Card Sound Bridge VERNON C. PAGE, P.E.
3525 NORTHSIDE DRIVE
KEY WEST, FLORIDA 33040
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BRIDGE INSPECTION REPORT
OF
CARD SOUND BRIDGE
In
MONROE COUNTY, FLORIDA
On
KEY LARGO
May 1979
Monroe County, Florida Bridge No. 904990
State Road 905A Card Sound Bridge
Card Sound Road
STRUCTURE LOCATION
This bridge is located 0.533 mile East of the Dade - Monroe County Line
and 4.733 miles West of the intersection of State Road 905 and 905A
(Card Sound Road). It spans the Atlantic Intercoastal Waterway with
Card Sound to the North and Barnes Sound to the South.
The structure is part of the Card Sound Road and Toll Bridge Project.
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Monroe County, Florida Bridge No. 904990
State Road 905A Card Sound Bridge
Card Sound Road
GENERAL DESCRIPTION
This structure was designed in accordance with the 1965 edition
of the AASHO Standard Specifications for Highway Bridges. It was
constructed in accordance with the Florida State Road Department
Standard Specifications for Road and Bridge Construction dated 1966
and Special Provision. It was designed and constructed for a H -20
loading capacity and speed - limit of 45 miles per hour. Construction
was completed and the bridge opened to traffic in July of 1969. •
The Monroe County Board of Commissioners has placed a 30,000
pound weight restriction on the roadway approaches to this structure
due to the condition of the roadway and the type of foundation on
which it is constructed. This restriction is properly posted.
The bridge is a 40 span, 2,775 foot long concrete and structural
steel structure. It is a high level bridge with a 5.00% garde and a
700 foot vertical curve at the center. The vertical clearance over
the Intercoastal Waterway a s 65 feet above 1. H. W. E:l.. -• 0.8. The
horizontal clearance of the channel is 90 feet between the two fenders.
The fender system protection at the main channel is constructed
of creosote treated structural timber supported by cluster5 of crec mtc
treated tuner piling. Clearance lights and navigational aids are i ray.i.dcri .
t a minimum of 75 ton bearing capacity each with a 16' minimum
petr!tratiGo.
'1"i.::: °e at a t.Irr 4" transite tel.r,phone ducts encased in concrete
Tcatod underneath the North overhang. Two metal pull boxes 4' -6" by
l'-11" each are ] acated in the North safety curb, one each on spans
37. 'f}si > duct bank was instaltod during the construction of the
or^ i.dg c . It VI int.t alied for future use but at this time has not
ut.i.i:i.zed .
There aro two, 875 ' long fishing walks underneath the bridge,
or East and one West of the Intercoastal Waterway. These fishwalks
accecsiblr -: from the bridge by two sots of concrete stairways for
each rishwaik.
The fishwalks are constructed of prestressed concrete slabs,
(35' x 8'x 1') supported on concrete caps. The caps on one end of the
:!;►tb are supported by 12- inches square prestressed concrete piling
driven to 25 -ton bearing capacity each. The caps on the other end of
the slabs are supported by the pier footings for the main bridge. The
fishwalks have a three -rail 3' -6" high aluminum handrail on each side.
Lighting was provided for night -time fishing on both fishwalks. Due to
var:dalism the lights are no longer in operation.
A physical inspection of this structure and an underwater inspection
was made to determine existing conditions. A record of deficiencies found
is included as a part of this report.
The numbering of the bents, piers, and spans, etc., advances from
the West to the East.
