Division of Maintenance - Structure Maintenance and Investigations
October 2008
Element
Level
Inspection
Manual ii
Caltrans • Element Level Inspection Manual • October 2008 iii
Caltrans • Element Level Inspection Manual • October 2008
Key Word Description
Environment The environmental or operating factors that effect the deterioration rate of the element. See Appendix A- 1 for detailed descriptions and guidelines for environment determination.
1 – Benign
2 – Low
3 – Moderate
4 – Severe
Feasible Actions A listing of typical actions/ work recommendations that would be taken for an element in that condition state.
Quick Reference
Element Measurement Conventions
Location
Culverts
Appendix B- 1
Spandrel Arches
Appendix B- 1
Accounting for Skew
Appendix B- 1
Elements Not Visible During Inspection
Appendix B- 1
Diaphragms and Cross Bracing
Appendix B- 2
Box Girders
Appendix B- 2
Bent- Type Abutments
Appendix B- 2
Pile Bents
Appendix B- 3
Stringers/ Floor Beams/ Girders
Appendix B- 3
Concrete Channel Superstructure
Appendix B- 3
Trusses ( Total Quantity Determination)
Appendix B- 4
Trusses/ Arches ( Deteriorated Portions)
Appendix B- 4
Rail Length Limits
Appendix B- 4
Other Conventions
See Element
Conversion
Factor
Feet to Meters
Feet x 0.3048 = Meters
Inches to Millimeters
Inches x 25.4 = Millimeters
Square Feet to Square Meters
Square Feet x 0.093 = Square Meters
Length of element along skew
= Perpendicular to Rdwy Width/ Cosine ( skew angle) iv Caltrans • Element Level Inspection Manual • October 2008
Element No. Description................................................................................................. Page
12 Concrete Deck – Bare ( m2)..................................................................................... 14
13 Concrete Deck – Unprotected with AC Overlay ( m2)................................... 15
14 Concrete Deck – Protected with AC Overlay ( m2)......................................... 16
18 Concrete Deck – Protected with Thin Overlay ( m2)...................................... 17
22 Concrete Deck – Protected with Rigid Overlay ( m2)..................................... 18
26 Concrete Deck – Protected with Coated Bars ( m2)........................................ 19
27 Concrete Deck – Protected with Cathodic Protection ( m2)....................... 20
28 Open Grid Steel Deck ( m2)..................................................................................... 21
29 Concrete Filled Grid Steel Deck ( m2).................................................................. 22
30 Corrugated/ Orthotropic Deck ( m2).................................................................... 23
31 Timber Deck Bare ( m2)............................................................................................. 24
32 Timber Deck – with AC Overlay ( m2).................................................................. 25
38 Concrete Slab – Bare ( m2)....................................................................................... 14
39 Concrete Slab – Unprotected with AC Overlay ( m2)..................................... 15
40 Concrete Slab – Protected with AC Overlay ( m2)........................................... 16
44 Concrete Slab – Protected with Thin Overlay ( m2)........................................ 17
48 Concrete Slab – Protected with Rigid Overlay ( m2)...................................... 18
52 Concrete Slab – Protected with Coated Bars ( m2)......................................... 19
53 Concrete Slab – Protected with Cathodic Protection ( m2)......................... 20
54 Timber Slab Bare ( m2).............................................................................................. 26
55 Timber Slab – with AC Overlay ( m2)................................................................... 27
60 Prestressed Concrete Slab Bare ( m2).................................................................. 28
61 Prestressed Concrete Slab – Unprotected with AC Overlay ( m2)............. 29
101 Steel Closed Web/ Box Girder, Unpainted ( m).................................................... 2
102 Steel Closed Web/ Box Girder, Painted ( m).......................................................... 4
104 Prestressed Concrete Closed Web/ Box Girder ( m)........................................... 6
105 Reinforced Concrete Closed Web/ Box Girder ( m)............................................ 8
106 Steel Open Girder, Unpainted ( m).......................................................................... 2
107 Steel Open Girder, Painted ( m)................................................................................ 4
109 Prestressed Concrete Open Girder ( m)................................................................. 6
110 Reinforced Concrete Open Girder ( m).................................................................. 8
111 Timber Open Girder ( m).......................................................................................... 10
112 Steel Stringer, Unpainted ( m).................................................................................. 2
Index Caltrans • Element Level Inspection Manual • October 2008 v
113 Steel Stringer, Painted ( m)........................................................................................ 4
115 Prestressed Concrete Stringer ( m)......................................................................... 6
116 Reinforced Concrete Stringer ( m)........................................................................... 8
117 Timber Stringer ( m).................................................................................................. 10
120 Steel Bottom Chord of Truss, Unpainted ( m)..................................................... 2
121 Steel Bottom Chord of Truss, Painted ( m)............................................................ 4
125 Steel Truss Excluding Bottom Chord, Unpainted ( m)...................................... 2
126 Steel Truss Excluding Bottom Chord, Painted ( m)............................................ 4
130 Steel Deck Truss, Unpainted ( m)............................................................................. 2
131 Steel Deck Truss, Painted ( m)................................................................................... 4
135 Timber Truss/ Arch ( m)............................................................................................. 10
140 Steel/ Arch, Unpainted ( m)........................................................................................ 2
141 Steel/ Arch, Painted ( m).............................................................................................. 4
143 Prestressed Concrete Arch ( m)................................................................................ 6
144 Concrete Arch ( m)........................................................................................................ 8
145 Arch ( Other Material) ( m)....................................................................................... 12
146 Uncoated Cable ( Not Embedded in Concrete) ( EA)...................................... 30
147 Coated Cable ( Not Embedded in Concrete) ( EA)........................................... 31
151 Steel Floor Beam, Unpainted ( m)........................................................................... 2
152 Steel Floor Beam, Painted ( m).................................................................................. 4
154 Prestressed Concrete Floor Beam ( m)................................................................... 6
155 Reinforced Concrete Floor Beam ( m).................................................................... 8
156 Timber Floor Beam ( m)........................................................................................... 10
160 Steel Pin and Hanger Assembly, Unpainted ( EA)........................................... 32
161 Steel Pin and Hanger Assembly, Painted ( EA)................................................. 33
170 Railroad Car Frame ( EA).......................................................................................... 34
171 Miscellaneous Steel Superstructures ( EA)........................................................ 35
180 Seismic Restrainer Type II ( EA).............................................................................. 36
181 Seismic Restrainer C- 1 II ( EA)................................................................................. 36
182 Seismic Restrainer Other ( EA)............................................................................... 36
201 Steel Column or Pile Extension, Unpainted ( EA)............................................... 2
202 Steel Column or Pile Extension, Painted ( EA)..................................................... 4
204 Prestressed Concrete Column or Pile Extension ( EA)...................................... 6
Element No. Description. ............................................................................................... Page vi Caltrans • Element Level Inspection Manual • October 2008
Index…
205 Reinforced Concrete Column or Pile Extension ( EA)....................................... 8
206 Timber Column or Pile Extension ( EA)............................................................... 10
210 Reinforced Concrete Pier Wall ( m).......................................................................... 8
211 Pier Wall ( Other Material) ( m)................................................................................ 12
215 Reinforced Concrete Abutment ( m)...................................................................... 8
216 Timber Abutment ( m).............................................................................................. 10
217 Abutment ( Other Material) ( m)............................................................................ 12
220 Reinforced Concrete Submerged Pile Cap/ Footing ( EA)............................... 8
225 Steel Submerged Pile ( EA)........................................................................................ 2
226 Prestressed Concrete Submerged Pile ( EA)........................................................ 6
227 Reinforced Concrete Submerged Pile ( EA)......................................................... 8
228 Timber Submerged Pile ( EA)................................................................................. 10
230 Steel Bent Cap, Unpainted ( m)................................................................................ 2
231 Steel Bent Cap, Painted ( m)...................................................................................... 4
233 Prestressed Concrete Bent Cap ( m)....................................................................... 6
234 Reinforced Concrete Bent Cap ( m)........................................................................ 8
235 Timber Bent Cap ( m)................................................................................................ 10
240 Metal Culvert ( m)....................................................................................................... 38
241 Reinforced Concrete Culvert ( m)......................................................................... 39
242 Timber Culvert ( m).................................................................................................... 40
243 Other Culvert ( m)...................................................................................................... 41
250 Tunnel ( m).................................................................................................................... 42
251 Steel Shells Foundation Pile Filled with Concrete ( EA)................................ 43
252 Cast- In- Drilled- Hole ( CIDH) ( EA).............................................................................. 8
254 Steel Seismic Column Shells ( Full Height) ( EA)............................................... 44
255 Steel Seismic Column Shells ( Partial Height) ( EA)......................................... 45
256 Slope Protection ( EA)............................................................................................... 46
300 Strip Seal Expansion Joint ( m).............................................................................. 47
301 Pourable Joint Seal ( m)........................................................................................... 48
302 Compression Joint Seal ( m)................................................................................... 49
303 Assembly Joint Seal - Modular Type ( m)........................................................... 50
304 Open Expansion Joint ( m)...................................................................................... 52
308 Assembly Joint Seal - Non Modular Type ( m)................................................. 51
Element No. Description................................................................................................. Page Caltrans • Element Level Inspection Manual • October 2008 vii
309 Asphaltic Plug Joint Seal ( m)................................................................................. 53
310 Elastomeric Bearing ( EA)........................................................................................ 54
311 Moveable Bearing ( Roller, Sliding, etc.) ( EA).................................................... 56
312 Enclosed/ Concealed Bearing or Bearing System ( EA)................................. 55
313 Fixed Bearing ( EA)..................................................................................................... 57
314 Pot Bearing ( EA)......................................................................................................... 58
315 Disk Bearing ( EA)....................................................................................................... 59
320 Prestressed Concrete Approach Slab ( EA)........................................................ 60
321 Reinforced Concrete Approach Slab ( EA)......................................................... 61
330 Metal Bridge Railing ( m)......................................................................................... 62
331 Concrete Bridge Railing ( m).................................................................................. 63
332 Timber Bridge Railing ( m)...................................................................................... 64
333 Miscellaneous Bridge Railing ( m)........................................................................ 65
334 Miscellaneous Bridge Railing ( 2 ft. Sidewalk) ( m).......................................... 65
335 Miscellaneous Bridge Railing ( 5 ft. Sidewalk) ( m).......................................... 65
336 Metal Bridge Railing ( Pipe/ Picket) ( m)............................................................... 62
337 Metal Bridge Railing ( W6x25) ( m)....................................................................... 62
338 Metal Bridge Railing ( W8x31) ( m)....................................................................... 62
339 Concrete Bridge Railing ( Aesthetic) ( m)............................................................ 63
349 Open Joint – Steel Sliding Plates ( m)................................................................. 52
350 Open Joint – Steel Finger ( m)............................................................................... 52
356 Steel Fatigue Smart Flag ( EA)................................................................................ 66
357 Pack Rust Smart Flag ( EA)....................................................................................... 67
358 Deck Cracking Smart Flag ( EA)............................................................................. 68
359 Soffit of Concrete Decks and Slabs Smart Flag ( EA)..................................... 69
360 Settlement Smart Flag ( EA)................................................................................... 70
361 Scour Smart Flag ( EA).............................................................................................. 71
362 Traffic Impact Damage Smart Flag ( EA)............................................................ 72
363 Steel Section Loss Smart Flag ( EA)...................................................................... 73
Appendix A Element Environment and Guidelines............................................................. A- 1
Appendix B Element Quantity Conventions.............................................................. B- 1 to B- 4
Appendix C Column and Pile Element Guidelines............................................................... C- 1
Element No. Description................................................................................................. Page viii Caltrans • Element Level Inspection Manual • October 2008
Decks/ Slabs
Units
Decks
Slabs
Concrete ( Bare)
sq. m
12 ( 14)
38 ( 14)
Concrete Unprotected with AC Overlay
sq. m
13 ( 15)
39 ( 15)
Concrete Protected with AC Overlay
sq. m
14 ( 16)
40 ( 16)
Concrete Protected with Thin Overlay
sq. m
18 ( 17)
44 ( 17)
Concrete Protected with Rigid Overlay
sq. m
22 ( 18)
48 ( 18)
Concrete Protected with Coated Bars
sq. m
26 ( 19)
52 ( 19)
Concrete Protected with Cathodic Protection
sq. m
27 ( 20)
53 ( 20)
Open Grid – Steel
sq. m
28 ( 21)
Concrete Filled Grid – Steel
sq. m
29 ( 22
Corrugated/ Orthotropic/ Etc.
sq. m
30 ( 23
Timber ( Bare)
sq. m
31 ( 24)
54 ( 26
Timber with AC Overlay
sq. m
32 ( 25)
55 ( 27)
Prestressed Concrete Slab ( Bare)
sq. m
60 ( 28)
Prestressed Concrete Slab – Unpro­tected
with AC
sq. m
61 ( 29)
Element Index Tables
Note
• Number in boldface indicates Element Number.
