10.53.113-3.1 4

Part C: 3.5:7 3.5.16-3.5.19

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ID65

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7

GuidanceIf work will be carriedout on or near farmlandadopt the necessaryproceduresso as tominimise any damage ordisruption to crops e.g.keep to arranged accessroutes to and from thehighway structure site.If it will be necessary tocross or work on oradjacent to agriculturalland adopt the necessaryprocedures to avoid thespread of animal orplant diseases.Determine whether thereare any protected habitatsat or near the structureand if so develop suitablemethods of working.Adopt appropriateprocedures o ensure thatair and watercoursepollution is avoided.Adopt the necessaryprocedures to avoid anydamage or destruction ofrare or protected plants.Adopt the necessaryprocedures to avoid thedisturbance of bats ortheir roosts in bridges.

VolumePart C: 3.5:

3.5.16 3.5.1

IPart C: 3.5:3.5.16 3.5.19

Part C: 9 3.13.1 . ~ 3 . i.24

Part C: 3.11:3.11.25 3.1 .28

Part C: 3.13.11.5 3.1 .73.1 1.29 3.11.31

Part C: 3.11:3.11.8 3.1 . i s3.1 1.29 3.11.31

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D71

72

73

74

76

GuidanceAdopt the necessaryprocedures to avoid thedisturbance of birds andtheir nests.Adopt the necessaryprocedures to avoid thedisturbance of otters,water voles, badgers orother protected wildlife.Upon arrival on site,confirm the identity ofthe structure ensure thatit is the correct one).Be aware that theappearance of somestructural materials maysometimes be misleading.Be aware that somestructures may havebeen subjected torepairs or alterationswhich are superficiallysimilar to the rest of thestructure but which mayconceal a different formof construction.Ensure that all PPE isfitted securely andcorrect y.

VolumePart C: 3.1 :3.1 1.14 3.1 .173.1 1.29 3.1 .31

Part C: 3.1 1:3.1 1.29 3.1 .313.1 .I 3.1 .21

Part C: 4.1:4.1.1

Part C: 4.1:4.1.2

Part C: 4.14.1.2

Part C: 3.6:3.6.30

ct ion

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Inspection Manual for Highway Structures-Volume 2, Part A

ID IGuidanceThe team leader shouldmake all members of theinspection team awareof the particular risksassociated with theinspection, through asite-specific briefing.

78

79

80

DO not commence orcontinue to work unlessit is safe to do so

Do not work while underthe influence of alcoholor drugs or when tired orin ll health.Avoid handling ordisturbing rubbish but ifit is necessary to do so,ensure that theappropriate PPE is worn.

81

82

Avoid handling birddroppings at m s t ornest sites unless suitablerespirators andor otherPPE are worn.Be aware of remoteareas and follow theauthoritys procedureswhen entering such areas.

PartA: 4.2:4.2.3

Part C: 3.3:Part C: 3.5:3.3.19 ti3.3.293.5.45 3.5.47

Part C: 3.3:3.3.11 3.3.12

~ ~~

Part C: 3.3:3.3.14 3.3.1

Part C: 3.3:Part C: 3.11:

3.3.17q3 . i i .17

Part C: 3.5:3.5.20

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83

84

Section Guidance and Cross-References

Before commencing work,ensure that necessarytraffic managementmeasures are in placeand operate satisfactorily.

Part C: Q 4 1:14 1 3

85

86

387

If scaffolds are used,they should be checkedbefore every use forvandalism r unauthorisedremoval of parts andtagged to specify thesafe working load) by asuitably experiencedand qualified person.Ensure that adequatesafety zones are alwaysmaintained betweenworking and traffickedareas if working withinany form of trafficmanagement.At intervals during thework, undertake checksto ensure that any trafficmanagementarrangements are stilloperating correctly.Be alert at all times andaware of surroundinghazards and, if necessary,appoint a lookout.