. ;{G INSTRUCTIONS: 1. S /Lnc, SnSINGLE STRUCTURE. LRC APPLIES TO MULTIPLE STRUCTURES, L -LEFT. rt nilIG+HT,
C- CENTEU
2. INSPECTION RATING: O 1 2 3-- 4- 5.*poor, 6- 7...fair, 8 -9 -good
3. A ■ALPHAHETIC. N =NUMERIC
D BRIDGE STATE .BOA U. S. ROAD 1 DATE
i CO. SECT. NUMBER NUMBER NUMBER INSPECTED LOAD
8 NO. NO. •-- " -r—r - I r
A N,N,NjN A A N,N 1 Di
'Y AIN MO. DAY YR. POSTEDDESIGN
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I 1 I I I I I 1 ■ 1 1 r , 1 , 87 I , s 9 AI 1 I 1 015 3 19 1 I 1 1 J L 1 _ 1 1
I- 35
TYPE BRIDGE: A FIXED al VERTICAL LIFT ] SWING SPAN 98 1 BASCULE -S. LE BASCULE-D.
Card Sound Bridge Bridge Number 904990
LOCAL BRIDGE NAME: _
- 1 Crir -r) 1
ITEMS OF INSPECTION J RATING i REMARKS (Reference to Attached Comments, Sketches, etc.)
COL.
1. PILING G. k3
2. PIERS F 61 ,8 .
3. CAPS 62 t 7 .____ _
4. BEARING PLATES 6 1 8 1
13. BEAMS 1 64a 8 -
6. DECK I 65 j i
7. JOINTS 1 67 7 3 •
8. HANDRAILS AND CATWALKS 67 7 _-J
9. TRUSSES 63 i _ i I
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10, MACHINERY f ���� �� — �_
__ _ _ _.____� __ __ _. __ _,_ _ _
11. LEC1RICAL 70
12. MAIN ELECTRICAL CAOLE 71 1
13. AUXILIARY POWER I - /2 i_.T_______
1'1. CONTROL 1IOUSE I 73
11.i. COUN 1ERWLIGHTS II74
i11 SYSTEM i /5 1 71
17. (
NAVIGATION AIDS 1 r1
18. VEHICLE WARNING DEVICES 1 7 7 1 __.._
1'1 APPROACHES 1 16 l
'O 11N0E11WATER INVESJIGATJQNl 1
OVERALL BRIDGE RATING 1 139 I 8 1 General condition goer.]
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COMMENTS AND /OR RECOMMENDATIONS;
1 4
II !
INfIrECTION PARTY:
NAME TITLE s I'IAId1£ T1 r I A'
,ter:-= • >- �--- - -3 --- ...�.- .. -._.__ . - 1.�:�v...-- ---- -_ _� � -. _. _ _ . "_° _ _ _.
1 ' . .' C1 2Xlai. Fare __.__ -_.._ _____ _ _ _ _ y. `•_
x• On.a1 Estenoz 1 G.
r. J n Banks i q; . _ ..._J
• Enter In thousands of pounds
OISTRISUTIONI COPY 1. DI STRICT OMCI'S
COPY 2 • STATIC MAINTICNAUCIC ICNOINEICR
COPY 3 • BRIDGE MAINTICNANC4 - ORLANDO
COPY 4 • FILE
Ccurrt;r, Florida Bridge No. 904990
y; j ; % Card Sound Bridge
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STRUCTURAL DEFICIENCIES
C T' i lloco;rifiierid
: . : ant No. 4 Pile No. 1 (cased and banded) Under hammer test, casing
soinds hollow; possibly inadequate filling of casing.
No. 5 Pile No. 1 - same as above.
r;. i. 7 Pile. No. 1 has a small crack :a i.iaterl.ine
_:cnt Rio. f Pile No. 2 has numerous rust stains: 17 on west side and
on east side. Grind out and seal. Pile No. 4 has 6 rust
staina on east side; grind out and seal. Pile No. 5 has
small spall on S.W. corner.
Bent No. 9 Pile No. 3 has casing split at waterline.
Punt No. 17: Pile No. 1 has small spall. N.E. corner - no steel exposed.
Pile No. 4 has small spall west face: - no steel exposed.
2. Piers
Pier No. 8 North N.E. pile has 1" deep spall 4' below cap.
