Assessing, Coding, and Marking of Highway Structures in Emergency Situations, Volume 3: Coding and Marking Guidelines (2016)

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This part of the field manual will discuss the specific PDA procedures and considerations for bridges, tunnels, walls, culverts, and overhead signs. Each chapter provides a general overview of the highway structure, a schematic, the PDA procedure, a list of elements, and the damage states to define minor, moderate, and severe damage levels for each element. Preliminary Damage Assessment of Highway Structures P A R T I I

Part II: PDA of Highway Structures 29 Bridges Bridges are the most common and complex type of highway structures in the United States. They are built with the purpose of providing passage over or under a physical object such as a watercourse, railway, road, or valley. Hence, collapse or closure of a bridge often has serious implications for the traveling public. Bridges play a critical role in the transport of emergency vehicles, personnel, and equipment in the aftermath of natural disasters. As a result their level of structural safety must be quickly evaluated. The NBI classifies 10 bridge materials and 23 bridge design types, as shown in Table 5-1. This information in the NBI should be accessible to the PDAR. Each bridge is composed of several key elements that function to provide resistance to loads. Figure 5-1 shows a schematic of the key bridge elements. Each of these elements needs to be assessed in the PDA stage. 5 Bridges Table 5-1. National Bridge Inspection Standards coding for bridge material (43A) and design (43B). NBIS Code 43A – Material NBIS Code 43B – Design Code Description Code Description 1 Concrete 1 Slab 2 Concrete continuous 2 Stringer/multi-beam or girder 3 Steel 3 Girder and floorbeam system 4 Steel continuous 4 Tee beam 5 Prestressed concrete* 5 Box beam or girders – multiple 6 Prestressed concrete continuous* 6 Box beam or girders – single or spread 7 Frame (except frame culverts) 7 Wood or timber 8 Orthotropic 8 Masonry 9 Truss – deck 9 Aluminum, wrought iron, or cast iron 10 Truss – thru 11 Arch – deck 0 Other 12 Arch – thru 14 Stayed girder 15 Movable – lift 16 Movable – bascule 17 Movable – swing 18 Tunnel 19 Culvert (includes frame culverts) 20 Mixed types 21 Segmental box girder 22 Channel beam 00 Other *Post-tensioned concrete should be coded as prestressed concrete. Source: FHWA (1995).

Part II: PDA of Highway Structures 30 Bridges 5.1 PDA Procedure for Bridges 1. Review the general PDA procedures detailed in Section 3.4. 2. Document PDARs’ names, IDs, bridge identification number, and arrival time. Mark the primary structure material. Take a photo of the ID placard and when possible take a sec- ond overall photo of the bridge. Photos taken at the site should preferably be geo-tagged. 3. Examine traffic flow on the bridge and mark on the assessment form. Although traffic may be using the bridge, that does not indicate the bridge is safe. Be sure to note how the bridge responds to traffic, particularly larger vehicles. Inspect all bridges assuming they may be damaged. 4. Make a quick visual inspection of the entire bridge. a. If the bridge has spans of different materials such as concrete, steel, or timber, evaluate each span separately. The coding/marking for the bridge will be based on the span type that produces the worst ratings. b. If the bridge structure is collapsed or non-functional (including totally or partially inundated), mark the structure as UNSAFE. c. In the case of hydro-hazards (flooding or storm surge), if the bridge deck is partially or totally inundated, mark the structure as UNSAFE. d. High water levels or high water velocities should be reported. (Note that some bridges may have high water level markings; others may require judgment). e. If deemed as UNSAFE, go to Step 10. 5. Begin by inspecting approaches and inspect the elements listed in Table 5-2. Scour may be visible or invisible. Note any signs of scour potential such as erosion around the founda- tion and abutment elements (refer to Section 4.9 for signs of scour). If scour is apparent, follow the procedure in the scour section of this manual (Section 4.9). Figure 5-1. Bridge schematic illustrating basic elements. Source: Modified from Missouri DOT (2014).

Part II: PDA of Highway Structures 31 Bridges 6. Document all appropriate damages (none, minor, moderate, severe) in the assessment form for each bridge element after inspection. (See Section 5.2 for specific guidance on elements and Chapter 10 for photographic examples). Provide comments and observa- tions in the assessment form. 7. Take photos of observed damage. When necessary for scale indications, use a tape mea- sure, person, clipboard, or other distinguishing object to relate size variations. 8. Determine an overall damage rating (0–100%) using Section 3.5.1. 9. Discuss the observations with the team members and come to a consensus for the bridge (INSPECTED or UNSAFE). In the case that team members are equally split on the deci- sion, classify as UNSAFE. 10. If any element damage is severe, mark the bridge as UNSAFE. 11. If UNSAFE, notify the ME immediately. 12. Place and secure the placard and appropriate decal in the predetermined location, in accordance with Section 2.3.1 of this manual. 13. Proceed to the next site. Table 5-2. Bridge inspection checklist. Element Check for: 1. Approach/ Embankment Raised or lowered, cracks, or buckling. Settlement of embankment. 2. Parapets, Handrails, and Curb Line Misalignment, bowing, dips, shifting, or separations. 3. Deck Cracks, spalling, missing concrete, alignment, deflection, cracks, or exposed rebars. 4. Expansion Joint Misalignment, cracks, spalling, exposed rebar, unusual openings, displacements, or torn expansion materials. 5. Abutments and Wingwalls Cracks, spalling, movement, or scour at the ground level. 6. Girder Misalignment, bending or buckling, spalling, or missing bolts or rivets. 7. Bearings Unseating, misalignment, unusual deformation, or sheared or bent bolts. 8. Bent Cap and Column Exposed rebar, bearing movement, missing keeper, chipped concrete, cracking, or movement at the ground level. 9. Foundation Liquefaction, sand boils, settlement, misalignment, or scour. 10. Geotechnical Landslides, liquefaction, lateral spreading, slope failures, soil fissures, or differential settlement. 11. Scour Water elevation, bridge closure water level, overtopping, debris buildup, or displacement. Source: Modified from Missouri DOT (2014) and O’Connor (2010).