Part C: Q 3 6:3 6 13

Part C: 3 5: a,13 5 8

Part C: 54 1:4 1 3

PartC: 53 3 a,3 3 1o 3 3 27

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Inspection Manual for Highway Structures Volume 2, Part A

Gany ut inspections ina logical and systematicmanner to the fullrequirements of thespecific inspection briefand within the constraintsimposed by any safety,traffic management andaccess considerations.Before starting to identifyindividual defects, reviewthe overall condition ofthe structure and focuson identifying anystructural defects andtheir effects.Be alert to anythingunusual and focus onany part of the structurethat m y cause particularconcern.Never use any type ofaccess equipment alone.If a ladder is used, neverlean out from it andnever carry objects inyour hands whileascending r descending;cany any equipmentrequired in a haversackor shoulder bag.

-

'art C 4.1:4.1.4 4.1.6

art C 4.1 :l 4.1.4

Part C 4.1:4.1.7

Part C 3.6:3 6 5

~~

Part C 3.6:3.6.10

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93

94

95PFK

9


Take into account adviceand guidance on carryingout inspections ofstructures constructedfrom various materialsand detailed guidance ondefects that may occur.If a testing programmeis being implemented,review and assess itssuitability as the testingis being undertaken.

Part C: 4.1:PartC 424.1

Part D4.1 I-4.1 I0

Part E: 2.22.2.9

Record the observed Part C: 5.2:defects along with their 1 .2.1-5.2.4associated severity and Part C: 5.3:inspection pro-forma, asspecified by the authority.extent levels on an 15.3.1

Inform the SupervisingEngineer, immediately ifa defect wouldcompromise the integrityof the structure and thesafety of the public.

Part C 5.3:5.3.2-5.3.6

(D

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T9

98

99

100

101

02

A-26

On completing an PartC 4.1:inspection, verify that all fl 4.1.9the information requiredhas been captured.Clear t h site thoroughly of Part C 4.1:all inspection equipment fl 4.1.9and materials.

D

If working on a highway, Part C 4.1: a,ensure that the area issafe for public usebefore the highway isreopened to traffic.

fl 4.1.9

On railways, follow a Part C 4.1: D

reporting procedure toensure safety at the endof a possession.

formal checking and fl 4.1.9 m

Sign and date inspection Part C 5 2:forms in paper format,as evidence in case offuture potential claimsby the public.

fl 5 2 5

Produce an inspectionreport in a formatappropriate to theinspection type.The SupervisingEngineer shouldperiodically review andsign inspection reportsand also identifymaintenance needs.

Part C 5 4


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Section 3 Guidance and Cross -References

obtained from allappro priate format forexample a computerised

105 If the inspection was th efirst on a structure usethe data co llected tocreate a structurespecific p ro-forma forfuture use.106 Evaluate the inspectionfindings.

Part C: 5.5

Part C: 5.2:75.2 .4

Part C: 5 6

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PartDefect PhotographsThis Part prov ides a library of photographs illustrating thedifferent types of d efects that are likely t be encountered inhighway structures structural com ponents and structuralmaterials. It also covers the definition of severityJJnd providesdescr iptions of t he general severity ratings used.

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Inspection Manual for Highway Structures - Volume 2 Part B

1 Introduction

8 2

1 1

1.1.1

1.1.2

GENERALThis Part of the Manual contains a selection ofphotographs illustrating different types of defectsthat are likely to be encountered in highway structures.The condition of the structural or bridge elementsillustrated in the photographs is presented in termsof the severity of the damage or defect.Severity is the degree to which the defeddamageaffects the function of one element or a number ofelements on the structure. This definition has beenadopted from the CSS Guidance documents onbridge inspection reporting l ,21. nspectors shouldcheck with the authority the form of the reportingsystem to be adopted, as several have beendeveloped and are utilised by particular ownersseealso Volume 1 Part C:Section 5).

1.1.3 All defects illustrated in this Part of the Manual areassigned a seventy rating which generally correspondsto one of the following ratings:1 As new condition or defect has no significant

effect on the element visually or functionally).2 Early signs of deterioration, minor defect/

damage, no reduction in functionality of element.3. Moderate defeddamage, some lossof

functionality could be expected.4 Severe defect/damage, significant lossof

functionality and/or element is close tofailure/collapse.5. The element is non-functionaVfailed.