Pier No. 9 North N.W. pile has 3" long spall 1l" down from cap.
l Lr No. ].'. North S.W. pile has crater spall 1' down from cap.
Pier No. 14 Piles under both piers show mild scouring. Monitor.
Pier No. 13 Spalling on top of pier tie beam. This is an old repair
that has failed.
Pier No. 26 North Vertical crack 4' long. Scarify and patch.
Note: There are numerous light hairline cracks in the pier colWn
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3. Decks
Span No. 2 Hairline crack West end; 3 edge spalls West end.
Spa].l. around 3rd scupper, South side.
Span No. 3 Numerous edge cracks and small spalls each end.
Span No. 5 Minor surface spalls East end.
Span No. 9 Two edge :Tails, South lane, West end.
Span No. 10 Crack 28 long, South side near center.
Span No. 14 5" dia. surface spali near West end. Hebar exposed rear
North curb near center.
Span No. 17 Edge crack South side East end.
Span No. 21 Several transverse hairline cracks.
"fan No. 22 About 15 transverse hairline cracks.
Span No. 22 Exposed mbar near N. curb.
Span No. 24 Minor surface hairline cracks.
edr• end; 3
^ chips N. side E. en; dia. pal ]. side `
,,pan No. 2K Two , 3" 3. si e> r: n�•Pz'
Span No. 31 Edge cr ckcing and spalling both ends.
Span No. 32 Minor edge cracking E. end.
Span No. 34 Numerous pock spalls W. end.
Span No. 37 Longitudinal hairline crack W. end S. side.
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:1� =in No. 40 End prz] 1. i r� €, ':; • Cn'i, �.;lia. n ^i, ll.it t;
4. Handrails:
Span No. 1 S. rail has minor hairline crack; N. r,i1. har,; ;: 11 ”
spaii on first post.
Span No. 2 S rai hts .;mall shill outside 3r11 i!�.?' ' , bi.° f „cvir:
N. rail has 6" dia. small on top 10' fror::
Span No. 3 S. rail has spall on E. side of third post; rebar exposed.
N. rail has rebar exposed on first post: bad crack on
second last post.
Span No. 4 S. rail has spall on bottom rail 4' from W. end.
Span No. 5 N. rail has 3" dia. spall on sixth post; rebar exposed.
Repaired spall on last post has popped out.
Span No. 6 Minor spalls with bars showing first post. Also rebars showing
fourth, fifth and sixth posts (all S. side).
N. rail has exposed rebar on fifth post.
Span No. 7 Map cracking on bottom rail between sixth and seventh post.
Rebar exponcd on outside near post five.
Span No. 11 South side has two small spalls on top rail near cont.'r.
Elan No. 13 Steel exposed on last post.
Span No. 15 N. ra:tl third 1 ^ 5t post rebar exposed on out:, ide .
Span No. 1 S. rail rebar cxp osed on outside first and fifth ;e::1,5
San No. 17 N. rail: stirrup exposed at W. post. Also numerou:>
and tie -wires exposed.
Span No. 1.8. South rail rebar exposed outside first column.
Span No. 19 S. rai'I reb5r expo ed outside third and fifth po >l .
and on in;; id h2t,ween posts 6 and 7, bni,w, 1, >; =.E:, , P :; '7,
and bt.t::... ,a p t.r.; 9 and 10
North rail - rebars exposed riea.r ninth po5t and ne,.ar• 1 !4.h 1 L.
Span No. 21 S. rail third pr::,t from E. end has outr,id _ cct,•
N. rail rebar exposed between first ar i
fourth and f f±h poste: two near rnl h,pan on oo
one showing on last post.
•
Span No. 22 South rail rebars exposed on second post and eighth post (outside).
Span No. 23 South rail small spall inside near second post and third post,
also near fifth post on inside.
North rail: spall outside second, sixth and seventh poet:;;
inside near eighth and ninth posts; outside near ninth and
tneth robs. (bad).
man No. 24 North rail has e :• :posed rebars on seventh and ninth posts.