• Italicized number within parentheses (##) indicates the page number of the condition state language. Caltrans • Element Level Inspection Manual • October 2008 ix
Superstructure Items
Units
Steel Unpainted
Steel Painted
Prestressed Concrete
Reinforced Concrete
Timber
Other
Closed Web/ Box/ Girder
m
101 ( 3)
102 ( 5)
104 ( 7)
105 ( 9)
Open Girder
m
106 ( 3)
107 ( 5)
109 ( 7)
110 ( 9)
111 ( 11)
Stringer ( Stringer- Floor Beam System)
m
112 ( 3)
113 ( 5)
115 ( 7)
116 ( 9)
117 ( 11)
Truss ( Bottom Chord)
m
120 ( 3)
121 ( 5)
Truss ( Excluding Bottom Chord)
m
125 ( 3)
126 ( 5)
Deck Truss ( Excluding Bottom Chord)
m
130 ( 3)
131 ( 5)
Timber Truss/ Arch
m
135 ( 11)
Arch
m
140 ( 3)
141 ( 5)
143 ( 7)
144 ( 9)
145 ( 13)
Uncoated Cable ( Not Embedded in Con­crete)
EA
146 ( 30)
Coated Cable ( Not Embedded in Concrete)
EA
147 ( 31)
Floor Beam
m
151 ( 3)
152 ( 5)
Pin and Hanger Assembly
EA
160 ( 32)
161 ( 33)
Railroad Car Frame
EA
170 ( 34)
Miscellaneous Steel Superstructure
EA
171 ( 35)
Smart Flags
Units
Element No.
Steel Fatigue
EA
356 ( 66)
Pack Rust
EA
357 ( 67)
Deck Cracking
EA
358 ( 68)
Soffit, Under Surface of Decks
EA
359 ( 69)
Settlement
EA
360 ( 70)
Scour
EA
361 ( 71)
Traffic Impact
EA
362 ( 72)
Steel Section Loss
EA
363 ( 73)
Note
• Number in boldface indicates Element Number.
• Italicized number within parentheses (##) indicates the page number of the condition state language. x Caltrans • Element Level Inspection Manual • October 2008
Element Index Tables…
Substructure Element
Units
Steel Unpainted
Steel Painted
Prestressed Concrete
Reinforced Concrete
Timber
Other
Column or Pile Extension
EA
201 ( 3)
202 ( 5)
204 ( 7)
205 ( 9)
206 ( 11)
Pier Wall
m
210 ( 9)
Abutment
m
215 ( 9)
216 ( 11)
Submerged Pile Cap/ Footing
EA
220 ( 9)
Submerged Pile
EA
225 ( 3)
227 ( 9)
228 ( 11)
Cap
m
230 ( 3)
234 ( 9)
235 ( 11)
Culvert
m
240 ( 38)
241 ( 39)
242 ( 40)
243 ( 41)
Tunnel
m
250 ( 42)
Steel Shell Filled with Concrete
EA
251 ( 43)
CIDH Piles
EA
252 ( 8)
Seismic Column Shells ( Full Height)
EA
254 ( 44)
Seismic Column Shells ( Partial Height)
EA
255 ( 45)
Slope Protection
EA
256 ( 46)
Note
• See Appendix C for Column and Pile guidelines.
• Number in boldface indicates Element Number.
• Italicized number within parentheses (##) indicates the page number of the condition state language. Caltrans • Element Level Inspection Manual • October 2008 xi
Other Super/ Substructure Ele­ments
Units
Metal
Prestressed Concrete
Reinforced Concrete
Timber
Other
Uncoated Cable ( Not Embedded in Concrete)
EA
146 ( 30)
Coated Cable ( Not Embedded in Concrete)
EA
147 ( 31)
Steel Pin and Hanger Assembley Unpainted
EA
160 ( 32)
Steel Pin and Hanger Assembley Painted
EA
161 ( 33)
Seismic Restrainer Cable
EA
180- 182 ( 36)
Strip Seal Expansion Joint
m
300 ( 47)
Pourable Joint Seal
m
301 ( 48)
Compression Joint Seal
m
302 ( 49)
Assembly Joint/ Seal - Modular)
m
303 ( 50)
Assembly Joint/ Seal - Non Modular
m
308 ( 51)
Open Expansion Joint
m
304 ( 52)
Open Joint – Steel Sliding Plates
m
349 ( 52)
Open Joint – Steel Finger
m
350 ( 52)
Asphaltic Plug Joint
m
309 ( 53)
Elastomeric Bearing
EA
310 ( 54)
Movable Bearing ( Roller, Sliding, etc.)
EA
311 ( 56)
Enclosed/ Concealed Bearing
EA
312 ( 55)
Fixed Bearing
EA
313 ( 57)
Pot Bearing
EA
314 ( 58)
Disk Bearing
EA
315 ( 59
Approach Slab
EA
320 ( 60)
321 ( 61)
Bridge Railing
m
330 ( 62)
331 ( 63)
332 ( 64)
333 ( 65)
Bridge Railing Cont.
m
336- 338 ( 62)
339 ( 63)
334- 335 ( 65)
Note
• Number in boldface indicates Element Number.
• Italicized number within parentheses (##) indicates the page number of the condition state language. xii Caltrans • Element Level Inspection Manual • October 2008
Caltrans • Element Level Inspection Manual • October 2008 1
UNPAINTED
STEEL
PAINTED
STEEL
PRESTRESSED
CONCRETE
REINFORCED
CONCRETE
DECKS & TIMBER
SLABS
BEARINGS CULVERTS
RAIL
SMART
FLAGS
JOINTS
2 Caltrans • Element Level Inspection Manual • October 2008
Element Number Description
101 Steel Closed Web/ Box Girder, Unpainted ( m)
This element defines only those steel closed web/ box girder units that are not painted or are constructed of weathering steel or galvanized.
106 Steel Open Girder, Unpainted ( m)
This element defines only those steel open girder units that are not painted or are constructed of weathering steel.
112 Steel Stringer, Unpainted ( m)
This element defines all unpainted steel stringers which support the deck in a stringer- floor beam system.
120 Steel Bottom Chord of Truss, Unpainted ( m)
This element defines the bottom chord of unpainted steel trusses or those constructed of weathering steel. This element includes through trusses and Pony trusses.
125 Steel Truss excluding bottom chord, Unpainted ( m)
This element defines all truss elements except the bottom chord of unpainted steel trusses or those constructed of weathering steel. This element includes through trusses and Pony trusses.
130 Steel Deck Truss excluding bottom chord, Unpainted ( m)
This element defines all members of unpainted steel deck trusses or those constructed of weathering steel.
140 Steel/ Arch, Unpainted ( m)
This element defines all members of only those steel arches that are not painted or are constructed of weather­ing
steel.
151 Steel Floor Beam, Unpainted ( m)
This element defines only those steel floor beams that are not painted or are constructed of weathering steel.
201 Steel Column or Pile Extension, Unpainted ( EA)
This element defines only those columns or pile extensions that are unpainted or constructed of weathering steel.
225 Steel Submerged Pile ( EA)
This element defines only those unpainted steel foundation piles that are submerged in soil or water. Piles that are completely submerged, in soil or water, and not visible for inspection, should typically be recorded as quan­tity
1 EA in Condition State 1. If the foundation piles are partially visible for inspection, record the actual number of inspected piles and the corresponding condition states. The exposure may be intentional or caused by scour.
230 Steel Pier Cap, Unpainted ( m)
This element defines only those steel pier/ bent caps that are not painted or are constructed of weathering steel.
Notes
• See Appendix B for quantity conventions and Appendix C for Column and Pile guidelines.
Unpainted Steel Elements
101
106
112
120
125
130
140
151
201
225
230 Caltrans • Element Level Inspection Manual • October 2008 3
Condition Description Feasible Action
1 There is little or no corrosion of the unpainted steel. The Do Nothing
weathering steel is coating uniformly and remains in
excellent condition. Oxide film is tightly adhered.
2 Surface rust, surface pitting, has formed or is forming on Do Nothing
the unpainted steel. The weathering steel has not corroded Clean and Paint
beyond design limits. Weathering steel color is yellow- orange
to light brown. Oxide film has a dusty to granular texture.
3 Steel has measurable section loss due to corrosion but Do Nothing
does warrant structural analysis. Weathering steel is dark Clean and Paint
brown or black. Oxide film is flaking.
4 Corrosion is advanced. Oxide film has a laminar texture with Clean and Paint
thin sheets of rust. Section loss is sufficient to warrant Spot Blast Clean and Paint structural analysis to ascertain the impact on the ultimate Rehab Element
strength and/ or serviceability of either the element or the Replace Element bridge.
Notes
• The Steel Section Loss Smart Flag 363 should be used for elements in Condition State 3 and 4.
• Downgrade elements significantly damaged by traffic impact ( e. g., highload hit) and use a Traffic Impact Smart Flag 362 and a Steel Fatigue Smart Flag 356 if cracks are present.
101
106
112
120
125
130
140
151
201
225
230
Unpainted Steel Elements
UNPAINTED STEEL 4 Caltrans • Element Level Inspection Manual • October 2008
Element Number Description
102 Steel Closed Web/ Box Girder, Painted ( m)
This element defines only those steel closed web/ box girder units that are painted.
107 Steel Open Girder, Painted ( m)
This element defines only those steel open girder units that are painted.
113 Steel Stringer, Painted ( m)
This element defines only those steel stringers that support the deck in a stringer- floor beam system that are
painted.
121 Steel Bottom Chord of Truss, Painted ( m)
This element defines the bottom chord of steel trusses that are painted. This element includes through trusses
and Pony trusses.
126 Steel Truss excluding bottom chord, Painted ( m)
This element defines all truss elements except the bottom chord of steel trusses that are painted. This element
includes through trusses and Pony trusses.
131 Steel Deck Truss excluding bottom chord, Painted ( m)
This element defines all members of steel deck trusses that are painted.
141 Steel/ Arch, Painted ( m)
This element defines all members of only those steel arches that are painted.
152 Steel Floor Beam, Painted ( m)
This element defines only those steel floor beams that are painted.
202 Steel Column or Pile Extension, Painted ( EA)
This element defines only those columns or pile extensions that are painted.
231 Steel Pier Cap, Painted ( m)
This element defines only those steel pier/ bent caps that are painted.
Notes
• See Appendix B for quantity conventions and Appendix C for Column and Pile guidelines.
102 Painted Steel Elements
107
113
121
126
131
141
152
202
231
Caltrans • Element Level Inspection Manual • October 2008 5
Condition Description Feasible Action
1 There is no evidence of corrosion and the paint system Do Nothing
is sound and functioning as intended to protect the
metal surface.
2 There is little or corrosion. Surface or freckled rust has formed Do Nothing or is forming. The paint system may be chalking, peeling, Spot Blast, Clean, and Paint
curling or showing other early evidence of paint system Replace Paint System
distress but there is no exposure of metal.
3 Surface or freckled rust is prevalent. There may be exposed Do Nothing
metal but there is no active corrosion which is causing Spot Blast, Clean, and Paint loss of section. Replace Paint System
4 Corrosion may be present but any section loss due to active Do Nothing
corrosion does not yet warrant structural analysis of either the Spot Blast, Clean, and Paint
element or the bridge. Replace Paint System
5 Corrosion has caused section loss and is sufficient to warrant Rehab Element
structural analysis to ascertain the impact on the ultimate Replace Element
strength and/ or serviceability of either the element or
the bridge.
Notes
• The Steel Section Loss Smart Flag 363 should be used for Condition States 4 and 5. However, elements previously in Condition States 4 and 5, but were thoroughly cleaned and repainted, and the paint is holding up well, the Condition State can be improved with a Steel Section Loss Smart Flag 363 remaining.
• Poor condition paint on one portion of a girder ( such as the bottom flange) means that the entire linear meters of beam in that area can be rated to the condition of the worst portion.
• Downgrade elements significantly damaged by traffic impact ( e. g., highload hit) and use a Traffic Impact Smart Flag 362 and a Steel Fatigue Smart Flag 356 if cracks are present.
Painted Steel Elements
102
107
113
121
126
131
141
152
202
231
PAINTED STEEL 6 Caltrans • Element Level Inspection Manual • October 2008
Element Number Description
104 Prestressed Concrete Closed Web/ Box Girder ( m)
This element defines only those closed web/ box girder units constructed of prestressed concrete.
109 Prestressed Concrete Open Girder ( m)
This element defines only those prestressed concrete open girder units constructed of prestressed concrete.
115 Prestressed Concrete Stringer ( m)
Defines only those prestressed concrete stringers that support the deck in a stringer- floor beam system
143 Prestressed Concrete Arch ( m)
This element defines only those arches constructed of prestressed concrete.
154 Prestressed Concrete Floor Beam ( m)
This element defines only those floor beams constructed of prestressed concrete.
204 Prestressed Concrete Column or Pile Extension ( EA)
This element defines only those columns or pile extensions that are constructed of prestressed concrete. If the pile type is different than the extension type; record the extension type.
226 Prestressed Concrete Submerged Pile ( EA)
This element defines only those prestressed concrete piles that are continuously submerged and are visible for inspection. The exposure may be intentional or caused by scour.
233 Prestressed Concrete Cap ( m)
This element defines only those caps that are constructed of prestressed concrete and not integral with the superstructure ( has a bearing surface).
Notes
• For Box Girder with hinges add element number 312 Enclosed/ Concealed Bearing System ( EA) for each hinge location.
• See Appendix B for quantity conventions and Appendix C for Column and Pile guidelines.
Prestressed Concrete Elements
104
109
115
143
154
204
226
233 Caltrans • Element Level Inspection Manual • October 2008 7
Condition Description Feasible Action
1 The element shows no deterioration. There may be Do Nothing
discoloration, efflorescence, and/ or superficial cracking but
without affect on strength and/ or serviceability.
2 Minor cracks and spalls may be present and there may be Do Nothing
exposed reinforcing with no evidence of corrosion. There is Seal Cracks and Minor Patching
no exposure of the prestress system.