Part II: PDA of Highway Structures 32 Bridges 5.2 Bridge Damage States Tables 5-3 through 5-13 provide more detailed information on damage states for bridge elements 1 through 10 in Table 5-2 [Damage states are modified from Missouri DOT (2014), O’Connor (2010), Ramirez et al. (2000a, 2000b), and Sardo et al. (2006)]. Refer to Section 4.9 for possible screening signs of scour. Table 5-3. Damage states for bridge approach/embankment. Minor Moderate Severe Approach slab settlement 0–1 inch Approach slab settlement between 1–6 inches Approach slab settlement over 6 inches Embankment settlement 0–6 inches Embankment settlement 6–12 inches Embankment settlement over 12 inches Table 5-4. Damage states for parapet, handrail, and curb line. Minor Moderate Severe Damage does not impede traffic Damage impedes traffic Damage severely disrupts traffic Table 5-5. Damage states for deck. Minor Moderate Severe Normal driving conditions Reduced driving speed or damage quickly repairable Impassable Localized crushing of concrete at joints Limited crushing of concrete over the full length of joint Crushing of concrete over the full length of joint or within the span Very slight misalignment of joints Moderate misalignment of joints Severe misalignment of joints Shifting of bearings Bearing/superstructure failure Differential settlement of deck panels Punching failure Table 5-6. Damage states for expansion joint. Minor Moderate Severe 0–1 in. offset in vertical or horizontal alignment 1–6 inches offset in vertical or horizontal alignment Over 6 inches offset in vertical or horizontal alignment

Part II: PDA of Highway Structures 33 Bridges Table 5-7. Damage states for abutments and wingwalls. Minor Moderate Severe Spalling at expansion joint Damage of pedestals and exposed anchor bolts Tilting or sliding of the wall Fine inclined cracks in wingwall Any other damage (e.g., cracks, spalling, rotation) Major horizontal cracks near mid-height of wall Minor localized spalling of concrete cover Moderate localized spalling of concrete cover Crushing of concrete at the bottom section of wall Major inclined flexural and shear cracking Major damage of back and side walls Scour compromising the structural integrity Minor Moderate Severe Minor localized spalling Shifting over bearings Unseating off bearings Table 5-10. Damage states for bearings. Minor Moderate Severe Minor flange buckling Buckling of flanges and web Major buckling of flanges and web Slight shifting over bearings Shifting over bearings Unseated off its bearings Slightly buckled lateral bracing Fracture of a bracing member Fracture of a critical bracing member Small fracture of flange extended over no more than 1 inch Serious fracture of flange extended over 1/4 of the flange width Localized yielding of bolts-holes, at bolted connection Sheared bolts at bolted connections Table 5-9. Damage states for steel girder. Minor Moderate Severe Fine closed flexural cracks Closed flexural cracks Open flexural cracks Slight shifting over bearings Shifting over bearings Unseated bearings Localized spalling of concrete cover near ends Localized spalling of concrete cover Spalling of concrete cover and exposed strands at girder ends Fine closed shear cracks Shear cracks Crushing of concrete Table 5-8. Damage states for concrete girder.

Part II: PDA of Highway Structures 34 Bridges Minor Moderate Severe Foundation settlement 0–2 inches Foundation settlement 2–6 inches Foundation settlement over 6 inches Minor foundation scour Moderate foundation scour Severe foundation scour Low-velocity flow Moderate-velocity flow High-velocity flow Evidence of foundation movements, but net displacements are small Distinct and measurable net displacements, but repairable Distinct and measurable net displacements that are difficult to repair or un- repairable Table 5-12. Damage states for foundation. Minor Moderate Severe Landslides/rockfalls 0–4 inches Landslides/rockfalls 4–12 inches Landslides/rockfalls over 12 inches Settlements 0–2 inches Settlements 2–6 inches Settlements over 6 inches Liquefaction 0–1 inch Liquefaction 1–4 inches Liquefaction over 4 inches Lateral spreading 0–1 inch Lateral spreading 1–4 inches Lateral spreading over 4 inches Slope failure 0–1 inch Slope failure 1–4 inches Slope failure over 4 inches Soil fissures 0–1 inch Soil fissures 1–4 inches Soil fissures over 4 inches Minor differential settlement (0–1 inch) Moderate differential settlement (1–4 inches) Severe differential settlement (over 4 inches) Table 5-13. Damage states for geotechnical elements. Minor Moderate Severe Fine shear cracks Very visible shear cracks Steep shear cracks Vertical cracks in beams or horizontal cracks in columns and piers Diagonal cracks in beams and/or loss of concrete cover Bar buckling in beams, columns, and piers Small transverse cracks at the column ends (without longitudinal cracks) Localized crushing of concrete Crushing of concrete cover Slight spalling of concrete cover Major spalling of concrete cover Slightly exposed transverse and main bars Exposed transverse and main bars Fractured transverse ties Table 5-11. Damage states for bent cap and column.

Part II: PDA of Highway Structures 35 Bridges 5.3 Bridge Assessment Form Figure 5-2 shows the PDA form for bridges. Figure 5-2. Bridge assessment form (page 1/2).

Part II: PDA of Highway Structures 36 Bridges Figure 5-2. (page 2/2).

Part II: PDA of Highway Structures 37 Tunnels Tunnels are often critical links in the transportation network as many are built when no other transportation options are feasible. The structural integrity of tunnels is critical to the operation of the transportation network. There are four common shapes of highway tunnels: circular, rectangular, horseshoe, and oval/egg (FHWA 2005). Figure 6-1 presents a typical schematic used for inspection of circular tunnels. Although this schematic is for circular tunnels, the elements and layout are similar with rectangular, horseshoe, and oval tunnels. When applicable, the upper and lower plenums should be inspected for damage. Circular tunnels use a clock designation system to determine the location of damage with respect to the tunnel. This clock designation system assumes the section cut is looking up-station and is applicable to other types of tunnels as well. 6 Tunnels Figure 6-1. Circular tunnel schematic and clock system designations. Source: Modified from FHWA (2005).