Span No. 25 North rail has rebars exposed outside top rail: also post seven.
•
Span No. 23 South rail has rebar exposed inside near ninth post.
Span No. 28 South rail rebar exposed top rail near fifth post and out: icJe
near eighth post.
North rail has spa) outside first post near bottem; 51
outride and under rail near fourth post. Spa.11 out: irle
of seventh post.
Spurr No. 29 South ra:i1 siolls on outside post one, three, four and -ix.
Span No. 30 South rr it rr b'r exposed outside fourth post, and on L-p
rail between second and third posts.
Span No. 31 South rail ha:; rebar exposed near third port and ator i;r,<,t.
North rai1 outside posts 1 and 10 - spoiling and run-a.r-
Span No. 32 South rail ha:r rebars exposed on top rail near E. r rd
North rail Ur t f: ; ec.ind and third po:;t, t i:rr"' i;c :.. ,r
top railiu ; - ' Lars showing.
Span No. 33 South rail h•rin numerous rebars and tie wire :;howi n`r •i n t.hc,
top rail; 'a1 ;o in the 1-s :t post.
Span No. alt South rail has tho end of a rebar expo:;;: c? rn f ii ,t po' L .
N. rail bety, en third and fourth post; ' ,o ,t.
Span No. 35 South rail exposed rebars on inside between posts 4 and 5,
8 and 9, and 9 and 10.
North rail has rebars showing outside second, third, fifth and
sixth posts; and inside top rail near seventh post.
Span No. 36 South rail - rebars exposed top rail between posts 2 and 3,
and between posts 7 and 8: and outside between posts 9 and 30.
North rail - rebars exposed on outside of bottom rail between
posts 2 and 3, and 3 and 4: also on the inside of the top rail
between poets 2 and 3; and outside of post 113.
Span No. 37 South rail - on first post: also outside third post also on the
top rail between posts 6 and 7, 7 and 8, 8 and 9.
Span No. 38 South rail - rebars exposed on top rail between posts 1 and 2,
2 and 3, 7 and 8. Also on posts 3 and 5.
North rail - rebar exposed on bottom rail outside near first
post, plus map cracking between posts 2 and 3. Top rail has
rebar expo;;od between posts 9 and 10.
Span No. 39 South rail. - Exposed rebar in inside of top rail_ bc,t.l,r s,r.
posts 2 and 6; also on the outside between posts 3 and 4.
Also on bottom rsil between posts 6 and 7, and o tH d'l ..
North r ] -- rob, + exposed on outside ni bottr rail n
post; and on i.o; -i.:le of top rail betw,o n poai,;; 8 and
on the inside Nee of post 9.
Span No. 40 South rail - rebars exposed on first po ;t, on thf, :i.nt trl
posts 8 and 9, ar'd the outside of post JO. r1; i',h" t; :
rail between posts 1. and 2, 2 and 3, 6 r.n j 7, 9 •?.nd. 10.
North rail - mbar showing inside first po: 1, and r :;th j
5. Sidewalks
Span No. 1 Minor hairline cracks on north. walk.
Span No. !± South walk - rebars exposed 20" and 12" E. cnd.
Span No. 5 Longitudinal. crack 20' long at E. end.
;ipan No. 7 North walk - rebar exposed 8" long near third post.
Span No. 9 South walk - exposed rebar near ninth post.
Sian No. 35 South walk - transverse crack near fifth column.
6. Curbs
;rl.n No. 1 North cure - minor hairline cracks.
Span No. 6 North curb -• hairline crack near E. end.
51-1.n No. 12 Rebar-; : nu, near third and seventh po,9t :;; ;,t, r_i 1 on
;ur fa let, r ;f.n posts 8 and 9.
;; No. 16 SOUL') . l" -. i :i ;r ry near center of i .
_ - 1
:;ran No. 19 ; >outh curb - robars exposed between po ;t:; d ani 7.