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Section 1 ntroduction

1 2 LAYOUT OF PART B1.2.1 The layout of this part of the Manual is summarised

in the table below.

1. Introduction This section covers the definition ofseverity and provides descriptionsof the general severity ratings usedthroughout Part BThis section includes a selection of. Structural and

Component photographs illustrating generalDefects structural or component defects

irrespective of the structural material.This section includes a selection ofphotographs illustrating differenttypes of defects that are likely to beencountered on concrete elements.

3.Concrete Defects

4 Steel Defects This section includes a selection ofphotographs illustrating differenttypes of defects that are likely to beencountered on steel elements.

5. Masonry Defects This section includes a selection ofphotographs illustrating differenttypes of defects that are likely to beencountered on masonry elements.

6. Defects in OtherMaterials

This section includes a selection ofphotographs illustrating differenttypes of defects that are likely to beencountered on elements made frommiscellaneous materials suchas castiron wrought iron timber etc.

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2.1

StructuralComponent DefectsSCOUR

a. Severity: - Minor scour adjacent to wing wall

Inspection Manual for Highway Structures -Volum e 2 Part B

b. Severity: 2 - Minor scour at abutment wall

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Section Structural i Component Defects

c Severity: 3 Scour around base o f pier

d Severity: 3 Flood debris at bridge piers This couldlead to scour and overstress if not cleared

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Inspection Manual for Highway Structures Volume 2 Part B

B 6

e. Severity: Severe scour to masonry arch causingoss of voussoirs at arch springing

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2 2

Section 2 Structural Component Defects

SUBSTRUCTURE ROTATION TILTINGa Severity: 2 Slight rotation in wingwall

b Severity: 3 Significant rotation o abutment wall

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c Severity: 4 Rotation and settlement of wingwall

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Section2 Structural Component efects

2.3 SETTLEMENTa. Severity: 2 Vertical cr cks suggest differential settlement

b Severity: 3 - Dip in the carriageway due to settlementunderneath the abutment

. *

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c. Severity: 3 Evidence o differential settlement rotationof left-hand panel).

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d. Severity: 4 Differential settlement of reinforcedearth wall

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2 4


ORRODED BEARINGSa Severity: 2 Minor corrosion on edges of bearing plates

b Severity: 3 - Extensive corrosion on bearing

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Inspection Manual or HighwayStructures Volume 2 Part

c. Severity: 4 Severe corrosion to bearing

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2 5

Section Structural Component Defects

BE RINGSCLOSE TO END OFTRAVELa Severity: 3 - Sliding bearing is at extreme end of travelat average temperature

k

b Severity: 4 - Bearing is beyond the designed extent oftravel at averaae temDerature

I 7

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Inspection Manual for Highway Structures - olume 2 Part B

I

B 14

2 6 BEARINGS SEATING DEFECTSa Severity: 2 - Minor localised spalls and rust staining onbearingshelf

..eA

b Severity: 3 Extensive delamination on bearing shelf

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c. Severity: Extensive rust staining and spalling onbearing shelf

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Inspection Manual for Highway Structures Volume2 Part B

2 7 ELASTOMERICBEARINGS: SPLllTlNGDEFECTS

b Severity: Splitting and deformation of elastomericbearing

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2 8


B URIED EXP NSION JOINTSa Severity: 2 Minor surface cracking over buried joint

b Severity: 4 Severe surface cracking over buried joint

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2 9 ASPHALTIC PLUG JOINTS: CRACKS

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.10 ASPHALTIC PLUG JOINTS: DEBONDINGI Severity: 2 Debonded asphaltic plug joint

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Inspection Manualfor ighwayStructures Volume 2 Part B

b Severity: 2 Slight rutt ing at asphaltic plug joint withsome flow of binder

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Section2 Structural Component Defects

c Severity: 3 Loss of aggregate

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6 22

2 12 ASPHALTIC PLUG JOINTS: TRACKINGa Severity: 2 Slight tracking with significant flow o binder

b Severity: 3 Severe tracking

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Section Structural Comp onent Defects