Part II: PDA of Highway Structures 38 Tunnels 6.1 PDA Procedure for Tunnels The PDA can be conducted on short tunnels. However, for long tunnels (e.g., > 1,000 feet), it is recommended to split the tunnel into sections and evaluate each section as a new structure. If there are only a few tunnels in the area, it may be preferable to skip the PDA and immediately proceed with a DDA of tunnels so that trained/certified inspectors can perform the assessment. 1. Review the general PDA procedures detailed in Section 3.4. 2. If necessary, assist in rescuing and/or helping motorists to exit the tunnel as quickly as possible. 3. If significant flooding, fire, or other internal damage is viewed from outside the tunnel making it unsafe, the PDAR should notify the ME to proceed with DDA. In this event, PDARs should look to assess any obvious signs of damage and report these as a PDA evaluation. 4. Work with maintenance crews to adjust ventilation equipment as necessary if a fire event has resulted. 5. Make a visual inspection of the tunnel entrance prior to entering. a. If the tunnel is partially or fully collapsed or non-functional, mark the tunnel as UNSAFE. b. If the tunnel is partially or totally inundated, mark the tunnel as UNSAFE. c. If deemed as UNSAFE, go to Step 9. d. If at any time during the PDA the tunnel appears unsafe, exit the tunnel immediately. 6. Begin inspecting the tunnel by examining the elements in Table 6-1. For long tunnels (> 1,000 feet), examine each 1,000-foot segment as a new tunnel. 7. Document all appropriate damages (none, minor, moderate, severe) in the assessment form for each tunnel element after inspection. See Section 6.3 for specific guidance on elements and Chapter 11 for photographic examples. Provide comments and observa- tions in the assessment form. 8. Make an overall damage rating (0–100%) using Section 3.5.1. 9. If any element damage is severe, mark the tunnel as UNSAFE. Discuss the observa- tions with the team members and come to a consensus for the tunnel (INSPECTED or UNSAFE). For long tunnels, when discussing the overall marking, use the worst case tun- nel segment to mark the whole tunnel. 10. If UNSAFE, notify the ME immediately.

Part II: PDA of Highway Structures 39 Tunnels Table 6-1. Tunnel inspection checklist. Element Material Check for: Liner Steel Corrosion, cracking, connections, distortion, leakage Cast-in- place concrete Delamination/spall/patched area, exposed rebar, efflorescence/rust staining, cracking, distortion, leakage Precast concrete Delamination/spall/patched area, exposed rebar, efflorescence/rust staining, cracking, distortion, leakage Shotcrete Delamination/spall/patched area, exposed rebar, efflorescence/rust staining, cracking, distortion, leakage Timber Connection, decay/section loss, check/shake, crack, split/delamination, distortion, leakage Masonry Efflorescence/rust staining, mortar breakdown, split/spall, patched area, masonry displacement, distortion, leakage Unlined Loose or cracked rock, roof bolt distress, patched areas, leakage Roof Girder Steel Corrosion, cracking, connections, distortion Concrete Delamination/spall/patched area, exposed rebar, efflorescence/rust staining, cracking Prestressed concrete Delamination/spall/patched area, exposed rebar, exposed prestressing, cracking, efflorescence Interior Walls Concrete Delamination/spall/patched area, exposed rebar, efflorescence/rust staining, cracking Portal Concrete Delamination/spall/patched area, exposed rebar, efflorescence/rust staining, cracking, settlement Masonry Efflorescence/rust staining, mortar breakdown, split/spall, patched area, masonry displacement, settlement Ceiling Slab Concrete Delamination/spall/patched area, exposed rebar, efflorescence, cracking Ceiling Girder Steel Corrosion, cracking, connections, distortion Concrete Delamination/spall/patched area, exposed rebar, efflorescence/rust staining, cracking Prestressed concrete Delamination/spall/patched area, exposed rebar, exposed prestressing, cracking, efflorescence/rust staining Ceiling Panels Steel Corrosion, cracking, connections, distortion Concrete Delamination/spall/patched area, exposed rebar, efflorescence/rust staining, cracking Invert Slab Concrete Delamination/spall/patched area, exposed rebar, efflorescence/rust staining, cracking Slab-on- Grade Concrete Delamination/spall/patched area, exposed rebar, cracking, settlement Invert Girder Steel Corrosion, cracking, connections, distortion Concrete Delamination/spall/patched area, exposed rebar, efflorescence, cracking Prestressed concrete Delamination/spall/patched area, exposed rebar, exposed prestressing, cracking, efflorescence/rust staining Source: Modified from FHWA (2010).

Part II: PDA of Highway Structures 40 Tunnels 6.2 Tunnel Cracking Types A crack is caused by tensile forces exceeding the tensile strength of the concrete. Cracks are categorized as follows (FHWA 2005): • Transverse cracks—Fairly straight cracks that are roughly perpendicular to the span direc- tion of the concrete member. • Longitudinal cracks—Fairly straight cracks that run parallel to the span of the concrete slab or beam. • Horizontal cracks—Generally occur in walls but may exist on the sides of beams. Similar in nature to transverse cracks. • Vertical cracks—Occur in walls and are similar to longitudinal cracks. • Diagonal cracks—Roughly parallel to each other in slabs. Usually shallow and are of vary- ing length, width, and spacing. • Pattern or map cracks—Interconnected cracks that vary in size and width. Found in both walls and slabs. • D-cracks—Series of fine cracks at close intervals with random patterns. • Random cracks—Irregular cracks on the surface of the concrete. 6.3 Tunnel Damage States Tables 6-2 through 6-7 provide damage states for tunnels [modified from FHWA (2005)] and incorporate observations from Lanzano et al. (2008). Table 6-2. Damage states for scaling. Minor Moderate Severe Loss of surface mortar 0– 0.25 inch deep Loss of surface mortar from 0.25–1 inch Loss of coarse aggregate particles as well as surface mortar depth of loss over 1 inch Table 6-3. Damage states for cracking. Minor Moderate Severe 0–0.03 inch 0.03–0.125 inch Over 0.125 inch