3 Some delamination and/ or spalls may be present. There Do Nothing
may be minor exposure but no deterioration of the prestress Clean Steel and Patch
system. Corrosion of non- prestressed reinforcement may be
present but loss of section is incidental and does not
significantly affect the strength and/ or serviceability of either
the element or the bridge.
4 Delamination, spalls and corrosion of non- prestressed Rehab Element
reinforcement are prevalent. There may also be exposure Replace Element
and deterioration of the prestress system ( manifested by loss
of bond, broken strands or wire, failed anchorages, etc.).
There is sufficient concern to warrant an analysis to ascertain
the impact on the strength and/ or serviceability of either the
element or the bridge.
Notes
• Downgrade elements significantly damaged by traffic impact ( e. g., highload hit) and use a Traffic
Impact Smart Flag 362.
Prestressed Concrete Elements 104
109
115
143
154
204
226
233 PRESTRESSED
CONCRETE
8 Caltrans • Element Level Inspection Manual • October 2008
Element Number Description
105 Reinforced Concrete Closed Web/ Box Girder ( m)
This element defines only those closed web/ box girder units constructed of reinforced concrete.
110 Reinforced Concrete Open Girder ( m)
This element defines only those reinforced concrete open girder units constructed of reinforced concrete. This can include deck girders, T- girders and through girders.
116 Reinforced Concrete Stringer ( m)
This element defines only those reinforced concrete stringers that support the deck in a stringer- floor beam system.
144 Concrete Arch ( m)
This element defines only those arches ( open/ closed spandrel, earth filled, bowstring, etc.) constructed of reinforced concrete.
155 Reinforced Concrete Floor Beam ( m)
This element defines only those floor beams constructed of reinforced concrete.
205 Reinforced Concrete Column or Pile Extension ( EA)
This element defines only those columns or pile extensions that are constructed of reinforced concrete. If the pile type is different than the extension type; record the extension type.
210 Reinforced Concrete Pier Wall ( m)
This element defines only those pier walls constructed of reinforced concrete. This element includes multi- column bents with full height in fill or debris walls. Partial height walls between columns should be neglected ( record the columns only).
215 Reinforced Concrete Abutment ( m)
This element defines only those abutments constructed of reinforced concrete.
220 Reinforced Concrete Submerged Pile Cap/ Footing ( EA)
This element defines only those reinforced concrete pile caps and/ or footings that are continuously submerged and are visible for inspection. The exposure may be intentional or caused by scour.
227 Reinforced Concrete Submerged Pile ( EA)
This element defines only those reinforced concrete piles that are continuously submerged and are visible for inspection. The exposure may be intentional or caused by scour.
234 Reinforced Concrete Pier/ Bent Cap ( m)
This element defines only those caps that are constructed of reinforced concrete.
252 Cast- In- Drilled- Hole ( CIDH) ( EA)
This element defines only those reinforced concrete piles that are continuously submerged and are visible for inspection. The exposure may be intentional or caused by scour.
Notes
• For Box Girder with hinges add element number 312 Enclosed/ Concealed Bearing System ( EA) for each hinge location.
• See Appendix B for quantity conventions and Appendix C for Column and Pile guidelines.
Reinforced Concrete Elements
105
110
116
144
155
205
210
215
220
227
234 252 Caltrans • Element Level Inspection Manual • October 2008 9
Condition Description Feasible Action
1 The element shows little or no deterioration. There may be Do Nothing
discoloration, efflorescence, and/ or superficial cracking, but
without affect on strength and/ or serviceability.
2 Minor cracks and spalls may be present but there is no Do Nothing
exposed reinforcing or surface evidence of rebar corrosion. Seal Cracks and Minor Patching
3 Some delamination and/ or spalls may be present and some Do Nothing
reinforcing may be exposed. Corrosion of rebar may be Clean Steel and Patch
present but loss of section is incidental and does not
significantly affect the strength and/ or serviceability of
either the element or the bridge.
4 Advanced deterioration. Corrosion of reinforcement and/ or Rehab Element loss of concrete section is sufficient to warrant analysis to Replace Element ascertain the impact on the strength and/ or serviceability of either the element or the bridge.
Notes
The Condition State 1 description for reinforced concrete allows for “ superficial cracking”. • These cracks are the light/ hairline cracks (< 0.5 mm wide) which often are evident even in new concrete.
The Condition State 2 description for reinforced concrete mentions “ minor cracking”. These are • 0.5 mm wide or wider.
Condition State 4 description refers to “ warrants analysis…”. Guidelines for meeting this con­•
dition are when reinforcing bars are exposed and are measured to have equal to or more than 10% section loss of the steel.
• Downgrade elements significantly damaged by traffic impact ( e. g., highload hit) and use a Traffic Impact Smart Flag 362.
Reinforced Concrete Elements
105
110
116
144
155
205
210
215
220
227
234
REINFORCED CONCRETE 10 Caltrans • Element Level Inspection Manual • October 2008
Element Number Description
117 Timber Stringer/ Girder ( m)
This element defines only those stringers/ girders constructed of timber.
135 Timber Truss/ Arch ( m)
This element defines all members of trusses and arches that are constructed of timber.
156 Timber Floor Beam ( m)
This element defines only those floor beams constructed of timber.
206 Timber Column or Pile Extension ( EA)
This element defines only those columns or pile extensions that are constructed of timber. If the pile type is
different than the extension type; record the extension type.
216 Timber Abutment ( m)
This element defines only those abutments constructed of timber.
228 Timber Submerged Pile ( EA)
This element defines only those timber piles that are continuously submerged and are visible for inspection.
The exposure may be intentional or caused by scour.
235 Timber Cap ( m)
This element defines only those pier caps that are constructed of timber.
Notes
• See Appendix B for quantity conventions and Appendix C for Column and Pile guidelines.
117 Timber Elements
135
156
206
216
228
235
Example: Use Elements 235 ( cap), 206 ( columns), and 216
( abutment) for the bridge abutment shown above.
Caltrans • Element Level Inspection Manual • October 2008 11
Condition Description Feasible Action
1 Investigation indicates no decay. There may be superficial Do Nothing
cracks, splits and checks having no affect on strength or
serviceability.
2 Decay, insect infestation/ marine bore infestation, abrasion, Do Nothing
splitting, cracking, checking, or crushing may exist but none Rehab and/ or Protect Element
is sufficiently advanced to affect strength or serviceability of
the element.
3 Decay, insect/ marine borer infestation, abrasion, splitting, Do Nothing
cracking or crushing has produced loss of strength or Rehab Element
deflection of the element but not of a sufficient magnitude to Replace Element
affect the serviceability of the bridge.
4 Advanced deterioration. Decay, insect/ marine borer Rehab Element
infestation, abrasion, splits, cracks or crushing has produced Replace Element
loss of strength or deflection that affects the serviceability of
the bridge.
Notes
• Downgrade elements significantly damaged by traffic impact ( e. g., highload hit) and use a Traffic
Impact Smart Flag 362
Timber Elements 117
135
156
206
216
228
235
TIMBER
12 Caltrans • Element Level Inspection Manual • October 2008
Element Number Description
145 Arch ( Other Material) ( m)
This element defines only those arches ( open/ closed spandrel, earth filled, bowstring, etc.) constructed of “ other
material” types ( i. e., stone masonry).
211 Pier Wall ( Other Material) ( m)
This element defines only those pier walls ( shafts) constructed of material other than reinforced concrete. This
includes masonry pier walls.
217 Abutment ( Other Material) ( m)
This element defines abutments made of masonry or any other material except concrete or timber.
Notes
• Other Material may consist of a combination of materials ( i. e., concrete columns with timber
lagging or H- piles with sheet pile backwall... etc) the columns and cap are to be coded separately.
• See Appendix B for quantity conventions and Appendix C for Column and Pile guidelines.
145 “ Other” Superstructure/ Substructure Elements
211
217
Caltrans • Element Level Inspection Manual • October 2008 13
“ Other” Superstructure/ Substructure Elements
Condition Description Feasible Action
1 There is little or no deterioration. Surface defects only Do Nothing
are in evidence.
2 There may be minor deterioration, cracking and Do Nothing
weathering. Mortar in joints may show minor Rehab Element
deterioration.
3 Moderate to major deterioration and cracking. Major Do Nothing
deterioration of joints. Rehab Element
4 Major deterioration, splitting, or cracking of materials Rehab Element
may be affecting the structural capacity of the element. Replace Element
145
211
217
14 Caltrans • Element Level Inspection Manual • October 2008
This element defines those concrete bridge decks/ slabs with no surface protection of any type and constructed with uncoated reinforcement. Report the condition state that represents the condition of the entire deck.
Condition Description Feasible Action
1 The surface of the deck has no patched areas and there are Do Nothing
no spalls/ delamination in the deck surface.
2 Patched areas and/ or spalls/ delamination exist in the Do Nothing
deck surface. The combined distressed area is 2% or less of Repair spalls and delamination the total deck area.
3 Patched areas and/ or spalls/ delamination exist in the Do Nothing
deck surface. The combined area of distress is more than Repair spalls and delamination
2% but less than 10% of the total deck area. Repair deck and place overlay
4 Patched areas and/ or spalls/ delamination exist in the Do Nothing
deck surface. The combined area of distress is more than Repair deck and place overlay 10% but less than 25% of the total deck area. Replace deck/ slab
5 Patched areas and/ or spalls/ delamination exist. The Repair deck and place overlay
combined area of distress is more than 25% of the total Replace deck/ slab deck area.
Notes
• The entire quantity shall be placed in one condition state.
• Do not use this element for RC Culverts.
• The condition of the deck area within 1/ 2 meter of all joints should be recorded as part of the joint element.
• Only rate the TOP or WEARING SURFACE for spalls and delaminating concrete.
• Deck cracking and soffit cracking and/ or spalling are tracked as Smart Flag Elements 358 and 359, respectively.
• A patch is considered a repair of a concrete deck/ slab with AC or other nonsuitable patching ma­terial.
A sound concrete spall repair with suitable material should not downgrade the Condition State of the deck/ slab.
• The condition state of the deck/ slab should not be upgraded when a methacrylate treatment is ap­plied
with out spall and/ or delamination repairs.
Concrete Deck – Bare ( m2)
Concrete Slab – Bare ( m2)
12
38 Caltrans • Element Level Inspection Manual • October 2008 15
This element defines those concrete bridge decks/ slabs with no surface protection of any type. The deck is covered with an asphaltic concrete overlay.
Condition Descriptions Feasible Action
1 The surfacing on the deck has no patched areas and there Do Nothing
are no potholes in this surfacing.
2 Patched areas and/ or potholes or impending potholes exist. Do Nothing
Their combined area is less than 2% of the total deck area. Repair potholes, spalls, and delam. Repair delam. and replace overlay
3 Patched areas and/ or potholes or impending potholes exist. Do Nothing
Their combined area is more than 2% but less than 10% of Repair potholes, spalls, and delam. the total deck area. Repair delam. and replace overlay
4 Patched areas and/ or potholes or impending potholes exist. Do Nothing
Their combined area is more than 10% but less than 25% of Repair potholes, spalls, and delam. the total deck area. Repair delam. and replace overlay
5 Patched areas and/ or potholes or impending potholes exist. Repair delam. and replace overlay Their combined area is more than 25% of the total deck area. Replace deck/ slab
Notes
• The entire quantity shall be placed in one condition state.
• Do not use this element for RC Culverts.
• The condition of the deck area within 1/ 2 meter of all joints should be recorded as part of the joint element.
• Soffit cracking and/ or spalling is tracked as Smart Flag Element 359.
• A Deck Cracking SMART Flag Element 358 that existed prior to an AC overlay or added follow­ing
an AC remove and replace inspection, should remain.
• This element includes decks with a thin AC chip seal.
• Use this element when no plans are available to confirm surface protection.
13
39
Concrete Deck – Unprotected with AC Overlay ( m2)
Concrete Slab – Unprotected with AC Overlay ( m2)
DECKS & SLABS 16 Caltrans • Element Level Inspection Manual • October 2008
This element defines those concrete bridge decks/ slabs protected with a membrane. The mem­brane
is covered with an asphaltic concrete overlay.
Condition Description Feasible Action
1 The surfacing on the deck has no patched areas and there Do Nothing
are no potholes in this surfacing.
2 Patched areas and/ or potholes or impending potholes exist. Do Nothing
Their combined area is less than 2% of the total deck area. Repair potholes, membrane, spalls & delam Repair substrate and place overlay
3 Patched areas and/ or potholes or impending potholes exist. Do Nothing
Their combined area is more than 2% but less than 10% of Repair potholes, spalls, and delam. the total deck area. Repair delam. and replace overlay
4 Patched areas and/ or potholes or impending potholes exist. Do Nothing
Their combined area is more than 10% but less than 25% of Repair potholes, spalls, and delam.
the total deck area. Repair delam. and replace overlay
5 Patched areas and/ or potholes or impending potholes exist. Repair delam. and replace overlay Their combined area is more than 25% of the total deck area. Replace deck/ slab
Notes
• The entire quantity shall be placed in one condition state.
• Do not use this element for RC Culverts.
• The condition of the deck area within 1/ 2 meter of all joints should be recorded as part of the joint element.
• Soffit cracking and/ or spalling is tracked as Smart Flag Element 359.
• A Deck Cracking SMART Flag Element 358 that existed prior to an AC overlay or added fol­lowing
an AC remove and replace inspection, should remain.
• “ Protected” indicates the presence of a waterproofing membrane or similar protection system.