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nspection Manual for ighway Structures Volume 2 art B

2.14 ELASTOMERIC EXPANSION JOINTSa. Severity: 2 Slight cracking o f transition strips

b. Sa- ;+. : 2 Missing holding down bolts

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c Severity: 3 Transition str ips breaking up

d Severity: 3 Missing holding down bolts andtransition strip

. . z

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Inspection Manual for Highway Structures Volume 2 Part

e. Severity: - Cracking of transition strip with significantdamage to elastomeric joint

f. Severity: 5 Loss of transition strip and metal runnerswith distortion to jo int rubber

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Section 2 Structural omponent Defects

2 15 FR GMENTED SURF CING DJ CENT TOEXP NSION JOINTS

a Severity: 3 Moderate break up of road surfacingadjacent to joint with debris in joint seal

b Severity: 4 Severe break up of road surfacingadjacent to joint with debris in joint seal

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Inspection Manual for Highway Structures

2 16 H LF JOINTS

Volume 2 Part B

a Severity: - Minor rust staining at a half joint

Note: The above image illustrates a typical half-joint with ruststaining due to leaking. In instances such as this a severityrating is assigned based on what is visible on site. Howeverfurther examination is recommended prior to assigning adefinitive severity code due to uncertainty surrounding thegeneral condition and potential rate of deterioration of thesetype of joints.

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Section2 Structural Component Defects

2 17 PARAPETS AND SAFETY FENCESIMPACT DAMAGE

a Severity: 2 Minor impact damage

I

b Severity: 2 - Moderate damage t parapet infill

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8 30

c Severity: 3 Displacement of coping at end of parapetwall

d Severity: 4 mpact to centre section of parapetresulting in tilting of section

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e Severity: 5 Broken post at end o parapet

f Severity: 5 - Impact has caused demolition o a lengthof parapet wall


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2 18 PARAPETS AND SAFETY FENCESCORROSION

a Severity: 2 - Slightly corroded parapet holding downbolt on undersideo deck

8 32

b Severity: 2 Corrosion of parapet


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Section Structural Component Defects

c Severity: 3 - Severe corrosion on base of post withslight corrosion of holding down bolts

d Severity: 5 Severe corrosion at base o post; theparapet has virtually no strength

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Inspection Manual for HighwayStructures Volume 2 art

2.19 PARAPETSCORRODEDOR CRACKED WELDSa. Severity: 3 Significant corrosion at wel s

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2 20 DR IN GEa Severity: 2 Leaking drainage causing minor staining

b Severity: 2 - Leaking drainage causing minor staining

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Inspection Manual for Highway tructures olume 2 Part B

c Severity: 3 - Leaking drainage causing minorstructural damage

B 36

d Severity: 3 Leaking drainage causing minorstructural damage

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Concrete Defects3 1 PLASTIC SHRINK GE CR CKSa Severity: 4 Plastic shrinkage cracks n new bridge deck

b Severity: 4 Core extracted from the above bridge deck

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Inspection Manual for Highway Structures -Volume 2 Part B3 2 DRYING SHRINK GE CRACKSa Severity: 2 - Drying shrinkage cracks

B 38

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Section Conc rete Defects

3 3 CR ZING

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Inspection Manual for Highway Structures Volume 2 Part 6

6 40

3.4 POOR COMPACTION: HONEYCOMBINGa. Severity: - Poor compaction beneath void formernote polystyrene)

b. Severity: 3 - Poor compaction leading to significanthoneycombing

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3 5

Section 3 Concrete Defects

REINFORCEMENT CORROSION CRACKING:CHLORIDES

a. Severity: 3 No evidence of corrosion on surface butsubsequent testing revealed high chloride concentrations

b. Severity: Severe cracking and delamination in thenn of nier below a nak inn ewn neinn h i n t

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Inspection Manual for HighwayStructures Volume 2 Part B

8 4 2

3 6 MAP CRACKING AND ALKALI SILICAREACTION

a Severity: 2 Map cracking on top surface

b Severity: 3 Aggregate alkali reaction cracking inwingwall with brown staining typical of such crack patterns