Part II: PDA of Highway Structures 41 Tunnels Table 6-4. Damage states for spalling. Minor Moderate Severe 0–0.5 inch deep or 3–6 inches in diameter 0.5–1 inch deep and 3–6 inches in diameter More than 1 inch deep and greater than 6 inches in diameter Minor Moderate Severe Leaving holes 0–0.4 inch in diameter Leaving holes 0.4–2 inches in diameter Leaving holes between 2–3 inches in diameter; pop-outs larger than 3 inches in diameter are spalls Table 6-5. Damage states for pop-outs. Minor Moderate Severe Concrete surface is wet with no drips Flows at a volume less than 30 drips/minute Flows at a volume greater than 30 drips/minute Table 6-6. Damage states for leakage. Minor Moderate Severe Light corrosion formation pitting the paint surface Corrosion formation with scales or flakes Stratified corrosion or corrosion scale with pitting of the metal surface Table 6-7. Damage states for corrosion.

Part II: PDA of Highway Structures 42 Tunnels 6.4 Tunnel Assessment Form Figure 6-2 shows the PDA form for tunnels. Figure 6-2. Tunnel assessment form (page 1/2).

Part II: PDA of Highway Structures 43 Tunnels Figure 6-2. (page 2/2).

Part II: PDA of Highway Structures 44 Culverts Culverts enable water to pass below a road. They are designed for both hydraulic and struc- tural loadings. The impacts of emergency events can increase the hydraulic loading and lead to serious failures or collapse of the culvert. Culverts are typically considered minor struc- tures, but they are of great importance for adequate drainage and the integrity of the trans- portation network (Marek 2011). Typical culvert shapes are circular/elliptical, arch, or rectangular (box) in cross section (see Figure 7-1). A typical culvert is characterized by basic elements that include the material and cross-sectional shape, invert, roadway, embankment, and headwall and wingwall (see Figure 7-2). Culvert materials include concrete, corrugated aluminum or steel, and plastic. 7 Culverts Source: Modified from Highways Agency (2007). Figure 7-1. Common types and cross sections of pipe culverts (top four) and box culverts (bottom two).

7.1 PDA Procedure for Culverts 1. Review the general PDA procedures detailed in Section 3.4. 2. Document PDARs’ names, IDs, structure identification number, and arrival time. Mark the shape and material of the culvert. Take a photo of the ID placard and when possible take a second overall photo of the culvert. Photos taken at the site are preferably geo-tagged. 3. Examine traffic flow on the culvert and mark on the assessment form. 4. Make a quick visual inspection of the entire culvert. a. If the culvert is collapsed or non-functional (including totally or partially inundated), mark the culvert as UNSAFE. b. In the case of hydro-hazards (flooding, storm surge, debris backup), if the roadway above the culvert is partially or totally inundated, mark the culvert as UNSAFE. c. High water levels or high water velocities should be reported. (Note that some culverts may have high water level markings; others may require judgment). d. If deemed as UNSAFE, go to Step 10. 5. Begin PDA evaluation by reviewing the elements listed in Table 7-1. If scour is apparent, follow the procedure in the scour section of this manual (Section 4.9). Part II: PDA of Highway Structures 45 Culverts Figure 7-2. Culvert schematic. Element Check for: 1. Embankment Depressions, settlement, slumps, voids 2. Roadway Cracking, spalling, patches, potholes 3. Culvert condition Visible damage, settlement, misalignment, separation, cracking, spalling 4. Headwall /wingwall Offset, alignment, cracking, spalling, settlement 5. Invert Cracking, spalling, corrosion, scaling, buckling 6. Scour Undermining, erosion, settlement Table 7-1. Culvert inspection checklist.

6. Document all appropriate damages (none, minor, moderate, severe) in the assessment form for each culvert element after inspection. See Section 7.2 for specific guidance on elements and Chapter 12 for photographic examples. Provide comments and observa- tions in the assessment form. 7. Take photos of observed damage. When necessary for scale indications, use a tape mea- sure, person, clipboard, or other distinguishing object to relate size variations. 8. Determine an overall damage rating (0–100%) using Section 3.5.1. 9. Discuss the observations with the team members and come to a consensus for the culvert (INSPECTED or UNSAFE). In the case that team members are equally split on the deci- sion, classify as UNSAFE. 10. If any element damage is severe, mark the culvert as UNSAFE. 11. If UNSAFE, notify the ME immediately. 12. Place and secure the placard and appropriate decal in the predetermined location, in accordance with Section 2.3.1 of this manual. 13. Proceed to the next site. 7.2 Culvert Damage States Tables 7-2 through 7-9 provide damage states for culverts [modified from New York State DOT (NYSDOT 2006) and Trevis (2013)]. Minor Moderate Severe Minor erosion away from the structure Moderate erosion near the structure with no cracks on the headwall Slope stability problem near the culvert and/or extensive hairline cracks near the headwall Minor settlement and/or small depressions Depressions, soil cracks, slumps, and/or voids along the embankment Large depressions, soil cracks, slumps, and/or voids along the shoulder Table 7-2. Damage states for culvert embankment. Minor Moderate Severe Not more than minor settlement of the roadway with no cracks Minor settlement of the roadway or major cracks Heavy settlement of the roadway or major cracks Minor misalignment of guardrail posts Significant misalignment of several guardrail posts in a row Extensive vertical or horizontal misalignment of several guardrail posts Minor isolated cracking and spalled areas Significant cracking, spalling, potholes, or maintenance patches affecting up to 20% of any single travel lane Extensive cracking, spalling, potholes, or maintenance patches affecting up to 20% of any single travel lane Table 7-3. Damage states for roadway. Part II: PDA of Highway Structures 46 Culverts