• Use this element when plans or visual inspection confirm that surface protection is present.
Concrete Deck – Protected with AC Overlay ( m2)
Concrete Slab – Protected with AC Overlay ( m2)
14
40 Caltrans • Element Level Inspection Manual • October 2008 17
This element defines those concrete bridge decks/ slabs protected with a thin ( less than 13/ 4") overlay ( Portland cement, epoxy chip seal, polymer, etc.).
Condition Description Feasible Action
1 The surface of the deck has no patched areas and there are Do Nothing
no spalls/ delamination in the deck surface. No wear- out
is visible.
2 Patched areas and/ or spalls/ delamination exist in the Do Nothing
deck surface. The combined distressed area is 2% or less of Repair spalls and delamination
the deck area.
3 Patched areas and/ or spalls/ delamination exist in the Do Nothing
deck surface. The combined area of distress is more than Repair spalls and delamination 2% but less than 10% of the total deck area.
4 Patched areas and/ or spalls/ delamination exist in the Do Nothing
deck surface. The combined area of distress is more than Repair spalls and delamination 10% but less than 25% of the total deck area. Replace overlay
5 Patched areas and/ or spalls/ delamination exist. The Replace overlay combined area of distress is more than 25% of the total Replace deck
deck/ slab area.
Notes
• The entire quantity shall be placed in one condition state.
• Do not use this element for RC Culverts.
• The condition of the deck area within 1/ 2 meter of all joints should be recorded as part of the joint element.
• Only rate the TOP or WEARING SURFACE for spalls and delaminating concrete.
• Soffit cracking and/ or spalling is tracked as Smart Flag Element 359.
• A Deck Cracking SMART Flag Element 358 that existed prior to a thin overlay ( excluding AC) should be carried in Condition State 1 and revised accordingly during future inspections.
• A patch is considered a repair of a concrete deck/ slab with AC or other nonsuitable patching ma­terial.
A sound concrete spall repair with suitable material should not downgrade the Condition State of the deck/ slab.
• This element is not intended for use on bridges with a polyester concrete overlay or methacrylate treatment ( use Element 22/ 48).
Concrete Deck – Protected with Thin Overlay ( m2)
Concrete Slab – Protected with Thin Overlay ( m2)
18
44 18 Caltrans • Element Level Inspection Manual • October 2008
This element defines those concrete bridge decks/ slabs protected with a rigid ( 3/ 4" or greater) overlay ( low slump Portland cement, polyester concrete, polymer, etc.)
Condition Description Feasible Action
1 The surface of the deck has no patched areas and there are Do Nothing
no spalls/ delamination in the deck surface. No wear- out
is visible.
2 Patched areas and/ or spalls/ delamination exist in the Do Nothing
deck surface. The combined distressed area is 2% or less of Repair spalls and delamination
the deck area.
3 Patched areas and/ or spalls/ delamination exist in the Do Nothing
deck surface. The combined area of distress is more than Repair spalls and delamination 2% but less than 10% of the total deck area. Repair deck and place overlay
4 Patched areas and/ or spalls/ delamination exist in the Do Nothing
deck surface. The combined area of distress is more than Repair deck and place overlay 10% but less than 25% of the total deck area. Replace deck
5 Patched areas and/ or spalls/ delamination exist. The Repair deck and place overlay
combined area of distress is more than 25% of the total Replace deck/ slab deck area.
Notes
• The entire quantity shall be placed in one condition state.
• Do not use this element for RC Culverts.
• The condition of the deck area within 1/ 2 meter of all joints should be recorded as part of the joint element.
• Only rate the TOP or WEARING SURFACE for spalls and delaminating concrete.
• Soffit cracking and/ or spalling is tracked as Smart Flag Element 359.
• A Deck Cracking SMART Flag Element 358 that existed prior to a rigid overlay ( excluding AC) should be carried in Condition State 1 and revised accordingly during future inspections.
• A patch is considered a repair of a concrete deck/ slab with AC or other nonsuitable patching ma­terial.
A sound concrete patch repair should not downgrade the condition state of the deck/ slab.
• The condition state of the deck/ slab should not be upgraded when a methacrylate treatment is ap­plied
with out spall and/ or delamination repairs.
22
48
Concrete Deck – Protected with Rigid Overlay ( m2)
Concrete Slab – Protected with Rigid Overlay ( m2) Caltrans • Element Level Inspection Manual • October 2008 19
This element defines those concrete bridge decks/ slabs constructed with coated ( epoxy, galva­nized,
stainless steel, etc.) reinforcement bars.
Condition Description Feasible Action
1 The surface of the deck has no patched areas and there are Do Nothing
no spalls/ delamination in the deck surface.
2 Patched areas and/ or spalls/ delamination exist in the Do Nothing
deck surface. The combined distressed area is 2% or less of Repair spalls and delamination the deck area.
3 Patched areas and/ or spalls/ delamination exist in the Do Nothing
deck surface. The combined area of distress is more than Repair spalls and delamination 2% but less than 10% of the total deck area. Repair deck and place overlay
4 Patched areas and/ or spalls/ delamination exist in the Do Nothing
deck surface. The combined area of distress is more than Repair deck and place overlay 10% but less than 25% of the total deck area. Replace deck
5 Patched areas and/ or spalls/ delamination exist. The Repair deck and place overlay
combined area of distress is more than 25% of the total Replace deck/ slab deck area.
Notes
• The entire quantity shall be placed in one condition state.
• Do not use this element for RC Culverts.
• The condition of the deck area within 1/ 2 meter of all joints should be recorded as part of the joint element.
• Only rate the TOP or WEARING SURFACE for spalls and delaminating concrete.
• Deck cracking and soffit cracking and/ or spalling are tracked as Smart Flag Elements 358 and 359, respectively.
• A patch is considered a repair of a concrete deck/ slab with AC or other nonsuitable patching ma­terial.
A sound concrete patch repair should not downgrade the condition state of the deck/ slab..
• The condition state of the deck/ slab should not be upgraded when a methacrylate treatment is ap­plied
with out spall and/ or delamination repairs.
Concrete Deck – Protected with Coated Bars ( m2)
Concrete Slab – Protected with Coated Bars ( m2)
26
52 20 Caltrans • Element Level Inspection Manual • October 2008
This element defines those concrete bridge decks/ slabs protected with a cathodic system.
Condition Description Feasible Action
1 The surface of the deck has no patched areas and there are Do Nothing
no spalls/ delamination in the deck surface.
2 Patched areas and/ or spalls/ delamination exist in the Do Nothing
deck surface. The combined distressed area is 2% or less of Repair spalls and delamination
the deck area.
3 Patched areas and/ or spalls/ delamination exist in the Do Nothing
deck surface. The combined area of distress is more than Repair spalls and delamination 2% but less than 10% of the total deck area. Repair deck/ slab and place overlay
4 Patched areas and/ or spalls/ delamination exist in the Do Nothing
deck surface. The combined area of distress is more than Repair deck/ slab and place overlay 10% but less than 25% of the total deck area. Replace deck/ slab
5 Patched areas and/ or spalls/ delamination exist. The Repair deck/ slab and place overlay combined area of distress is more than 25% of the total Replace deck/ slab deck area.
Notes
• The entire quantity shall be placed in one condition state.
• Do not use this element for RC Culverts.
• The condition of the deck area within 1/ 2 meter of all joints should be recorded as part of the joint element.
• Only rate the TOP or WEARING SURFACE for spalls and delaminating concrete.
• Deck cracking and soffit cracking and/ or spalling are tracked as Smart Flag Elements 358 and 359, respectively.
• A patch is considered a repair of a concrete deck/ slab with AC or other nonsuitable patching ma­terial.
A sound concrete patch repair should not downgrade the Condition State of the deck/ slab..
• The condition state of the deck/ slab should not be upgraded when a methacrylate treatment is ap­plied
with out spall and/ or delamination repairs.
Concrete Deck– Protected w/ Cathodic Protection ( m2)
Concrete Slab– Protected w/ Cathodic Protection ( m2)
27
53 Caltrans • Element Level Inspection Manual • October 2008 21
This element defines those bridge decks that are constructed of steel grids that are open and
unfilled.
Condition Description Feasible Action
1 There is no corrosion. The paint system, if any, is sound. The Do Nothing
connectors ( welds, rivets, etc.) are sound.
2 There is little or no corrosion. The paint system, if any, may Do Nothing
be showing early signs of distress. The connectors are still
sound. The combined distressed area is 2% or less of the
deck area.
3 Surface or freckled rust has formed. The paint system is Do Nothing
no longer fully effective. There is no loss of section. The Surface clean and restore top coat
connectors may be starting to show signs of distress— Rehab connectors
cracked welds or broken rivets. The combined area of
distress is more than 2% but less than 10% of the total
deck area.
4 Corrosion is moderate. Surface pitting may be present but Do Nothing
any section loss is incidental. Numerous connectors are Spot blast, clean and paint
failing at scattered locations. The strength or serviceability Rehab connectors
of the section is not yet affected. The combined area of
distress is more than 10% but less than 25% of the total
deck area.
5 Corrosion is advanced. Numerous connectors have failed. Rehab connectors and replace
Section loss and/ or connectivity is sufficient to warrant paint system
analysis to ascertain the impact on the ultimate strength Replace Element
and/ or serviceability of either the element or the bridge.
Notes
• The entire quantity shall be placed in one condition state.
Open Grid Steel Deck ( m2) 28
22 Caltrans • Element Level Inspection Manual • October 2008
This element defines those bridge decks that are constructed of steel grids with either all of the openings or just those in the wheel tracks filled with concrete.
Condition Description Feasible Action
1 There is no corrosion. The paint system, if any, is sound. Do Nothing
The connectors ( welds, rivets, etc.) are sound. The concrete
filler is sound.
2 There is little or no corrosion. The paint system, if any, may Do Nothing
be showing early signs of distress. The connectors are still Surface clean
sound. The concrete filler is sound. The combined distressed
area is 2% or less of the deck area.
3 Surface or freckled rust has formed. The paint system is no Do Nothing
longer fully effective. There is no loss of section. The Surface clean and restore top coat
connectors may be starting to show signs of distress Rehab connectors and concrete filler
cracked welds or broken rivets. The concrete filler may have
broken out at scattered locations. The combined area of
distress is more than 2% but less than 10% of the total deck area.
4 Surface or freckled rust has formed. The paint system is no Do Nothing
longer fully effective. There is no loss of section. Numerous Spot blast, clean and paint
connectors are failing at scattered locations. Small areas of Rehab connectors and concrete filler
concrete are missing. The combined area of distress is more
than 10% but less than 25% of the total deck area.
5 Corrosion is advanced. Numerous connectors have failed.
Section loss and/ or connectivity is sufficient to warrant Rehab connectors and concrete filler
analysis to ascertain the impact on the ultimate strength Replace Element
and/ or serviceability of either the element or the bridge. Much of the concrete filler is missing.
Notes
• The entire quantity shall be placed in one condition state.
Concrete Filled Grid Steel Deck ( m2)
29 Caltrans • Element Level Inspection Manual • October 2008 23
This element defines those bridge decks that are constructed of corrugated metal filled with Portland Cement Concrete, asphaltic concrete, or other material. This element includes ortho­tropic
steel decks.
Condition Description Feasible Action
1 There is no evidence of corrosion and any protective systems are Do Nothing
sound and functioning as intended to protect the metal
surface. The surfacing, if any, on the deck has no repaired
areas and there are no potholes.
2 There is little or no active corrosion. Surface or freckle rust Do Nothing
has formed or is forming. The protective system may be chalking, Repair potholes
peeling, curling, or showing other early evidence of paint
system distress, but there is no exposure of metal. Minor
cracking or potholes may exist in the surfacing. The combined distressed area is 2% or less of the deck area.
3 Surface or freckle rust is prevalent. There may Do Nothing
be exposed metal but there is no active corrosion which is Repair potholes
causing loss of section. Potholes exist in the surfacing and there
may be significant cracking. The combined area of distress is
more than 2% but less than 10% of the total deck area
4 Corrosion may be present but any section loss due to Do Nothing active corrosion does not yet warrant structural analysis Repair potholes of either the element or the bridge. Potholes may be large Rehab deck and expose the metal decking. The combined area of distress is more than 10% but less than 25% of the total deck area.
5 Corrosion has caused section loss and is
sufficient to warrant structural analysis to ascertain the Rehab deck
impact on the ultimate strength and/ or serviceability of either Replace deck
the element or the bridge. The surfacing has failed.
Notes
• The entire quantity shall be placed in one condition state.
• This element is intended for steel corrugated decks with an asphalt or concrete riding surface
• This element is not intended for steel corrugated stay- in- place deck forms.
• Protective systems may consist of paint, galvanizing, etc...
• Use this element for steel plates ( bare or overlaid) and with railroad car frames ( Element 170) consisting of a steel plate type deck.
Corrugated/ Orthotropic Deck ( m2)
30 24 Caltrans • Element Level Inspection Manual • October 2008
This element defines those bridge decks that are constructed of timber and are not overlaid.
Condition Description Feasible Action
1 Investigation indicates no decay. There may be cracks, splits Do Nothing
and checks having no effect on strength or serviceability.
2 Decay, insect infestation, abrasion, splitting, cracking or crushing may Do Nothing
exist but none is sufficiently advanced to affect serviceability Add wearing surface to protect deck
or strength of the element.