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c Severity: 4 Severe SR cracking with brown stainingin the cracks

Section Concrete Defects

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nspection Manual for Highway Structures Volume 2 Part B3 7 INCIPIENTSP LLa. Severity: 3 Incipient spall in deck soffit

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3 8 SP LLINGa Severity: 2 Minor area of spalling with exposed barsto base of pier

b Severity: 2 Minor areas of spalling at base ofabutment wall

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c Severity: 3 - Severe spalling at deck soffit

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3 9

Section 3 Concrete Defects

SCALING DUE TO FROST DAMAGE)a Severity: 2 Slight scaling of surface on a wingwall

b Severity: 3 Significant scaling at plinth ofpedestrian r et

5

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nspection Manual for Highway Structures Volume 2 Part3 10 EFFLORESCENCE

a Severity: 2 - Efflorescence at con struct ion jo ints

b Severity: 3 Leaching of calc ium sal ts at abutm ent jo int

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c Severitv: 4 Severe leachina throuah deck

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3.11 RUSTSTAININGa. Severity: 1 ron pyrites stains throughout bridgewhich is not an indication of corrosionI I

Insp ection Manual for Highway Structures Volume 2 Part

b. Severity: 1 Corrosion of reinforcement duringconstruction had led to staining of the soffii formworkadjacent to a construction oint

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c Severity:2 Rusty tie wir and debris in soffit of deck slab

d Severity: 3 Significant rust staining

I

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Inspection Manualfor ighway Structures olume 2 Part B

8 52

e Severity: - Significant leaking and rust stainingthrough wingwall

f Severity: - Heavy leaching and rust staining fromexpansion joints

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3.12 LE K GE THROUGH DECKa. Severity: 3 Significant leakage through invertedT Beam deck on centrelineof road


b. Severity: 4 Heavy leakage through deck at beam/slab joint

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8 54

3.13 TH UM SITE SULPH TE lT CKa. Severity: 3 - TS in the form o discrete blistering andlarge bands of attack on a bridge abutments

b. Severity: 4 Extreme example of TSA in a bridgecolumn in wet reworked lower lias clay


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3.14 SHUTTERING LEFT IN PLACE-S.W~ Pe n =hl -Ing left in place after removalrn

b. Severity: 3 Wooden sections left in place. These couldinhibit movement of the superstructure

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Inspection Manu al for Highway Structures Volume 2 Part B

4 1

Steel DefectsOSSOF SECTION DUE TO CORROSION

a Severity: 2 - Slight to moderate corrosion of steelmembers

_ _ I

b Severity: 3 -General corrosion over length of flange

I

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Section Steel Defects

c Severity: 5 Severe corrosion of flange


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4 2 CORROSION OF WELDED CONNECTIONSa Severity: 2 Slight corrosion o weld run

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Section 4 Steel Defects

4 3 CORROSION OF BOLTED R RIVETEDCONNECTIONS

a Severity: 2 Slight corrosion of nuts and washers

Ib Severity: 4 Loss of rivet heads due to corrosion

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InspectionManual for HighwayStructures Volume 2 art B

B-60

4 4 DEFORMATION OF PLATES DUETO CORROSION

a Severity: 3 - Significant deformation

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Section teel Defects

4 5 PAINT: BLISTERINGa Severity: 2 Slight blistering

b Severity: 3 Moderate blistering

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4 6

Inspection Manual for Highway Structures Volume 2 art B

b Severity: 2 Flaking paintwork

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Section Steel Defects

c. Severity: 3 Flaking and missing paint on main beam

d. Severity: 4 Breakdown of paint on footbridge beamallowing extensive corrosion

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4.7 FIR D M GEa. Severity: 3 Significant fire damage to paint system

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55.1

Masonry DefectsW TER PERCOLATION

a. Severity: 3 Severe staining and efflorescence inarch barrel

b. Severity: 4 Severe percolation with stalactites formed

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5 2 EROSIONa Severity: 2 Slight wind erosion

b Severity: 3 Significant loss of surface to parapetstones caused by rain action

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Section Masonry Defects

5 3 FREEZE THAW DAMAGEa Severity: 2 Minor oss of surface to a pier

1 Severitv: 3 Sianificant loss of surface within arch barrel

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c Severitw 4 Severe loss of face at base of aaraaet

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Section Masonry efects

5 4 MISSING M SONRYa Severity: 3 Moderate loss of bricks

b Severity: 4 Severe loss of bricks

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c Severity: 5 - Failure due t missing bricks

. ...