Part II: PDA of Highway Structures 47 Culverts 81/ Minor Moderate Severe Longitudinal cracks 0– inch in width Longitudinal cracks between –¼ inch in width Severe cracking and spall greater than ½ inch on culvert walls Spalls 0–¼ inch deep Spalls larger than ½ inch deep, and/or spalls have exposed rebar Spalls greater than ½ inch on culvert walls Minor separation of joints 0–1 inch Significant separation of joints between 1–3 inches Severe separation of joints greater than 3 inches Sections of culvert are partially collapsed Major corrosion of rebar 81/ Table 7-4. Damage states for concrete culvert. Minor Moderate Severe Minor cracking around bolt holes or seams at isolated sections Significant cracking and/or deterioration along bolt holes and isolated seams of plates Severe cracking and/or deterioration along bolt holes or plates Minor corrosion, pitting, and/or isolated distortions Significant deterioration and pitting with isolated section loss and holes Large holes and/or section loss throughout barrel Table 7-5. Damage states for metal culvert. Minor Moderate Severe Minor isolated tear caused by debris 0–6 inches in length and 0–½ inch in width Cracking, splits, or tears over 6 inches in length and up to ½–¾ inch in width Cracking, splits, punctures, or tears over 6 inches in length and over 1 inch in width Isolated perforations caused by abrasion Perforations caused by abrasion Loss of barrel material Table 7-6. Damage states for plastic culvert.

Part II: PDA of Highway Structures 48 Culverts Minor Moderate Severe Minor corrosion and abrasion Moderate corrosion and abrasion Heavy corrosion and abrasion Minor waterway blockage due to debris Moderate obstruction due to debris Maximum waterway is blocked due to debris No deformation Ends totally/partially broken Table 7-8. Damage states for inverts. Minor Moderate Severe Minor undermining of the culvert barrel or top of footing is exposed Significant undermining of the culvert barrel or undermining of the footing Extensive undermining of the culvert barrel or footing resulting in a possible settlement Culvert span to scour hole depth ratio is between 5 and 10 Culvert span to scour hole depth ratio is between 2 and 5 Culvert span to scour hole depth ratio is less than 2 Table 7-9. Damage states for scour. Minor Moderate Severe Minor spalls and cracks 0– inch in width Significant spalls and cracks –¼ inch in width Extensive spalls and cracks over ¼ inch in width No exposed rebar or surface evidence of rebar corrosion Exposed rebar with corrosion Corrosion of rebar and extensive section loss Minor differential or rotational settlement Significant differential or rotational settlement Extensive settlement of the wall Extensive deterioration with loss of concrete 81/ 81/ Table 7-7. Damage states for headwall/wingwall.

Part II: PDA of Highway Structures 49 Culverts 7.3 Culvert Assessment Form Figure 7-3 shows the PDA form for culverts. Figure 7-3. Culvert assessment form (page 1/2).

Part II: PDA of Highway Structures 50 Culverts Figure 7-3. (page 2/2).

Part II: PDA of Highway Structures 51 Walls For the purpose of this manual, walls are defined as any retaining, self-supported, or quay wall, regardless of height. In retaining walls, the primary function is to act as a retaining structure for embankments, fill slopes, or natural slopes. They can be externally stabilized structures, internally stabilized structures, fill-type retaining walls, cut-type retaining walls, mechanically stabilized earth walls, or other geotechnical structures depending on the geo- technical mechanism used to resist lateral loads. Table 8-1 provides a simplified classification of wall structural types. 8 Walls Fill-constructed walls (built from the bottom up) Externally stabilized Internally stabilized Rigid gravity walls Masonry gravity walls (stone, concrete, brick) Cast-in-place (CIP) concrete gravity walls Rigid semi-gravity walls CIP concrete cantilever T-wall or L-wall (including counterforted walls and buttressed walls) Prefabricated modular gravity walls Crib wall Bin wall Gabion wall Rockeries Mechanically stabilized earth (MSE) walls Segmental, precast facing MSE wall Prefabricated modular block facing Flexible facing (geotextile, geogrid, or welded-wire facing) Reinforced soil slopes Cut-constructed walls (built from the top down) Externally stabilized Internally stabilized Non-gravity cantilevered (embedded) walls Sheet-pile wall (steel, concrete, timber) Soldier pile and lagging wall Slurry (diaphragm) wall Tangent/secant pile walls Soil-mixed wall (SMW) Anchored walls* Ground anchor (tieback) Deadman anchor In-situ reinforced walls Soil-nailed wall Root-pile wall Insert pile wall Self-Supporting Walls Quay walls Sea walls Noise walls *Anchors are often used in combination with embedded walls of various types and may also be used in combination with semi-gravity cantilever walls. Source: Modified from Sabatini et al. (1997). Table 8-1. Classification of wall structural types.

