Inspection & Quality Control
Complete Inspection Checklists
Ensure your abutment meets all structural and safety requirements.
📋 Inspection Overview
✅ Three Critical Inspection Points
- Pre-Pour Foundation - Before base concrete
- Pre-Pour Wall - Before wall concrete
- Final Inspection - Before loading bridge
🔍 Inspection #1: Pre-Pour Foundation
Timing: Before pouring base slab concrete
Inspector: Self or building inspector
Duration: 30-60 minutes
Foundation Checklist
Excavation & Bearing Soil
- Excavation dimensions correct (9’ × 3’ × 1.5’ deep minimum)
- Reached firm bearing soil (no soft spots, organics, or mud)
- Bottom level within ±1”
- No standing water or wet areas
- Side slopes stable
Pass Criteria: Firm soil that forms a ball when squeezed but isn’t muddy
AB3 Aggregate Base
- Vapor barrier installed on bearing soil
- AB3 material correct (well-graded crushed stone)
- Installed in three 4” lifts
- Each lift compacted separately
- CRITICAL: Compaction test shows ≥95% Modified Proctor
- Final surface level within ±1/2”
- Thickness correct (12” total)
Pass Criteria: Compaction test documentation showing 95%+ (REQUIRED!)
Ground Anchors
- Quantity correct (6 anchors)
- Material: Fiberglass #4 rebar, 8’ long
- Driven to 6’ minimum depth
- Spacing correct (24” along length)
- Rows at 6” and 18” from front edge
- Plumb (within 1/4” per foot)
- Protruding 2’ above AB3
- Not damaged during installation
Pass Criteria: All anchors at correct depth and spacing
Base Slab Rebar
- All bars are #4 Grade 60 (check markings)
- Quantity correct:
- R1: 2 longitudinal bars @ 9’
- R2: 8 transverse bars @ 3’
- Rebar spacing correct (12” o.c. for transverse)
- Concrete cover: 3” minimum on all sides
- Rebar chairs at 3” height (not wood blocks!)
- All intersections tied with wire
- Bars clean (no loose rust, mud, or oil)
- No damaged or bent bars
Pass Criteria: Use cover meter or measure - 3” minimum cover is CRITICAL
Bearing Plates
- Quantity: 2 plates
- Size: 12” × 12” × 1/2” thick (A36 steel)
- Position Plate 1: 30” from left edge, 18” from front
- Position Plate 2: 66” from left edge, 18” from front
- Elevation: 36” above AB3 (top of wall height)
- Both plates level (within 1/16”)
- Elevated on chairs/supports (not sitting on AB3)
- Wired to rebar to prevent movement
Pass Criteria: Laser level shows plates at exact same elevation ±1/16”
Drainage Pipes
- Quantity: 2 pipes (4” PVC Schedule 40)
- Position 1: 36” from left edge
- Position 2: 72” from left edge
- Front elevation: 6” above AB3
- Back elevation: 3.6” above AB3 (2% slope)
- Slope toward creek side (confirmed with level)
- Supported to prevent movement
- Pipes clean inside (no debris)
Pass Criteria: 2% minimum slope confirmed with level
Inspection #1 Sign-Off
Inspector Certification
Inspector Name: _______________________________
Date: ______________ Time: ______________
Result: ☐ PASS - Approved to Pour ☐ FAIL - Corrections Required
Notes/Deficiencies:
_________________________________________________________________
_________________________________________________________________
Signature: _______________________________
🔍 Inspection #2: Pre-Pour Wall
Timing: After base cured 7 days, before pouring wall
Inspector: Self or building inspector
Duration: 30-45 minutes
Wall Inspection Checklist
Base Slab Condition
- Cured minimum 7 days
- No significant cracks (hairline OK)
- Surface clean (no debris, dirt, oil)
- Top surface level
- Bearing plates at correct elevation
- Test cylinders available for review
Pass Criteria: Compressive strength ≥2,000 PSI after 7 days
Wall Vertical Rebar (R3 & R4)
- Quantity correct:
- R3: 8 front verticals @ 3’
- R4: 8 back verticals @ 3’
- Spacing: 12” on center along 8’ length
- Bottom lap: 6” minimum into base
- Vertical through wall: 24”
- Top hook: 6” horizontal
- All bars Grade 60 #4
- Concrete cover: 3” on all faces
- Bars plumb (within 1/4” per foot)
- No damaged bars
Pass Criteria: Spacing accurate, proper lap lengths, correct cover
Wall Horizontal Rebar (R5)
- Quantity: 16 bars (8 per level × 2 levels)
- Length: 3’ each
- Level 1 elevation: ~12” above base (mid-wall)
- Level 2 elevation: ~30” above base (near top)
- Spacing: 12” o.c. along length
- Hooks: 6” at each end, wrapping verticals
- All intersections with verticals tied
- Concrete cover maintained
Pass Criteria: Horizontal bars at correct elevations, properly tied
Wall Forms
- Form material adequate (2×6 or 2×8 minimum)
- Form height: 24” (2 feet)
- Forms plumb (check with level)
- Adequate bracing (concrete is heavy!)