3 Decay, insect infestation, abrasion, splitting cracking or crushing has Do Nothing
produced loss of strength or deflection of the element but not of Add wearing surface to protect deck
sufficient magnitude to affect the serviceability of the bridge. Replace deteriorated timbers
4 Advanced deterioration. Decay, insect infestation, abrasion, splits, Replace deteriorated timbers
cracks or crushing has produced loss of strength or deflection that Replace deck
affects the serviceability of the bridge.
Notes
• The entire quantity shall be placed in one condition state.
• For timber decks without wheel runners the wheel line wear should be recorded as follows:
State 1 – No wheel line wear.
State 2 – Wheel line wear is present but not significant.
State 3 – Wheel line wear has worn 12 mm or deeper but does not effect serviceability.
State 4 – Wheel line wear warrants analysis for member strength for traffic safety..
31 Timber Deck Bare ( m2)
Caltrans • Element Level Inspection Manual • October 2008 25
This element defines those bridge decks that are constructed of timber and are overlaid with
asphaltic concrete.
Condition Description Feasible Action
1 Investigation indicates no decay. There may be cracks, splits Do Nothing
and checks having no effect on strength or serviceability.
There are no potholes in the surfacing.
2 Decay, insect infestation, splitting, cracking or crushing may Do Nothing
exist but none is sufficiently advanced to affect strength or Repair potholes
serviceability of the element. There may be minor potholes Remove AC overlay, repair
deteriorated or impending potholes in the surfacing. timber, and repave
3 Decay, insect infestation, splitting cracking or crushing has Do Nothing
produced loss of strength or deflection of the element but not Remove AC overlay, repair
deteriorated of sufficient magnitude to affect the serviceability of the timber, and repave
bridge. There may be major potholes or impending potholes Replace deck and AC overlay
in the surfacing.
4 Advanced deterioration. Decay, insect infestation, splits, Remove AC overlay, repair
deteriorated cracks or crushing has produced loss of strength or timber, and repave
deflection that affects the serviceability of the bridge. Replace deck and surfacing
Notes
• The entire quantity shall be placed in one condition state.
Timber Deck with AC Overlay ( m2) 32
26 Caltrans • Element Level Inspection Manual • October 2008
This element defines those slab span bridges that are constructed of timber and are not over-laid.
Condition Description Feasible Action
1 Investigation indicates no decay. There may be cracks, splits Do Nothing
and checks having no effect on strength or serviceability.
2 Decay, insect infestation, abrasion, splitting, cracking or crushing may Do Nothing
exist but none is sufficiently advanced to affect serviceability Rehab and/ or protect slab
or strength of the element.
3 Decay, insect infestation, abrasion, splitting cracking or crushing has Do Nothing
produced loss of strength or deflection of the element but not of Rehab slab
sufficient magnitude to affect the serviceability of the bridge. Replace slab
4 Advanced deterioration. Decay, insect infestation, splits,
cracks or crushing has produced loss of strength or deflection that Replace slab
affects the serviceability of the bridge.
Notes
• The entire quantity shall be placed in one condition state.
• Use this element for manufactured glue- lam slabs.
54 Timber Slab Bare ( m2)
Caltrans • Element Level Inspection Manual • October 2008 27
This element defines those slab span bridges that are constructed of timber and are overlaid
with asphaltic concrete.
Condition Description Feasible Action
1 Investigation indicates no decay. There may be cracks, splits Do Nothing
and checks having no effect on strength or serviceability.
There are no potholes in the surfacing.
2 Decay, insect infestation, splitting, cracking or crushing may Do Nothing
exist but none is sufficiently advanced to affect strength or Repair potholes
serviceability of the element. There may be minor potholes or Rehab and/ or protect Element
impending potholes in the surfacing.
3 Decay, insect infestation, splitting cracking or crushing has Do Nothing
produced loss of strength or deflection of the element but not Rehab slab and repair or replace
of sufficient magnitude to affect the serviceability of the surfacing
bridge. There may be major potholes or impending potholes Replace slab and surfacing
in the surfacing.
4 Advanced deterioration. Decay, insect infestation, splits,
cracks or crushing has produced loss of strength that affects Replace slab and surfacing
the serviceability of the bridge.
Notes
• The entire quantity shall be placed in one condition state.
• This element is intended for use with manufactured glue- lam slabs.
Timber Slab – with AC Overlay ( m2) 55
28 Caltrans • Element Level Inspection Manual • October 2008
These elements define those prestressed concrete bridge decks/ slabs with no surface protection of any type and constructed with uncoated reinforcement.
Condition Description Feasible Action
1 The surface of the slab has no patched areas and there are Do Nothing
no spalls/ delamination in the slab surface. Add a protective system
2 Patched areas and/ or spalls/ delamination exist in the Do Nothing
slab surface. The combined distressed area is 2% or less of Add a protective system
the slab area. Repair spalled/ delaminated areas
3 Patched areas and/ or spalls/ delamination exist in the Do Nothing
slab surface. The combined area of distress is more than Repair spalls and delamination
2% but less than 10% of the total slab area. Repair slab and place overlay
4 Patched areas and/ or spalls/ delamination exist in the Do Nothing
slab surface. The combined area of distress is more than Repair slab and place overlay
10% but less than 25% of the total slab area. Replace slab
5 Patched areas and/ or spalls/ delamination exist. The Repair slab and place overlay
combined area of distress is more than 25% of the total Replace slab slab area.
Notes
• The entire quantity shall be placed in one condition state.
• The condition of the slab area within 1/ 2 meter of all joints should be recorded as part of the joint element.
• Only rate the TOP or WEARING SURFACE for spalls and delaminating concrete.
• Deck cracking and soffit cracking and/ or spalling are tracked as Smart Flag Elements 358 and 359, respectively.
• A patch is considered a repair of a concrete deck/ slab with AC or other nonsuitable patching ma­terial.
A sound concrete patch repair should not downgrade the Condition State of the deck/ slab..
• A methacrylate treatment should not improve the Condition States of this element.
Prestressed Concrete Slab Bare ( m2)
60 Caltrans • Element Level Inspection Manual • October 2008 29
These elements define those prestressed concrete bridge decks/ slabs with no surface protection of any type. The slab is covered with an asphaltic concrete overlay.
Condition Description Feasible Action
1 The surfacing on the slab has no patched areas and there Do Nothing
are no potholes in this surfacing.
2 Patched areas and/ or potholes or impending potholes exist. Do Nothing
Their combined area is less than 2% the total slab area. Repair potholes and substrate Repair substrate and replace overlay
3 Patched areas and/ or potholes or impending potholes exist. Do Nothing
Their combined area is more than 2% but less than 10% of Repair potholes and substrate
the total slab area. Repair substrate and replace overlay
4 Patched areas and/ or potholes or impending potholes exist. Do Nothing
Their combined area is more than 10% but less than 25% of Repair potholes and substrate
the total slab area. Repair substrate and replace overlay
5 Patched areas and/ or potholes or impending potholes exist. Repair substrate and replace overlay
Their combined area is more than 25% of the total slab area. Replace slab
Notes
• The entire quantity shall be placed in one condition state.
• The condition of the slab area within 1/ 2 meter of all joints should be recorded as part of the joint element.
• Only rate the TOP or WEARING SURFACE for spalls and delaminating concrete.
• Soffit cracking and/ or spalling is tracked as Smart Flag Element 359.
• A Deck Cracking SMART Flag Element 358 that existed prior to an AC overlay or added fol­lowing
an AC remove and replace inspection, should remain.
Prestressed Concrete Slab – Unprotected with
AC Overlay ( m2)
61 30 Caltrans • Element Level Inspection Manual • October 2008
This element defines only those uncoated steel cables not embedded in concrete.
Condition Description Feasible Action
1 There is little or no corrosion of uncoated steel. Strand and anchor Do Nothing
sockets show no signs of distress.
2 Surface or freckled rust has formed or is forming. Do Nothing
Strand and anchor sockets show no signs of distress. Clean and coat
3 Corrosion may be present but any section loss is incidental Do Nothing
and does not affect the strength or serviceability of either Clean and coat
the element or the bridge. Cable banding, if any, may show some
loosening or slipping. Cable anchor devices may be loosening.
4 Corrosion is advanced. Cable strands or wires may be broken Rehab Element and coat
or severely abraded. Anchors may show signs of slippage. Replace Element
Section loss or other deterioration is sufficient to warrant analysis for strength and/ or serviceability of both the element
and the bridge.
Notes
• Count each catenary cable and each main suspension cable or cable stay.
• This element should not be used for seismic restrainer cables ( see Elements 180 - 182).
• This element should be used for steel girder post- tensioning cables.
• For coated cables use Element 147.
146
Uncoated Cable ( Not Embedded in Concrete) ( EA) Caltrans • Element Level Inspection Manual • October 2008 31
This element defines only those coated steel cables not embedded in concrete.
Condition Description Feasible Action
1 There is little or no evidence of active corrosion. Protective coating is Do Nothing
sound and functioning as intended to protect the metal surface.
Strand and anchor sockets show no signs of distress.
2 There is little or no evidence of active corrosion. Surface or freckled Do Nothing
rust has formed or is forming. The protective coating may be peeling, Clean and restore coating
chalking, curling or showing other early evidence of distress, but
there is no exposure of metal. Strand and anchor sockets show no
signs of distress.
3 Surface or freckled rust is prevalent. There may be exposed metal, but Do Nothing
there is no active corrosion which is causing loss of section. Protective Clean and restore coating
system is no longer effective. Strand and anchor sockets show no
signs of distress.
4 Corrosion may be present, but any section loss is incidental and does Do Nothing
not affect the strength or serviceability of either the element or the Clean and coat
bridge. Cable banding, if any, may show some loosening or slippage.
Cable anchor devices may be loosening.
5 Corrosion is advanced. Cable strands or wires may be broken or Rehab Element and replace coating system
or severely abraded. Anchors may show signs of slippage. Section Replace Element
loss or other deterioration is sufficient to warrant analysis for strength
and/ or serviceability of both the element and the bridge.
Notes
• Count each catenary cable and each main suspension cable or cable stay.
• This element should not be used for seismic restrainer cables ( see Elements 180 - 182).
• This element should be used for steel girder post- tensioning cables.
Coated Cable ( Not Embedded in Concrete) ( EA) 147
32 Caltrans • Element Level Inspection Manual • October 2008
This element defines only those steel pin and hanger assemblies that are either not painted or are constructed of weathering steel.
Condition Description Feasible Action
1 There is little or no corrosion of the unpainted steel. The Do Nothing
weathering steel is coating uniformly and remains in
excellent condition. Oxide film is tightly adhered.
2 Surface rust, or surface pitting, has formed or is forming on Do Nothing
the unpainted steel. The weathering steel has not corroded Clean and paint
beyond design limits. Weathering steel color is yellow orange
to light brown. Oxide film has a dusty to granular texture.
3 Steel has measurable section loss due to corrosion but does Do Nothing
not warrant structural analysis. Weathering steel is dark Clean and paint
brown or black. Oxide film is flaking.
4 Corrosion is advanced. Section loss is sufficient to warrant Rehab element structural analysis to ascertain the impact on the ultimate Replace Element
strength and/ or serviceability of either the element or the bridge.
Notes
• Indications of distress found using ultrasonic testing would typically place the assembly in Condition State 4.
• The ELI quantities should consist of each Pin and Hanger Connection/ Assembly as shown below ( i. e., a quantity of 1 per Girder for each hinge location).
• If painted use Element 161.
Unpainted Steel Pin and Hanger Assembly ( EA)
160 Caltrans • Element Level Inspection Manual • October 2008 33
This element defines only those steel pin and hanger assemblies that are painted.
Condition Description Feasible Action
1 There is no evidence of active corrosion and the paint system Do Nothing
is sound and functioning as intended to protect the metal surface.
2 There is little or no active corrosion. Surface or freckled rust has Do Nothing
formed or is forming. The paint system may be chalking, peeling, Spot blast, clean, and paint
curling or showing other early evidence of paint system distress but Repaint assembly
there is no exposure of metal.
3 Surface or freckled rust is prevalent. There may be exposed Do Nothing
metal but there is no active corrosion which is causing Spot blast, clean and paint
loss of section.
4 Corrosion may be present but any section loss due Do Nothing
to active corrosion does not yet warrant structural analysis Spot blast, clean, and paint
of either the element or the bridge. Repaint assembly
5 Corrosion has caused section loss and is sufficient to
warrant structural analysis to ascertain the impact on the ultimate Rehab Element
strength and/ or serviceability of either the element or the bridge. Replace Element
Notes
• Indications of distress found using ultrasonic testing would typically place the assembly in Condi-tion
State 5.
• The ELI quantities should consist of each Pin and Hanger Connection/ Assembly as shown below
( i. e., a quantity of 1 per Girder for each hinge location).
Painted Steel Pin and Hanger Assembly ( EA) 161
34 Caltrans • Element Level Inspection Manual • October 2008
This element is intended to be used for all superstructures composed of railroad car frames.
Condition Description Feasible Action
1 There is no evidence of corrosion and any paint systems are Do Nothing
sound and functioning as intended to protect the metal surface.
2 There is corrosion. Paint systems, if present, may be showing Do Nothing
signs of distress. The total superstructure area in this state of Surface clean and restore top coat of paint
distress is less than 10% of the total superstructure area.
3 There is corrosion. Paint systems, if present, may be showing Do Nothing
signs of distress. The total superstructure area in this state of Surface clean and restore top coat of paint
distress is more than 10% but less than 25% of the total
superstructure area.