Part II: PDA of Highway Structures 52 Walls Basic elements of a highway wall structure include the foundation system, sub-drainage system, and material. Walls themselves are made up of concrete, masonry, wood, or steel and are supported by gravity, piles, or ties to resist the geotechnical elements behind the wall. Table 8-2 provides a condition checklist breaking down primary and secondary exterior wall elements. This checklist was reproduced from the FHWA and the National Park Service Retaining Wall Inventory Field Guide. Used in conjunction with Table 8-3, the appropriate wall elements that should be given inspection ratings can be identified. Prior to arriving at the inspection site, PDARs should determine the wall type and appropriate primary and second- ary elements using Table 8-3. Primary element condition ratings Piles and shafts Soldier piles, sheet piles, micropiles or drilled shafts, as well as supplemental structures such as walers, comprising part or all of the visible wall Lagging Structural lagging between piles and walers Anchor heads All visible parts of tieback anchor, including pad (generally observed without removing cap) Wire/Geosyn. Facing Elements Visible facing/basket wire, soil reinforcing elements, hardware cloth, geotextile/geogrids and facing stone Bin or crib Visible portion of cellular gravity wall Concrete Visible precast or cast-in-place concrete wall and footing elements (does not include piles, lagging, crib blocks, manufactured block/brick, and architectural facing) Shotcrete Visible shotcrete (does not include piles, lagging, architectural facing, or other specific elements) Mortar Visible mortar used between uncut or masoned rock, manufactured blocks or brick, or used for wall repairs Manufactured block/brick Manufactured blocks and bricks, including concrete masonry unit’s segmental blocks, large gravity blocks, etc. (does not include concrete lagging or crib wall components) Placed stone Dry-laid or mortar-set uncut rock Stone masonry Dry-laid or mortar-set cut rock Wall foundation material* Soil or rock immediately adjacent to and supporting the wall Other primary wall element Any primary wall element not listed Secondary element condition ratings Wall drains* Function and capacity of visible drain holes, pipes, slot drains, etc., that provide wall subsurface drainage Road/Sidewalk/ Shoulder Road and/or sidewalk surface above or below a wall, and within the influence of the wall Upslope Groundslope area above a wall affecting wall condition and/or performance Downslope Groundslope area below the wall, distinct from the wall foundation material, affecting wall condition and/or performance Lateral slope* Groundslope laterally adjacent to a wall affecting wall condition and/or performance *Wall elements that should always be rated for all wall types Source: DeMarco et al. (2010). Table 8-2. Primary and secondary wall elements.

Part II: PD A of H ighw ay Structures 53 W alls PR IM AR Y E LEM EN TS Pil es an d S ha s La gg ing An ch or He ad s Wi re/ Ge os yn .Fa cin g E lem en ts Bin or Cri b Co nc ret e Sh otc ret e Mo rta r Ma nu fac tur ed Br ick Bl oc k Pla ce d S ton e Sto ne Ma so nry Wa ll F ou nd ati on Ma ter ial Ot he r P rim ary Ele me nt SE CO ND AR Y E LE ME NT S Wa ll D rai ns Ar ch ite ctu ral Fa cin g Tra ffic Ba rri er/ Fe nc e Ro ad /Si de wa lk/ Sh ou lde r Up slo pe Do wn slo pe La ter al Slo pe Ve ge ta† on Cu lve rt Cu rb/ Be am /D itc h Ot he r S ec on da ry Ele me nt W AL L P ER FO RM AN CE Pe rfo rm an ce Wall Type A n c h o r (AH) Anchor Tieback H-Pile XXOOOXXXXX (AM) Anchor Micropile XXOOOXXXX (AS) Anchor, Tieback Sheet Pile XXOOOXXXX (BC) Bin, Concrete XXOOOXXX (BM) Bin, Metal XXOOOXXX (CL) Canlever, Concrete XXOOOXXX (CP) Canlever, Soldier Pile XXOOOXXXX (CS) Canlever, Sheet Pile XXOOOXXX (CC) Crib, Concrete XXOOOXXX (CM) Crib, Metal XXOOOXXX (CT) Crib, Timber XXOOOXXX (GB) Gravity Concrete Block Brick XXOOOXXXX (GC) Gravity, Mass Concrete XXOOOXXX (GD) Gravity, Dry Stone XXOOOXXOO (GG) Gravity, Gabion XXOOOXXX (GM) Gravity, Mortared Stone XXOOOXXOOX (MG) MSE, Geosyn. Wrapped Face XXOOOXXX (MP) MSE, Precast Panel XXOOOXXX (MS) MSE, Segmental Block XXOOOXXX (MW) MSE, Welded Wire Face XXOOOXXX (SN) Soil Nail XXOOOXXX (TP) Tangent Secant Pile XXOOOXXX (OT) Other, User Defined XXOOOXX r o h c n A y t i v a r G B i n C a n  l e v e C r i b M S E O t h e r Road/Sidewalk Shoulder: Rate only when these elements lie within the influence of the wall. The shoulder is generally defined as extending no greater than 5  horizontally from the roadway sidewalk and less than -5  ver‚cal offset. Upslope: Rate the upslope condi‚on for all walls above roadway grade, regardless of slope ra‚o. Rate the upslope condi‚on for all walls below roadway grade, regardless of slope ra‚o, when the ver‚cal offset to the wall from the roadway shoulder is greater than 5 . Otherwise evaluate the condi‚on of the upslope under the "Road/Sidewalk/Shoulder" element. Downslope: Rate the downslope condi‚ons for all walls below roadway grade, regardless of slope ra‚o. Rate the downslope condi‚on for all walls above roadway grade, regardless of slope ra‚o, when the ver‚cal offset to the wall from the roadway shoulder is greater than 5  (otherwise, evaluate the condi‚on of the downslope under the "Road/Sidewalk/Shoulder" element. Notes: X = Wall element that should always be rated for the given wall type (others may also apply) O = 1 of 2 primary wall elements required depending on material observed = 2 of 3 secondary wall elements requried depending on wall loca‚on rela‚ve to roadway. Source: Modified from DeMarco et al. (2010). Table 8-3. Wall elements that should be rated based on the wall structural type.