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Section Masonry Defects

5 5 CRACKS THROUGH MORT Ra Severity: 4 Crack along line of joint; poor bondconstruction

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5 6 CRACKS THROUGH MASONRYa Severity: 3 - Crack in centre of stone abutment

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5 7

Section 5 Masonry Defects

CORROSION OF EMBEDDED MET LWORKa Severity: 2 Spalling of brickwork in jack arch due tocorrosion of metalwork


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Inspection Manualfor ighway Structures Volume2 Part B~5 0 MORTAR LOSSa Severity: 2 - oss of mortar from surface of joints inspandrel wall

b Severity: 4 - Extensive mortar loss

Y


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6

6 1

MiscellaneousMaterials efectsCAST IRON: CRACKING AND FRACTURE

a Severity: 3 Crack through abutment wall plate

b Severity: 4 Crack through cast iron frame

a

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6 2 CAST IRON: BLOWHOLESa Severity: 3 Blow hole in c st iron member

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Section 6 Miscellaneous Materials Defects

6 3 CAST IRON: CORROSIONa Severity: 3 Moderate corrosion on arch rib

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Insp ection Manual for Highway Structures Volume 2 art B

8 78

6.4 WROUGHT IRON: CORROSIONa Severity: 2 Minor cor ros ion

b. Severity: 3 Signi f icant corros io n to f lange and web ofxmugMlronbeam

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Section 6 Miscellaneous Materials Defects

c Severity: Perforationof web stiffener


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Inspection Manual for Highway Structures Volume2 art B

6 5 WROUGHT IRON: DELAMINATION

a Severity: Delamination of wrought iron section


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Section Miscellaneous Materials Defects

6 6 TIMBERa Severity: 4 Ends o walkway boards rotting

1 Severity: 5 Complete local decay o timber retaining wall

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Inspection Man ual for Highway Structures Volume 2 Part B

eferences for Part B1

2

Bridge Condition Indicators Volume 2:GuidanceNote on Bridge Inspection Reporting CountySurveyors Society 2002Addendum to CSS Bridge Condition IndicatorsVolume 2 County Surveyors Society 2004

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cknow edgernentsProject SponsorHighways Agency

Technical Project oard embersBrian HillBrian AlisonMartin ottsAlex GardnerMartin JacksonRichard McFarlaneTudor RobertsRonnie Wilson

Highways AgencyHighways AgencyHighways AgencyTransport ScotlandHerefordshire County CouncilRoyal Borough of KingstonTransport WalesDepartment for Regional DevelopmentNorthern Ireland Roads Service

Project TeamDr Vicky Vassou AtkinsDr Garry Sterritt AtkinsDr Roger Cole Atkinslain Kennedy Reid AtkinsDave Black AtkinsDr Navil Shetty Atkins


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Inspection Manual for ighwayStructures Volume

Technical dvice and ssistanceAcknowledgement is due to the wide range of bridgemanagers engineers technicians and inspectors who haveassisted in the development of the Manual through previouswork attending workshops reviewing drafts providingmaterial and photographs and general support.DisclaimerThe Highways Agency the Technical Project Board theProject Team and the Technical Advisors who produced thisDocument have endeavoured to ensure the accuracy of thecontents. However the guidance recommendationsandinformation given should always be reviewed by those usingthem in the light of the facts of their particular case andspecialist advice be obtained as necessary. No liability forloss or damage that may be suffered by any person ororganisation as a result of the use of any of the informationcontained here or as the result of any errors or omissions inthe information contained here is accepted by the HighwaysAgency the Technical Project Board the Project Team theTechnical Advisors and any agents or publishers working ontheir behalf.

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/2012

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