- No gaps in forms (seal with tape if needed)
- Forms oiled for easy removal
- Snap ties or spreaders at 24” spacing
- Forms secure at base (won’t blow out)
Pass Criteria: Forms plumb within 1/4” per 10 feet
Inspection #2 Sign-Off
Inspector Certification
Inspector Name: _______________________________
Date: ______________ Time: ______________
Result: ☐ PASS - Approved to Pour ☐ FAIL - Corrections Required
Notes/Deficiencies:
_________________________________________________________________
_________________________________________________________________
Signature: _______________________________
🔍 Inspection #3: Final Inspection
Timing: Minimum 14 days after wall pour, before loading
Inspector: Building inspector (official)
Duration: 45-90 minutes
Final Inspection Checklist
Curing & Strength
- Minimum 14-day cure at 70°F
- Extended cure if cold weather
- Test cylinders broken and reviewed
- Compressive strength ≥3,000 PSI
- Documentation available
Pass Criteria: Test cylinders show 3,000 PSI minimum at 28 days
Concrete Quality
- No significant cracks (>1/16” width)
- No honeycombing or voids
- Proper consolidation around rebar
- Surface finish acceptable
- No spalling or deterioration
- Bearing plates fully embedded
- Bearing plates at correct elevation
Pass Criteria: Sound concrete with no structural defects
Dimensional Accuracy
- Overall length: 8’-0” ±1/4”
- Overall depth: 2’-0” ±1/4”
- Overall height: 3’-0” ±1/4”
- Wall plumb: within 1/4” per 10’
- Bearing plate spacing: 36” ±1/4”
- Bearing plates level: ±1/8”
- Bearing plate elevation: correct for beam height
Pass Criteria: All dimensions within tolerance
Drainage System
- Pipes functional and clear
- Water flows through pipes
- 2% slope maintained
- Outlets clear and accessible
- No clogs or obstructions
- Screens/grates installed
Pass Criteria: Water flows freely through drainage system
Backfill & Grading
- Backfill properly compacted
- No voids behind wall
- Surface graded away from wall
- No ponding water near abutment
- Approach area stable
Pass Criteria: Proper compaction and drainage
Safety & Access
- Site cleaned up
- No tripping hazards
- Temporary barriers if needed
- Access clear for beam installation
- Forms removed and disposed of
Pass Criteria: Site safe for beam installation
Final Inspection Sign-Off
Official Inspector Certification
Inspector Name: _______________________________
License #: ______________ Jurisdiction: ______________
Date: ______________ Time: ______________
FINAL DETERMINATION:
☐ APPROVED - Ready for beam installation
☐ CONDITIONAL - Corrections required (see notes)
☐ REJECTED - Major deficiencies
Conditions/Notes:
_________________________________________________________________
_________________________________________________________________
_________________________________________________________________
Maximum Load Rating: _____________ lbs per abutment
Inspector Signature: _______________________________
Date: ______________
📷 Photo Documentation
Required Photos for Inspection
Take photos at each stage:
Foundation Stage:
- Excavation (before AB3)
- AB3 installation (during compaction)
- Ground anchors installed
- Base rebar grid (before pour)
- Bearing plates positioned
Wall Stage:
- Base after 7-day cure
- Wall rebar installed
- Forms erected and braced
- During wall pour
- Wall after form removal
Final Stage:
- Completed abutment (all angles)
- Bearing plates (close-up)
- Drainage outlets
- Overall site conditions
File naming: [Date]_[Stage]_[Description].jpg
⚠️ Common Inspection Failures
Top 10 Reasons Abutments Fail Inspection
❌ #1: Insufficient Concrete Cover
Required: 3" minimum
Common mistake: Using wood blocks instead of proper chairs
Fix: Remeasure before pour, use correct height chairs
❌ #2: Poor AB3 Compaction
Required: 95% Modified Proctor
Common mistake: No compaction test
Fix: Hire testing company ($100-200)
❌ #3: Bearing Plates Misaligned
Required: Exact position ±1/4"
Common mistake: Not using laser level
Fix: Rent laser level, measure three times
❌ #4: Inadequate Lap Splices
Required: 6" minimum into base
Common mistake: Verticals not lapped enough
Fix: Ensure 6" lap before wall pour
❌ #5: Premature Loading
Required: 14 days minimum cure
Common mistake: Loading after 7 days
Fix: Wait for test cylinders, minimum 14 days
📊 Inspection Summary Form
Print this page for your records
ABUTMENT INSPECTION SUMMARY
Project Location: _______________________________________
Owner: _______________________________________
Contractor: _______________________________________
| Inspection | Date | Result | Inspector |
|---|---|---|---|
| Foundation (Pre-Pour) | ________ | ☐ Pass ☐ Fail | ________ |
| Wall (Pre-Pour) | ________ | ☐ Pass ☐ Fail | ________ |
| Final Inspection | ________ | ☐ Pass ☐ Fail | ________ |
PROJECT STATUS:
☐ APPROVED FOR BEAM INSTALLATION
☐ CONDITIONAL APPROVAL (see notes)
☐ NOT APPROVED
Notes: __________________________________________________
_________________________________________________________________
_________________________________________________________________
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