Part II: PDA of Highway Structures 54 Walls 8.1 PDA Procedure for Walls 1. Review the general PDA procedures detailed in Section 3.4. 2. Arrive at the inspection site and determine the traffic level surrounding the wall. Docu- ment PDARs’ names, IDs, structure identification number, and arrival time. 3. Identify whether any wall damage or debris: a. Presents an immediate safety hazard or impedes traffic (UNSAFE) b. Poses an impending hazard to the roadway (UNSAFE) c. Could be cleaned up by maintenance crews relatively quickly (UNSAFE—make a note of maintenance needs on the assessment form) d. Is self-contained on the side of the road (INSPECTED, but make a note that repairs are needed). 4. Determine the structural type. a. If the wall type is known, use Table 8-3 to determine the appropriate primary and secondary elements to inspect. b. If the wall type is not known, inspect at minimum, the wall foundation material, wall drains, and wall performance. Inspect any other wall elements based on judgment. 5. Take a photo of the ID placard and when possible take a second overall photo of the wall. Photos taken at the site are preferably geo-tagged. 6. Begin PDA according to the initial wall items listed in the assessment form (wall perfor- mance, corrosion/weathering, cracking/breaking, distortion/deflection, and lost bearing/ missing elements) as well as the primary and secondary elements (Table 8-2) defined using Step 4. 7. Document all appropriate damages (none, minor, moderate, severe) in the assessment form for each wall element after inspection. See Section 8.2 for specific guidance on ele- ments and Chapter 13 for photographic examples. Provide comments and observations in the assessment form. 8. Determine an overall damage rating (0–100%) using Section 3.5.1. 9. Code and mark the structure as INSPECTED or UNSAFE after completing the assess- ment form. 10. If UNSAFE, notify the ME immediately. 11. Place and secure the placard and appropriate decal in the predetermined location, in accordance with Section 2.3.1 of this manual. 12. Proceed to the next site. 8.2 Wall Damage States Tables 8-4 through 8-9 provide information on damage states of walls, as modified from DeMarco et al. (2010).

Part II: PDA of Highway Structures 55 Walls Minor Moderate Severe Observation of minor distress Observations of element distress combinations that indicate wall component problems Combined element distresses indicating serious stability problems with components or global wall stability Global wall rotation, settlement, and/or overturning Table 8-4. Damage states for wall performance. Minor Moderate Severe Evidence of minor corrosion/staining, contamination, or cracking/spalling Moderate corrosion/ staining, contamination or cracking/spalling Metallic elements are corroded Minor weathering/ weakening of bedrock, softening of soil, or saturated ground conditions Significant weathering/ weakening of bedrock, softening of soil, or saturated ground conditions Extensive weathering/ weakening of bedrock, softening of soil, or saturated ground conditions Minor impacts from vegetation within the wall or within adjacent elements Moderate impacts from vegetation are evident within the wall adjacent elements Severe impacts from vegetation are evident within the wall or within adjacent elements Concrete/shotcrete is extensively spalled, cracked, and/or weakened Table 8-5. Damage states for corrosion/weathering. Minor Moderate Severe Evidence of minor element cracking, breaking, or damage Localized element cracking, breaking, abrasion, and/or drainage Extensive severe element cracking, breaking, abrasion or damage Concrete, shotcrete, and mortar is still sound, durable, and shows little or no signs of shrinkage, cracking, or spalling Concrete, shotcrete, and mortar is occasionally soft or drummy, has lost durability, and shows cracking and/or spalling Concrete, shotcrete, and mortar is consistently soft, drummy, or missing and shows pervasive cracking and/or spalling intercepting corroding reinforcement Drains are open and in working order but contain minimal debris Drains not fully operational Drainage is missing, damaged, or clogged Table 8-6. Damage states for cracking/breaking.

Part II: PDA of Highway Structures 56 Walls Minor Moderate Severe Small, localized soil displacements but no signs of significant settlement, bulging, bending, heaving, or distortion/deflection Significant localized settlement, bulging, bending, heaving, misalignment, distortion, deflection, and/or displacement Excessive settlement, bulging, bending, heaving, distortion, misalignment, deflection, and/or displacement Table 8-7. Damage states for distortion/deflection. Minor Moderate Severe No wall elements are missing but may have minor cosmetic defects Some wall elements are missing (e.g., chinking, lagging, brickwork) or non-functional Many of key wall elements are missing (e.g., placed wall stone, chinking, lagging), no longer bearing, or non- functional Foundation soils/rock are more than adequate to support the wall, consistently dense, drained, and strong but slight soil displacements may be apparent Foundations susceptible to erosion, scour, or vegetation impacts Foundation soils/rock show signs of failure, excessive settlement, scour, erosion, substantial voids, bench failure, or slope over-steepening or may be adversely affected by vegetation No slope failures have occurred but surficial erosion may be present Isolated slope failures have occurred Substantial slope failures have occurred Wall elements are still fully bearing against retained soil/rock units but may show slight damage Localized open voids exist along the back and top of the wall Table 8-8. Damage states for lost bearing/missing elements. Minor Moderate Severe Low extent of low severity stress High extent of low severity stress Medium-to-high extent of high severity stress Distress does not significantly compromise the element function Distress does not compromise element function, but lack of treatment may lead to impaired function Element is no longer serving intended function Distress present over a modest amount of the wall Elements will need to be mitigated in order to avoid significant repairs or element replacement Marginally functioning, severely distressed wall element in jeopardy of failing without element repair Table 8-9. Damage states for primary and secondary wall elements.

Part II: PDA of Highway Structures 57 Walls 8.3 Wall Assessment Form Figure 8-1 shows the PDA form for walls. Figure 8-1. Wall assessment form (page 1/2).

Part II: PDA of Highway Structures 58 Walls Figure 8-1. (page 2/2).

Part II: PDA of Highway Structures 59 Overhead Signs Overhead signs play a vital role in communicating messages to safely direct traffic. They can be sign bridges, cantilever sign structures, or mast arm structures. The nomenclature used in Figure 9-1 is consistent with AASHTOWare™ Bridge Manage- ment software (formerly, Pontis) based systems and the nomenclature developed by Garlich and Thorkildsen (2005). 9 Overhead Signs Source: Modified from Garlich and Thorkildsen (2005). Figure 9-1. Overhead sign schematic.