4 There is corrosion. Paint systems, if present, may be showing Do Nothing
signs of distress. The total superstructure area in this state of Surface clean and restore top coat of paint
distress is more than 25% of the total superstructure area.
5 Corrosion is advanced. Section loss in any portion of the
element is sufficient to warrant analysis to ascertain the Replace Element
impact on the ultimate strength and/ or serviceability of
either the element or the bridge.
Notes
• Railroad car frames shall be recorded as quantity 1 EA for bridges constructed with multiple
railroad car frames ( i. e., multiply spans, in parallel... etc).
• A Steel Fatigue Smart Flag ( Element 356) should be used when cracks are observed.
• A Steel Section Loss Smart Flag ( Element 363) should be used when section loss is observed.
• Use an Orthotropic Deck ( Element 30) for railroad cars with a steel plate type deck.
170 Railroad Car Frame ( EA)
Caltrans • Element Level Inspection Manual • October 2008 35
This element is intended to be used for all other miscellaneous steel superstructure elements that were not previously defined. Example of such structures are army steel tread way, boat hatch cover, army steel pontoon, etc. The entire superstructure area ( equivalent deck area) composed of these miscellaneous elements will be treated as an each regardless of the number of spans.
Condition Description Feasible Action
1 There is no evidence of corrosion and any paint systems are Do Nothing
sound and functioning as intended to protect the metal surface.
2 There is corrosion. Paint systems, if present, may be showing Do Nothing
signs of distress. The total superstructure area in this state of Surface clean and restore top coat of paint
distress is less than 10% of the total superstructure area.
3 There is corrosion. Paint systems, if present, may be showing Do Nothing
signs of distress. The total superstructure area in this state of Surface clean and restore top coat of paint
distress is more than 10% but less than 25% of the total superstructure area.
4 There is corrosion. Paint systems, if present, may be showing Do Nothing
signs of distress. The total superstructure area in this state of Surface clean and restore top coat of paint distress is more than 25% of the total superstructure area.
5 Corrosion is advanced. Section loss in any portion of the
element is sufficient to warrant analysis to ascertain the Replace Element
impact on the ultimate strength and/ or serviceability of
either the element or the bridge.
Miscellaneous Steel Superstructures ( EA)
171 36 Caltrans • Element Level Inspection Manual • October 2008
Element Number Description
180 Seismic Restrainer Type II ( EA)
This element defines restrainer cables used for hinges with long hinge seats and occasionally in combination with pipe seat extenders. The standard length varies from fifteen to forty feet and the restrainer system at a hinge may consist of six to twelve cables.
181 Seismic Restrainer C- 1 ( EA)
This element defines restrainer cables used for hinges with short hinge seats (< 9 inches). The current standard number of cables per drum is five. The original systems consisted of seven cables per drum.
182 Seismic Restrainer Other ( EA)
This element defines restrainer cable systems that are not Type II or C- 1 restrainer cable systems.
Seismic Restrainers ( EA)
180
181
182
Details of Type II Restrainer Cable System:
Details of C- 1 Restrainer Cable System: Caltrans • Element Level Inspection Manual • October 2008 37
Condition Description Feasible Action
1 There is little or no corrosion of the metal and the galvanizing Do Nothing
is sound and functional and installed as designed.
2 Surface or freckled rust has formed or is forming. Do Nothing
If a protective coating is present, the coating has minor Clean and apply protective system
areas of deterioration. Less than 20% of the restraint Reset cables
system is set improperly ( excessive slack or tightness).
3 Any protective coating has failed. Surface pitting may Do Nothing
be present. Between 20% to 50% of the restraint system is Replace cables with corrosive resistance system
set improperly ( excessive slack or tightness). Reset cables
4 Corrosion is advanced. Section loss is sufficient to warrant
analysis to ascertain the impact on the ultimate strength Replace cables with corrosive resistance system
and/ or serviceability of the element. More than 50% of the Reset cables
restraint system is set improperly. Broken cables or excessive
slack or tightness.
Notes
• The element should be in Condition State 1 if not visible.
• Use a quantity of one per bent with restrainers.
• For box girders with a hinge, the as- built plans should be checked for type of restrainer and
recorded accordingly.
Seismic Restrainers ( EA) 180
181
182
Examples of other Seismic Restrainer Cable System
38 Caltrans • Element Level Inspection Manual • October 2008
This element defines all metal ( steel, aluminum, galvanized) culverts, including arches, round
or elliptical pipes, etc.
Condition Description Feasible Action
1 The culvert shows little or no deterioration. Some discoloration Do Nothing
or surface corrosion may exist but there is no metal pitting. There is
little or no deterioration or separation of seams.
2 There may be minor to moderate corrosion and pitting, Do Nothing
especially at the barrel invert. Little or no distortion exists. There may Rehab culvert
be minor deterioration and/ or separation of seams. Minor loss of fill material.
3 Significant corrosion, deep pitting or some holes in the invert, Do Nothing
minor cracking or abrasion of the metal may exist. There may be Rehab culvert
considerable deterioration and/ or separation of seams. Significant
loss of fill material.
4 Major corrosion, extreme pitting or holes in the barrel may exist. Replace culvert
Major distortion, deflection, or settlement may be evident. Major
cracking or abrasion of the metal may exist. Major separation of
seams may have occurred.
Notes
• This element includes galvanized metal culverts.
• Measurements are along the barrel length.
240 Metal Culvert ( m)
Caltrans • Element Level Inspection Manual • October 2008 39
This element defines all precast and cast- in- place ( conventional or prestressed) concrete arch,
pipe and box culverts.
Condition Description Feasible Action
1 Superficial cracks and spalls may be present, but there is no Do Nothing
exposed reinforcing or evidence of rebar corrosion. There is
little or no deterioration or separation of joints.
2 Deterioration, minor chloride contamination, minor abrasion, and Do Nothing
minor cracking and/ or leaching may have begun. There may be Seal cracks and/ or patch
deterioration and separation of joints.
3 There may be moderate to major deterioration, abrasion, extensive Do Nothing
cracking and/ or leaching and large areas of spalls. Minor to Seal cracks and/ or patch
moderate distortion, settlement, or misalignment may have Rehab culvert
occurred. There may be considerable deterioration and
separation of joints.
4 Major deterioration, abrasion, spalling, cracking, major distortion, Rehab culvert
deflection settlement, or misalignment of the barrel may be Replace culvert
in evidence. Major separation of joints may have occurred.
Holes may exist in floors and walls.
Notes
• Measurements are along the barrel length.
• See Appendix B for culvert quantity conventions.
• A Deck Element, Deck and Soffit Cracking SMART Flags ares not used with this element.
Reinforced Concrete Culvert ( m) 241
CULVERTS
40 Caltrans • Element Level Inspection Manual • October 2008
This element defines all timber box culverts.
Condition Description Feasible Action
1 The timber and fasteners are in sound condition. Do Nothing
2 There may be minor decay and weathering. Corrosion at Do Nothing
fasteners and connections may have begun. There is little or Repair culvert
no distortion and/ or deflection.
3 There may be significant decay, weathering and warped or Do Nothing
broken timbers. Significant decay and corrosion at fasteners Rehab culvert
and connections may be evident. Minor to moderate distortion
of the culvert may exist.
4 There may be major decay and many warped, broken or Rehab culvert
missing timbers. There is major decay and corrosion at Replace culvert
fasteners and connections. Major distortion or deflection of
the culvert may exist.
Notes
• Measurements are along the barrel length.
• See Appendix B for culvert quantity conventions.
242 Timber Culvert ( m)
Caltrans • Element Level Inspection Manual • October 2008 41
This element defines all culverts not included under steel, concrete or timber culverts. It will include masonry and combinations of other materials.
Condition Description Feasible Action
1 There is little or no deterioration. Surface defects only are in Do Nothing
evidence. There are no scour or misalignment problems.
2 There may be minor deterioration, abrasion, cracking and Do Nothing
misalignment. Repair culvert
3 Moderate to major deterioration, abrasion, cracking and/ or minor Do Nothing
to moderate distortion or deflection has occurred. Repair culvert
4 Major cracking, abrasion, distortion, deflection, settlement or Rehab culvert
misalignment and/ or major deterioration affecting structural Replace culvert integrity may have occurred
Notes
• This element includes masonry culverts.
• Measurements are along the barrel length.
• See Appendix B for culvert quantity conventions.
Other Culvert ( m)
243 42 Caltrans • Element Level Inspection Manual • October 2008
This element should be used to define bored tunnels not cut- and- cover type tunnels.
Condition Description Feasible Action
1 The element shows little or no signs of deterioration. There Do Nothing
may be minor cracking, corrosion and/ or other minor
deterioration having no effect on strength or serviceability.
2 Minor cracking, spalls, or corrosion may be present and Do Nothing
should be repaired to prevent further deterioration that could Repair Element
jeopardize the structural integrity of the element.
3 Advanced deterioration. Corrosion or loss of section is
sufficient to warrant analysis to ascertain the impact on the Rehab Element
serviceability or strength of the element. Replace Element
Notes
• This element should be used for box culverts not designed to carry water.
• For a cut- and- cover type tunnel use appropriate superstructure and abutment elements.
• Measurements are along the tunnel length.
250 Tunnel ( m)
Do not use Tunnel element for cut- and- cover
type tunnels
Use this Tunnel element only for bored
and lined type tunnels
Caltrans • Element Level Inspection Manual • October 2008 43
This element is intended to be used for submerged piles and pile extensions filled with con-crete.
Condition Description Feasible Action
1 There is no evidence of corrosion and the paint system is Do Nothing
sound and functioning as intended to protect the metal Surface clean Element
surface.
2 There is little or no corrosion. The paint system may be Do Nothing
chalking, peeling, curling or showing other early evidence Surface clean
of paint system distress but there is no exposure of metal. Surface clean and restore top coat
3 Surface or freckled rust has formed or is forming. The paint Do Nothing
system is no longer effective. There may be exposed metal Spot blast, clean and paint
but there is no loss of section.
4 The paint system has failed. Surface pitting may be present Do Nothing
but any section loss is incidental and does not yet affect the Spot blast, clean and paint
strength or serviceability of either the element or the bridge. Replace paint system
bridge. Small seam weld cracks may be present but are less
than 12 mm in length.
5 Corrosion is advanced. Section loss is sufficient to warrant Rehab and replace paint system
analysis to ascertain the impact on the ultimate strength Replace Element
and/ or serviceability of either the element or the bridge.
Notes
• This element should be used for Raymond step taper piles.
• For steel pile extensions use Elements 201 or 202. Use element 254 or 255 for seismic steel
column jackets.
• See Appendix C for Column and Pile Element Guidelines.
Steel Shell Foundation Pile Filled with Concrete ( EA) 251
44 Caltrans • Element Level Inspection Manual • October 2008
Condition Description Feasible Action
1 There is no evidence of active corrosion and the paint system Do Nothing
is sound and functioning as intended to protect the metal Surface clean
surface.
2 There is little or no active corrosion. The paint system may Do Nothing
be chalking, peeling, curling or showing other early evidence Surface clean
of paint system distress but there is no exposure of metal. Surface clean and restore top coat
All welds are intact.
3 Surface or freckled rust has formed or is forming. The paint Do Nothing
system is no longer effective. There may be exposed metal Spot blast, clean and paint
but there is no active corrosion which is causing loss of
section. Seam welds are intact.
4 The paint system has failed. Surface pitting may be present Do Nothing
but any section loss is due to active corrosion does not yet Spot blast, clean and paint
warrant structural analysis of either the element or the Replace paint system
bridge. Small seam weld cracks may be present but are less
than 12 mm in length.
5 Corrosion has caused section loss and is sufficient to warrant
analysis to ascertain the impact on the ultimate strength Major rehab Element
and/ or serviceability of either the element or the bridge. Replace Element
Seam weld cracks exceed 12 mm.
Notes
• Columns with full height shells will not use an associated column element 204, 205, 210
or 211.
254 Steel Seismic Column Shells ( Full Height) ( EA)
Caltrans • Element Level Inspection Manual • October 2008 45
Condition Description Feasible Action
1 There is no evidence of active corrosion and the paint system Do Nothing
is sound and functioning as intended to protect the metal Surface clean
surface.
2 There is little or no active corrosion. The paint system may Do Nothing
be chalking, peeling, curling or showing other early evidence Surface clean
of paint system distress but there is no exposure of metal. Surface clean and restore top coat
All welds are intact.
3 Surface or freckled rust has formed or is forming. The paint Do Nothing
system is no longer effective. There may be exposed metal Spot blast, clean and paint
but there is no active corrosion which is causing loss of
section. Seam welds are intact.
4 The paint system has failed. Surface pitting may be present Do Nothing
but any section loss is due to active corrosion does not yet Spot blast, clean and paint
warrant structural analysis of either the element or the Replace paint system
bridge. Small seam weld cracks may be present but are less
than 12 mm in length.
5 Corrosion has caused section loss and is sufficient to warrant analysis to ascertain the impact on the ultimate strength Major rehab Element
and/ or serviceability of either the element or the bridge. Replace Element
Seam weld cracks exceed 12 mm.
Notes
• Record the condition state of the visible portion of the column as the appropriate column element 204, 205, 210 or 211 in addition to the partial shell element.
Steel Seismic Column Shells ( Partial Height) ( EA)
255 46 Caltrans • Element Level Inspection Manual • October 2008
This element identifies all types of slope protection under the bridge; including grouted or
ungrouted riprap and concrete paving which provides erosion protection under the bridge.