:pan No. 20 Nrr' _ , t. n.1;:r r;n cracks on both eu_rh
'.t....rn_No• 21 Sou h c'; rb -- nilme rolls transverse h 1.ri.lr"'. ;?'rC1C' .
in No. 22 F3oti1 c;!r..'l. ;, _ 1r1,1 rn.:r rolls transverse h -a. i rl i ru? c'. ,..'iC.= .
pn.n No 23 South 5:1" Y 11 1 on curb and -i n ! Y7.
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^ J2 No. ' N(1 o e :po rCi )i . °. ". 'ti: .
pan No. 31t North •-ir,- crack near' i 1 !..
4
7. Fishwalks
There is a corner spall on the West end of the West fishwalk. On the
North stair, the center pile has exposed rehars. On the South stair,
the fourth pile has a corner spall (old repair). Under Span No. 9,
there is a corner spall on a rail post.
The fishwalk pile cap under Span No. 10 has' s. crack on the 4.. side.
The fishwalk pile cap under Span No. 11 has cracks on all iidcs with
some spalling on the E. side. The cap under Span No. 12 has crick° on
E. and W. sides; a i : undo me -, th between piles. The s conci i tiou
prevails on the cap under Span No. 13, and Span No. 14
On the stairs at the E. end, there are numerous rebar3 e In
the surface of the i tl k it se] f, there is a 24" dia. surr-Lcc:
There are surface srill s in the grout in the wrt1.k order Cpn No. 30.
Nearly all of the expansion joints in the fishwalk need rep i r work.
The original moulded Thi nl. ;rateria1 has settled or fallen nut The
resultant voids 'a.re t,c:coma tag filled with trash, some of which ; s
incompressible. The sealing affect is also lest, a 1o4i n
to penetrate through to the caps below .
There are numerous hairline cracks in the welds of the nlumiru'l
handrails. Because, of the difficult logistics of '.1 _'dn }:..
continue to monitor until !.hc conl:i.t i.on beconc;: more :;f:. ions
8. Fender System
Piling - About 1.0;1 of thy: piling in the West : ;idr, 11 :.}
severely in the splash zone area., and are below 50;: if :h,
cross - section area. On the East side, about 12,E are at least 50%
below original.
Timbers - Generally, the timbers are in good condition. Ilowuver, there
are numerous blocks that have worked loose and should be re- secured.
Cables - The cables on the dolphins and on the cluster piles should
be coated with bitumastic protective coating. The lower cables on
South outboard dolphin on the West side need:- early attention.
k
9. Roadway approaches - There are numerous cracks in the blacktop,
especially on the West side.
Guardrails - The guardrails are partially hidden by weeds and shrub,.
The last post bolt on the East rail is loose. Nearly all of the refl nci�.ors
have been vandalized.
Slope protection - There is .a heavy stormwater erosion cut on th +
side of the West end. On both ends, there are blow -out zone: in h.hcr
rip -rap that need elrly attention.
10. Joints - In general, the pre- moulded expansion joint rrateri-41 1 r tI,
deck is loose, cracking, becoming dislodged, fallen out, and is no
I Heger efficient. F, rt th �.� e,r' is ineffective in kr I+I tT, n . t , . ; ..
ibl from locig I n 11- c . 'f'Ii i i I T .,,t. tf l, 1,. t'
of the spalls at th0 deck :rrr' s . Expan,^ion dam ' i r ^ L r�r'.tr .
11 . Beams - All pre - stressed concrete beams were found to bP in Fywd cart' `.icarr.
12. Structural steel. - AU ' ;t,ruct '"'i steel in Spars 20, 21, a i 2 • -.
observed to he in good cnn i i.ion.
13. Bearing Shoes - A:; de Frr>in fl i1 corrosion, cc.ndtisran 1^ ge 1.
14. Abutments - No unsatisfactory conditions foumd.
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