Part II: PDA of Highway Structures 60 Overhead Signs 9.1 PDA Procedure for Overhead Signs 1. Review the general PDA procedures detailed in Section 3.4. 2. Examine the surrounding traffic and determine if inspection is safe. 3. Identify whether any sign damage or debris: a. Presents an immediate safety hazard or impedes traffic (UNSAFE) b. Poses an impending hazard to the roadway (UNSAFE) c. Could be cleaned up by maintenance crews relatively quickly (UNSAFE, make a note of maintenance needs on the assessment form) d. Is self-contained on the side of the road (INSPECTED, but make a note that repairs are needed). 4. Take a photo of the ID placard and when possible take a second overall photo of the wall. Photos taken at the site are preferably geo-tagged. 5. Begin inspecting elements in numerical order starting from the foundation and working skyward (use Table 9-1 for reference). 6. Document all appropriate damages (none, minor, moderate, severe) in the assessment form for each sign element after inspection. See Section 9.2 for specific guidance on ele- ments and Chapter 14 for photographic examples. Provide comments and observations in the assessment form. 7. Determine an overall damage rating (0–100%) using Section 3.5.1. 8. Code and mark the structure as INSPECTED or UNSAFE after completing assessment form. 9. If UNSAFE, notify the ME immediately. Elements Check for: 1. Foundation Cracking, spalling, and/or exposed rebar. Rust, surface pitting, and corrosion. 2. Anchor bolts Corrosion, misalignment, loose bolts, cracking, sheared bolts, and missing. 3. Base plate Corrosion, failed protective coating, and section loss. 4. Column support Corrosion, section loss, water, and plumbness. 5. Column to arm/chord connection Corrosion, section loss, and misalignment. 6. Truss chord/arms Corrosion, section loss, and misalignment. 7. Truss struts Corrosion, section loss, misalignment, and cracking. 8. Chord splice connections Corrosion, section loss, misalignment, and element defects. 9. Sign frame and L- brackets Loose connections, missing connections, deterioration, and cracking. 10. Sign panel Loose connections, deterioration, or loss of legibility. 11. Catwalk Deterioration, loose connections, misalignment, and damaged gratings. Source: Modified from Garlich and Thorkildsen (2005). Table 9-1. Overhead sign inspection checklist.

Part II: PDA of Highway Structures 61 Overhead Signs 10. Place and secure the placard and appropriate decal in the predetermined location, in accordance with Section 2.3.1 of this manual. 11. Proceed to the next site. 9.2 Overhead Sign Damage States Tables 9-2 through 9-12 provide more detailed information on damage states for overhead signs, as modified from Garlich and Thorkildsen (2005). Minor Moderate Severe Concrete foundation: Minor cracks and spalls but no exposed reinforcing Concrete foundation: Some delaminations and/or spalls and some reinforcing exposed Concrete foundation: Corrosion of reinforcement and/or loss of concrete Steel foundation: Surface rust and/or surface pitting Steel foundation: Corrosion of rebar present but loss of section is incidental and doesn’t affect serviceability Steel foundation: Sufficient section loss of steel Advanced deterioration Table 9-2. Damage states for foundation. Minor Moderate Severe Minor corrosion of the element present Moderate corrosion of the element present Heavy corrosion of the element present Anchor nuts misaligned or not fully engaged Bolts are cracked/sheared or multiple anchor nuts are loose/missing One or two loose nuts, but doesn’t affect serviceability Table 9-3. Damage states for bolts. Minor Moderate Severe Minor surface corrosion present Any protective coating present has failed Cracks present on the base plate to column support connection weld Surface pitting present but any section loss from corrosion is measurable Section loss is sufficient to limit serviceability Table 9-4. Damage states for base plate.

Part II: PDA of Highway Structures 62 Overhead Signs Minor Moderate Severe Minor damage or corrosion is present with no section loss Moderate damage or corrosion is present Heavy damage or corrosion of elements with localized section loss Handhole covers or post caps are missing Standing water observed inside the post Misaligned or have severe impact damage Column supports out of plumb Table 9-5. Damage states for column support. Minor Moderate Severe Minor corrosion with no section loss Moderate corrosion or damage is present to one or more components Major or multiple element defects Minor misalignments Significant misalignment of components Table 9-6. Damage states for column to arm/chord connection. Minor Moderate Severe Minor corrosion with no section loss Moderate corrosion or damage is present to one or more components Major or multiple element defects or section loss Minor misalignments Significant misalignment of components Cracks propagating into any truss member Table 9-7. Damage states for truss chords/arms. Minor Moderate Severe Minor corrosion with no section loss Moderate corrosion or damage is present to one or more components Major or multiple element defects or section loss Minor misalignments Significant misalignment of components Cracks propagating into any chord Table 9-8. Damage states for truss struts.

Part II: PDA of Highway Structures 63 Overhead Signs Minor Moderate Severe Minor corrosion with no section loss Moderate corrosion or damage is present to one or more components Major or multiple element defects or section loss Minor misalignments Significant misalignment of components Table 9-9. Damage states for chord splice connections. Minor Moderate Severe An occasional loose connection nut Multiple loose/missing backing strip nuts Connection components cracked, sheared, or missing nuts Significant deterioration or impact damage Cracks observed on the welds Table 9-10. Damage states for sign frame and L-brackets. Minor Moderate Severe A few loose or missing backing strip nuts Moderate deterioration Significant deterioration Minor loss of element legibility Collision damage present but not affecting legibility Table 9-11. Damage states for sign panel. Minor Moderate Severe Minor damage or deterioration Moderate deterioration of the connections Heavy deterioration of the connections Connections have loose nuts Handrails and locking pins misaligned Sections of grating or handrails misaligned, unstable, damaged, or missing Safety chains missing or deteriorated Table 9-12. Damage states for catwalk.

Part II: PDA of Highway Structures 64 Overhead Signs 9.3 Overhead Sign Assessment Form Figure 9-2 shows the PDA form for overhead signs. Figure 9-2. Overhead sign assessment form (page 1/2).

Part II: PDA of Highway Structures 65 Overhead Signs Figure 9-2. (page 2/2).