Condition Description Feasible Action
1 Little or no deterioration of the concrete or breakdown of the Do Nothing
asphalt aggregate surfacing. No undermining of slabs. The
erosion control system is functioning properly.
2 Some undermining or settlement of protection, some areas of Do Nothing
concrete spalling or minor amounts of erosion and breakdown of Repair protection
aggregate and asphalt surfacing. The erosion control system
is marginally effective.
3 Major undermining and/ or settlement of protection, major erosion Rehab Element
areas, concrete broken up or with major spalls. The effectiveness Replace Element
of the erosion control system is highly questionable.
Notes
• Record the one each for each location protected.
• This element is not for use with continuously lined channels.
• This element accounts for scour of the slope protection. Only use a SMART Scour Flag if the
substructure is affected by the scour.
256 Slope Protection ( EA)
Caltrans • Element Level Inspection Manual • October 2008 47
This element defines only those expansion joint devices which utilize a neoprene type water-proof
gland with steel extrusion to anchor the gland.
Condition Description Feasible Action
1 The element shows minimal deterioration. There is no leakage at any Do Nothing
point along the joint. Gland is secure and has no defects. Debris in
joint is not causing any problems. The adjacent deck and/ or header
is sound.
2 Signs of seepage along the joint may be present. Do Nothing
The seal may be punctured, ripped, or partially pulled out Replace gland and/ or patch concrete
of the extrusion. Minor spalls in the deck and/ or header may be
present adjacent to the joint.
3 Signs of leakage along the joint is present. The gland may Replace gland and/ or patch concrete
have failed from abrasion or tearing. The gland has pulled out Replace joint
of the extrusion. Major spalls may be present in the deck
and/ or header adjacent to the joint.
Notes
• Approach slab expansion joints are included in this element.
• See Appendix B to account for “ skew”.
• The condition of the deck area within 1/ 2 meter of all joints should be included as part of the joint
condition.
Strip Seal Expansion Joint ( m) 300
JOINTS
48 Caltrans • Element Level Inspection Manual • October 2008
This element defines only those joints filled with a pourable seal.
Condition Description Feasible Action
1 The element shows minimal deterioration. Adhesion is sound Do Nothing
with no signs of leakage. There are no cohesion cracks. The
adjacent deck and/ or header is sound.
2 Minor adhesion and/ or cohesion failures may be present. Do Nothing
Signs of seepage along the joint may be present. Joint may Clean joint and replace seals
be slightly impacted with debris. Minor spalls in deck
and/ or headers may be present adjacent to joint.
3 Major Adhesion and/ or cohesion failures are present. Clean joint, patch spalls, and replace seals
Joint may be heavily impacted with debris and/ or stones.
Major spalls may be present in the deck and/ or header
adjacent to the joint.
Notes
• Include approach slab expansion joints adjacent to the abutment.
• See Appendix B to account for “ skew”
• The condition of the deck area within 1/ 2 meter of all joints should be included as part of the
joint condition.
301 Pourable Joint Seal ( m)
Caltrans • Element Level Inspection Manual • October 2008 49
This element defines only those joints filled with a pre- formed compression type seal.
Condition Description Feasible Action
1 The element shows minimal deterioration. Adhesion is sound Do Nothing
with no signs of leakage. There are no cohesion cracks. The
adjacent deck and/ or header is sound. If joint is armored, there are no
signs of anchorage looseness.
2 Signs of seepage along the joint may be present. The seal may show Do Nothing
signs of abrasion or minor tearing. Significant debris is in all or part Clean joint and replace seals
of the joint. Minor spalls in the deck and/ or headers may be
present adjacent to the joint. If joint is armored, the anchorage
may be loose.
3 Major adhesion failures may be present. The gland may have failed Clean joint, patch spalls, and replace seals
from abrasion, tearing, or gaped. Signs or observance of leakage along
the joint may be present. Major spalls may be present in the deck
and/ or header adjacent to the joint. If joint is armored, the anchorage
has failed.
Notes
• Include approach slab expansion joints adjacent to the abutment.
• See Appendix B to account for “ skew”.
• The condition of the deck area within 1/ 2 meter of all joints should be included as part of the
joint condition.
• If a Type M seal is observed use this element.
Compression Joint Seal ( m) 302
50 Caltrans • Element Level Inspection Manual • October 2008
This element defines only those joints filled with an assembly mechanism that may or may not
have a seal. The modular type assembly consists of beams and/ or bars installed in the longitu-dinal
direction designed to support the assembly joint.
Condition Description Feasible Action
1 The element shows minimal deterioration. The anchors are Do Nothing
tight. The adjacent deck is sound. The paint system,
if present, is sound and functioning as intended to protect
the metal.
2 The element shows minor deterioration or damage. The paint, Do Nothing
system if present, may show some corrosion with slight pitting. Patch spalls
There may be minor weld cracking. Minor spalls in the deck
and/ or header may be present adjacent to the joint. Signs of
minor seepage along the joint may be present.
3 The element shows major deterioration or damage. Corrosion is Rehab assembly
advanced. The joint anchorage system may be loose or has failed. Replace assembly
Major spalls may be present in the deck and/ or header adjacent to
the joint. Signs of seepage along the joint are present.
Notes
• This element should be used for a Delastiflex DL and Mauer.
• Evidences of mechanical failure such as loose or broken springs, bolts, or support bars shall be
coded as Condition State 3.
• Delamination and fractures should be treated similar to spalling.
• Seal leakage should be recorded in Condition State 2 or 3 as appropriate.
• The condition of the deck area within 1/ 2 meter of all joints should be included as part of the
joint condition.
303 Assembly Joint Seal - Modular Type ( m)
Caltrans • Element Level Inspection Manual • October 2008 51
This element defines only those joints filled with an assembly mechanism that may or may
not have a seal, for example a plank seal. Use this element for all joint assemblies that are not
identified as modular ( i. e., Waboflex, Wabo Aluminum Strip, Delastiflex RV ( Delastiflex DL is
modular type), Aluminum etc...).
Condition Description Feasible Action
1 The element shows minimal deterioration. The anchors are Do Nothing
tight. There are no broken welds or fingers. The adjacent
deck is sound. The paint system, if it is present, is sound
and functioning as intended to protect the metal.
2 The element shows minor deterioration or damage. The paint, Do Nothing
system if present, may show some corrosion with slight pitting. Patch spalls
There may be minor weld cracking. Minor spalls in the deck
and/ or header may be present adjacent to the joint. Signs of
minor seepage along the joint may be present.
3 The element shows major deterioration or damage. Corrosion is
advanced. The joint anchorage system has failed. Major spalls Rehab expansion joint
may be present in the deck and/ or header adjacent to the joint. Replace expansion joint
Signs of seepage along the joint are present.
Notes
• Use Element 349 and 350 for sliding plate joints ( sealed or unsealed) and steel finger joints,
respectively.
• Evidences of mechanical failure such as loose or broken springs, bolts, or support bars shall be
coded as Condition State 3.
• Delamination and fractures should be treated similar to spalling.
• Seal leakage should be recorded in Condition State 2 or 3 as appropriate.
• The condition of the deck area within 1/ 2 meter of all joints should be included as part of the
joint condition.
Assembly Joint Seal - Non Modular Type ( m) 308
52 Caltrans • Element Level Inspection Manual • October 2008
This element defines only those joints that are open and includes steel finger joints, sliding
plate type joints that may have a seal, and joints filled with expansion paper or crack filler.
Condition Description Feasible Action
1 The element shows minimal deterioration. Joint armor, if Do Nothing
present, is secure, and there are no bent, misaligned, or broken
fingers. The adjacent deck and/ or header is sound.
2 There may be deck cracking indicating armor anchor Do Nothing
loosening. Minor spalls in the deck and/ or header may be Clean joint and/ or patch spalls
present adjacent to the joint. There may be corrosion on joint Add a joint seal
armor steel plates. Bent or misaligned fingers are observed. Rehab
3 There may be advanced corrosion of joint armor or steel plates. Rehab
Major spalls may be present in the deck and/ or header adjacent Replace
to the joint. Armor anchors have failed. There are missing
or broken fingers.
Notes
• The condition of the deck area within 1/ 2 meter of all joints should be recorded as part of the joint element.
304 Open Expansion Joints ( m)
349
350
Element 349 - Steel Sliding Plates
Element 304 Open Joint Element 304 Armored Open Joint
Element 350 Steel Finger Joint
Caltrans • Element Level Inspection Manual • October 2008 53
This element defines only those joints with a standard asphaltic plug and shall not be used for
joints paved over with a normal AC overlay.
Condition Description Feasible Action
1 The element shows minimal deterioration. There are no signs Do Nothing
of cracking, spalling, delamination, or leakage. The adjacent
deck and/ or header is sound.
2 The element may show minor cracking along the joint. Do Nothing
Signs of seepage along the joint may be present. Minor Patch potholes
potholes in deck may be present adjacent to joint.
3 Major depression at joint and/ or delamination failures may Replace asphaltic material
be present. Signs or observance of leakage along the joint Replace
is present. Major potholes may be present in the deck and/ or
header adjacent to the joint.
Notes
• Approach slab expansion joints are included in this element.
• See Appendix B to account for “ skew”
• The condition of the deck area within 1/ 2 meter of all joints should be recorded as part of the
joint element
Asphaltic Plug Joint Seal ( m) 309
Direction of Travel
2” min. AC
Anchor Nails
3/ 8 “ thick steel
bridging plate
Binder Plug
Backer Rod
Elastic AC
54 Caltrans • Element Level Inspection Manual • October 2008
This element defines only those bridge bearings that are constructed primarily of elastomers,
with or without fabric or metal reinforcement.
Condition Description Feasible Action
1 The element shows little or no deterioration. Shear deformations Do Nothing
are correct for existing temperatures. ( The vertical slope is
0 – 30 degrees.)
2 Both vertical and horizontal offsets are within the capability Do Nothing
of the bearings and are not yet significant. Minor cracking, Reset bearings
splitting or other deterioration may be present. Shear deformation
may be slightly excessive. Strength and/ or serviceability are
not affected. ( The vertical slope is 30 – 45 degrees.)
3 Vertical and/ or horizontal offsets are significant indicating Reset bearings
bearing failures. Advanced deterioration. Shear deformations Replace bearings
may be excessive. Top and bottom surfaces may no longer be
parallel. Loss of bearing may be imminent. ( The vertical slope
is greater than 45 degrees.)
Notes
• Use Enclosed/ Concealed Bearing or Bearing System ( Element 312) for elastomeric pads at box
girder hinges, abutments, and bents that can not be visually inspected.
310 Elastomeric Bearing ( EA)
Superstructure
Bearing
Abutment
Typical elastomeric pad at an Abutment
Caltrans • Element Level Inspection Manual • October 2008 55
This element defines only those bridge bearings that are enclosed so that they are not open for
detailed inspection.
Condition Description Feasible Action
1 The element shows little or no deterioration. There are no Do Nothing
vertical or horizontal offsets. There is no cracking of support
members. The supported member is stable under traffic.
2 Both vertical and horizontal offsets are within the capability Do Nothing
of the bearings and are not yet significant. The supported Rehab bearings
member may exhibit minimal vertical movement under
traffic. Cracking of support members is not yet significant.
There may be insignificant reduction of bearing due to
superstructure shortening.
3 Vertical and/ or horizontal offsets are significant indicating Rehab bearings
bearing failures. There may be significant vertical movement Replace bearings
under traffic. Cracking of the support members may be
significant. There may be significant reduction of bearing
due to superstructure shortening.
Notes
• This element should be used for the typical box girder hinge or for bearings at abutments that can
not be inspected.
• Record each bearing system consisting of the entire bridge width ( i. e., quantity would be two for a
bridge with 2 hinges).
Enclosed/ Concealed Bearing or Bearing System ( EA) 312
BEARINGS
56 Caltrans • Element Level Inspection Manual • October 2008
This element defines only those bridge bearings which provide for both rotation and longitudi-nal
movement by means of roller, rocker, or sliding mechanisms.
Condition Description Feasible Action
1 The element shows little or no deterioration. If a paint Do Nothing
system is present, it is sound and functioning as intended to
protect the metal. The bearing has minimal debris and
corrosion. Vertical and horizontal alignment is within limits.
Bearing support member is sound. Any lubrication system is
functioning properly. Grout pad is sound.
2 The paint system, if present, may show moderate to heavy Do Nothing
corrosion with minor pitting but still functions as intended. The Clean and paint
assemblies may have moved enough to cause minor cracking in the Rehab support and/ or reset bearing
supporting concrete. Debris buildup is affecting bearing movement.
Bearing alignment is still tolerable. Grout pad may have minor
cracking and spalling
3 Corrosion is advanced. There may be loss of section of the Clean and paint
supporting member sufficient to warrant supplemental Rehab support and/ or reset bearing
supports or load restrictions. Bearing alignment may be Replace
beyond tolerable limits. Shear keys may have failed. The
lubrication system, if any, may have failed. Grout pad may have
significant deterioration.
311 Moveable Bearing ( Roller, Sliding, etc.) ( EA)
Caltrans • Element Level Inspection Manual • October 2008 57
This element defines only those bridge bearings that provide for rotation only.
Condition Description Feasible Action
1 The element shows little or no deterioration. If a paint Do Nothing
system is present, it is sound and functioning as intended to
protect the metal. Vertical and horizontal alignment is within
limits. Bearing support member is sound. Any lubrication
system is functioning properly. Grout pad is sound.
2 The paint system, if present, may show moderate to heavy Do Nothing
corrosion with pitting but still functions as intended. The Clean and paint
assemblies may have moved enough to cause minor cracking in the Rehab support and/ or reset bearing
supporting concrete. Grout pad may have minor cracking and spalling
3 Corrosion is advanced. There may be loss of section of the Clean and paint
supporting member sufficient to warrant supplemental Rehab support and/ or reset bearing
supports or load restrictions. Shear Keys may have failed. Replace
The lubrication system, if any, may have failed. Grout pad may have
significant deterioration.
Fixed Bearing ( EA) 313
58 Caltrans • Element Level Inspection Manual • October 2008
314 Pot Bearing ( EA)
This element defines those high load bearings with confined elastomer. The bearing may be
fixed against horizontal movement, guided to allow movement in one direction, or floating to
allow sliding in any direction. This element should be used for Seismic Isolation Bearings.
Condition Description Feasible Action
1 The element shows minimal deterioration. The paint or other Do Nothing
anti- corrosion system is sound and functioning as intended to
protect the metal. The bearing has minimal debris and
corrosion. Vertical and horizontal alignment is within limits.
Bearing support member is sound. Any lubrication system is
functioning properly.
2 The anti- corrosion system may show some corrosion with Do Nothing
minor pitting. Debris buildup is affecting bearing movement. Rehab support or bearing
Bearing alignment and load carrying capacity is still tolerable.
3 Corrosion is advanced. Bearing alignment and load carrying Rehab bearing
capacity may be beyond limits. Shear keys and the lubrication Replace bearing
system, if any, may have failed. Elastomer may be actively
extruding from the device.
Caltrans • Element Level Inspection Manual • October 2008 59
This element defines those high load bearings with a hard plastic disk. The bearing may be fixed against horizontal movement, guided to allow movement in one direction, or floating to allow sliding in any direction. This element should be used for Spherical and Polytetrafluoro­ethylene
( PTFE) Bearings.
Condition Description Feasible Action
1 The element shows minimal deterioration. The paint or other Do Nothing
anti- corrosion system is sound and functioning as intended to
protect the metal. The bearing has minimal debris and
corrosion. Vertical and horizontal alignment is within limits.
Bearing support member is sound. Any lubrication system is
functioning properly.
2 The anti- corrosion system may show some corrosion with Do Nothing
minor pitting. Debris buildup is affecting bearing movement. Rehab support or bearing
Bearing alignment and load carrying capacity is still tolerable.
3 Corrosion is advanced. Bearing alignment and load carrying Rehab bearing capacity may be beyond limits. Shear keys and the lubrication Replace bearing
system, if any, may have failed.
Disk Bearing ( EA)
315
Superstructure
Hard Plastic Disk Bearing
Abutment
Elevation View
Plan View 60 Caltrans • Element Level Inspection Manual • October 2008
This element defines those structural sections with or without an asphalt or polyester concrete overlay, between the abutment and the approach pavement that are constructed of prestressed concrete.
Condition Description Feasible Action
1 The slab has not settled and shows no sign of deterioration Do Nothing
other than superficial surface cracks.
2 Minor cracking, spalls may be present but they do not affect Do Nothing
the ability of the slab to carry traffic. Settlement may be Perform mudjacking operations
occurring which increases the traffic impact on the bridge.
3 Cracks may extend completely through the slab cross- section, Do Nothing
but the slab does not act as if it is broken. Spalls may be Place overlay
heavy but they do not affect the structural integrity of the Replace slab
slab. Settlement may be occurring which increases the traffic
impact on the bridge.
4 The slab is broken or rocks under traffic loads. Settlement i
excessive and cannot be corrected without increasing the size Replace slab
of the slab.
Notes
• Each approach slab element should consist of the portion from the bridge to the 1st joint, not to exceed a distance of 30 feet.
• The examples below shows four approach slab units to be recorded.
• If overlays are placed w/ out repairs maintain the prior condition state of an approach slab.
Prestressed Concrete Approach Slab ( EA)
320
1 Structure 3
2 4
Approach Slabs
Lane Line
PCC Pavement
PCC Pavement
1 Structure 3
2 4
Approach Slabs
Lane Line
AC Pavement
AC Pavement Caltrans • Element Level Inspection Manual • October 2008 61
1 Structure 3
2 4
Approach Slabs
Lane Line
Reinforced Concrete Approach Slab ( EA)
321
This element defines those structural sections, with or without an asphalt or polyester concrete overlay, between the abutment and the approach pavement that are constructed of reinforced concrete.
Condition Description Feasible Action
1 The slab has not settled and shows no sign of deterioration Do Nothing
other than superficial surface cracks.
2 Minor cracking, spalls may be present but they do not affect Do Nothing
the ability of the slab to carry traffic. Settlement may be Perform mud jacking operations
occurring which increases the traffic impact on the bridge.
3 Cracks may extend completely through the slab cross- section, Do Nothing
but the slab does not act as if it is broken. Spalls may be Place overlay
heavy but they do not affect the structural integrity of the Replace slab slab. Settlement may be occurring which increases the traffic
impact on the bridge.
4 The slab is broken or rocks under traffic loads. Settlement is Replace slab
excessive and cannot be corrected without increasing the size
of the slab.
Notes
• Each approach slab element should consist of the portion from the bridge to the 1st joint, not to exceed a distance of 30 feet.
• The examples below shows four approach slab units to be recorded.
• If overlays are placed w/ out repairs maintain the prior condition state of an approach slab.
PCC Pavement
PCC Pavement
1 Structure 3
2 4
Approach Slabs
Lane Line
AC Pavement
AC Pavement
62 Caltrans • Element Level Inspection Manual • October 2008
Metal Bridge Railing ( m)
330
336
337
338
This element defines all types and shapes of metal bridge railing. Steel, aluminum, metal beam and rolled shapes, etc., are all considered part of this element. The element may be either painted, galvanized, or protected with some other coating.
Condition Description Feasible Action
1 There is no evidence of active corrosion. The protective coating Do Nothing
is sound and functioning as intended to protect the element.
2 There is little or no active corrosion. Surface or freckled rust has Do Nothing
formed or is forming. The protective coating may have minor Clean and coat
areas of deterioration.
3 Surface or freckled rust is prevalent. The protective coating Do Nothing
is no longer effective. There may be exposed metal, but Clean and coat
there is no active corrosion causing significant loss of section. Replace rail
4 Corrosion is advanced. Section loss is sufficient to warrant analysis Rehab rail to ascertain the impact on the strength and/ or serviceability of the Replace rail element.
Notes
• If the serviceability of the rail is affected by damaged posts or unsupported rail, code as Condition State 4. Record the lineal meters of rail affected by the defective or missing posts.
• Rails with any combination of metal and concrete should be recorded as element 333, 334 or 335.
• See Appendix B for length conventions.
Element Number Description
330 Includes all rails constructed of 100% steel ( excluding sidewalk) and not depicted below
336 Steel Rail ( pipe/ picket) Includes all vertical pipe
and picket rails constructed of only steel.
337 Steel Rail ( W6). Includes similar rails as shown. The rail must be steel with W6 posts.
338 Steel Rail ( W8). Includes similar rails as shown.
The rail must be all steel with W8 or larger posts.
W8x31 Steel Post
W6x25 Steel Post Caltrans • Element Level Inspection Manual • October 2008 63
This element defines all types and shapes of reinforced concrete bridge railing. All elements of the railing must be concrete.
Condition Description Feasible Action
1 The element shows little or no deterioration. There may be Do Nothing
discoloration, efflorescence, and/ or superficial cracking but
without effect on strength and/ or serviceability.
2 Minor cracks, surface scaling, or spalls may be present, Do Nothing
but there is no exposed reinforcing or surface evidence Seal cracks and minor patching
of rebar corrosion.
3 Some delamination and/ or spalls may be present, and some Do Nothing
reinforcing may be exposed. Corrosion of rebar may be Clean rebar and patch
present, but loss of section is incidental and does not significantly
affect the strength and/ or serviceability of either the element.
4 Deterioration is advanced. Corrosion of reinforcement and/ or Rehab rail
loss of concrete section is sufficient to warrant analysis to Replace rail ascertain the impact on the strength and/ or serviceability of
either the element.
Notes
• If the serviceability of the rail is affected by damaged posts or unsupported rail, code as Condition State 3. Record the lineal meters of rail affected by the defective or missing posts). Rails with any combination of metal and concrete should be recorded as element 333, 334 or 335.
• Include median rail quantities, see Appendix B for conventions.
Element Number Description
331 Concrete Rail – Includes all rails constructed only of concrete and not shown below. All of our modern safety shape rails should be recorded as element 331.
339 Concrete Rail ( Aesthetic)
Concrete Bridge Railing ( m)
331
339
RAIL 64 Caltrans • Element Level Inspection Manual • October 2008
This element defines all types and shapes of timber bridge railing.
Condition Description Feasible Action
1 There is no decay. There may be minor cracks, splits and/ or Do Nothing
checks.
2 There may be decay with or without splitting, cracking, Do Nothing
checking or crushing but none is sufficiently advanced to Rehab rail
affect serviceability.
3 Advanced deterioration. Decay, splits, cracks, checking or crushing Rehab rail
has produced loss of strength that may affect the serviceability of Replace rail
the element.
Notes
• If the serviceability of the rail is affected by damaged posts or unsupported rail, code as Condition
State 3. Record the lineal meters of rail affected by the defective or missing posts.
• Combination rails are coded as Element No. 333.
332 Timber Bridge Railing ( m)
Caltrans • Element Level Inspection Manual • October 2008 65
This element defines all types and shapes of bridge railing except those defined as metal, con­crete
or timber. This element includes combinations of materials.
Condition Description Feasible Action
1 The element shows no signs of deterioration. There may be Do Nothing
minor cracking, corrosion and/ or other minor deterioration
having no affect on strength or serviceability.
2 Minor cracking, spalls, decay of timber portions or corrosion Do Nothing
of metal may be present. Rehab rail
3 Advanced deterioration. Corrosion, decay or loss of section is Rehab rail
sufficient to warrant analysis to ascertain the impact on the Replace rail
serviceability or strength of the element.
Notes
• If the serviceability of the rail is affected by damaged posts or unsupported rail, code as Condition State 3. Record the lineal meters of rail affected by the defective or missing posts.
Element Number Description
333 Includes all rails constructed of a combination of materials and not depicted below.
334 Miscellaneous Rail ( 1 meter sidewalk) Includes all miscellaneous
rails having a sidewalk 1 meter or less in width.
335 Miscellaneous Rail ( sidewalk) includes all miscellaneous rails having a 1 meter or greater
sidewalk width.
Miscellaneous Bridge Railing ( m)
333
334
335 66 Caltrans • Element Level Inspection Manual • October 2008
356 Steel Fatigue Smart Flag ( EA)
This condition state language addresses only those bridges with steel elements which are al-ready
showing fatigue damage. It should not be applied to steel bridges prior to fatigue damage
becoming apparent.
Condition Description
1 Fatigue damage to the bridge has been repaired or arrested. The bridge may still be fatigue prone.
2 Fatigue damage exists which is not arrested ( normally, this condition state would be used the first time the element
is identified and at any other time when additional fatigue damage occurs.)
3 Fatigue damage exists which warrants analysis of the element to ascertain the serviceability of the element or the
bridge.
Notes
• This Smart Flag represents all the steel on a bridge. The quantity will always be one ( 1).
Do not count each fatigue crack individually.
• Use this Smart Flag when cracks are present due to impact damage ( i. e., highload hit or drift).
Caltrans • Element Level Inspection Manual • October 2008 67
Pack Rust Smart Flag ( EA) 357
This element defines only those connections ( including shapes in contact in built- up members)
of steel bridges which are already showing signs of rust packing between steel plates.
Condition Description
1 The connection is showing signs of rusting between plates. Seams of the connections exhibit rust staining.
2 Rusting between plates is beginning to distress the connection. Minor swelling exists.
3 Rusting between plates has caused serious distress to the connection. The plates may be badly distorted, however
all connectors ( rivets/ bolts) are still functioning.
4 Rusting between plates has caused serious distress to the connection which warrants analysis of the bridge to
ascertain the impact on the serviceability of the bridge. Some rivets or other connectors may have popped or are no
longer effective.
Notes
• This Smart Flag represents all occurrences of pack rust on a bridge. The quantity will always be
one ( 1). Do not count each occurrence of pack rust.
SMART
FLAGS
68 Caltrans • Element Level Inspection Manual • October 2008
358 Deck Cracking Smart Flag ( EA)
This condition state language addresses cracking on the top surface of concrete decks.
Condition Description
1 The surface of the deck is cracked, but the cracks are either filled/ sealed or insignificant in size ( less than 0.5 mm
wide) and density ( average spacing greater than 1.0 meter) to warrant repair activities.
2 Unsealed cracks which are 0.5 to 2.0 mm in width OR have an average spacing range of 300 mm to 1.0 meter.
3 Unsealed cracks which are 0.5 to 2.0 mm in width AND with an average spacing range of 300 mm to 1.0 meter.
4 Unsealed cracks in the deck which are greater than 2.0 mm in width AND/ OR an average crack spacing less than
300 mm.
Notes
• Condition State 1 should be used for bridge decks that have been treated with methacrylate.
• Bridge decks with a minimal number of cracks may not always warrant a Condition State of 3 or
4 and should be left to the discretion of the inspector.
• A Deck Cracking SMART Flag that existed prior to an AC overlay or added following an AC
remove and replace inspection, should remain in the same Condition State.
• This el