Materials & Equipment
Complete Materials List
Everything you need to build one 8’ × 2’ × 3’ bridge abutment.
📦 Materials Shopping List
Rebar & Steel
| Item | Specification | Quantity | Unit Cost | Total | Where to Buy |
|---|---|---|---|---|---|
| #4 Rebar | Grade 60, 10’ lengths | 14 bars | $8 | $112 | Home Depot, Lowe’s |
| Rebar Tie Wire | 16 gauge, black annealed | 1 roll | $15 | $15 | Home Depot, Lowe’s |
| Rebar Chairs | 3” height, plastic | 30 pcs | $1 | $30 | Concrete supply |
| Bearing Plates | 12”×12”×1/2” A36 steel | 2 plates | $100 | $200 | Steel fabricator |
| Ground Anchors | Fiberglass #4, 8’ long | 6 pcs | $40 | $240 | Concrete supply |
| SUBTOTAL: | $597 |
Concrete & Aggregates
| Item | Specification | Quantity | Unit Cost | Total | Where to Buy |
|---|---|---|---|---|---|
| Ready-Mix Concrete | 3000 PSI, 4” slump | 2.0 CY | $150/CY | $300 | Local ready-mix |
| AB3 Aggregate Base | Compacted base material | 0.75 ton | $40/ton | $30 | Aggregate supplier |
| Vapor Barrier | 6-mil polyethylene | 10’ × 4’ | $10 | $10 | Home Depot, Lowe’s |
| SUBTOTAL: | $340 |
Drainage
| Item | Specification | Quantity | Unit Cost | Total | Where to Buy |
|---|---|---|---|---|---|
| PVC Pipe | 4” Schedule 40, 10’ length | 1 length | $30 | $30 | Home Depot, Lowe’s |
| PVC End Caps | 4” diameter | 2 | $5 | $10 | Home Depot, Lowe’s |
| SUBTOTAL: | $40 |
Forms & Accessories
| Item | Specification | Quantity | Unit Cost | Total | Where to Buy |
|---|---|---|---|---|---|
| Form Lumber | 2×6 or 2×8, 8’ lengths | 8 boards | $8 | $64 | Home Depot, Lowe’s |
| Form Stakes | 2×2, 3’ long | 12 stakes | $3 | $36 | Home Depot, Lowe’s |
| Form Oil/Release | 1 gallon | 1 gal | $20 | $20 | Concrete supply |
| Duplex Nails | 16d, for forming | 5 lbs | $6 | $30 | Home Depot, Lowe’s |
| SUBTOTAL: | $150 |
💰 TOTAL PROJECT COST
Materials Cost Breakdown
| Rebar & Steel: | $597 |
| Concrete & Base: | $340 |
| Drainage: | $40 |
| Forms & Accessories: | $150 |
| TOTAL MATERIALS: | $1,127 |
Additional Costs (Optional)
- Labor (if hiring): $500-800
- Equipment Rental: $200-300
- Permits/Inspections: $100-500
- Contingency (10%): $110
TOTAL PROJECT: $1,100-2,800 (depending on labor and equipment)
🛠️ Tools & Equipment
Tools You’ll Need
Essential (Must Have)
- Plate Compactor - Rental: $75/day
- For AB3 compaction (95% required!)
- Alternative: Jumping jack compactor
- Concrete Vibrator - Rental: $40/day
- Electric immersion vibrator
- Alternative: Rent with concrete truck
- Laser Level or Transit - Rental: $50/day
- Critical for bearing plate elevation
- Alternative: Water level (DIY)
- Rebar Bender - Purchase: $150 or Rental: $30/day
- Manual or hydraulic
- Essential for making hooks
- Angle Grinder with Cut-off Wheel - Purchase: $80
- For cutting rebar
- Alternative: Rebar cutter ($100)
Standard Tools (Probably Have)
- Tape measures (25’ and 100’)
- Carpenter’s level (48”)
- Shovels (round point and square)
- Rake
- Wheelbarrow
- 5-gallon buckets
- Hammer
- Wire cutters
- Pliers
- Chalk line
- Marking paint or stakes
Nice to Have
- Rotary hammer drill (for ground anchors)
- Concrete mixer (if not using ready-mix)
- Power screwdriver
- Circular saw (for forms)
Safety Equipment
- Hard hat
- Safety glasses
- Work gloves (heavy leather)
- Steel-toed boots
- Dust mask/respirator
- Ear protection
- First aid kit
- Sunscreen
- Water cooler
📋 Material Specifications
Rebar Specifications
Grade 60 #4 Rebar
- Diameter: 1/2” (0.500”)
- Cross-sectional area: 0.20 sq in
- Weight: 0.668 lb/ft
- Yield strength: 60,000 PSI
- Tensile strength: 90,000 PSI
- Markings: Look for “60” rolled into bar
Identification:
- Must have mill markings
- Grade mark “60” or “S” (for 60 ksi)
- Producer identification
- Bar size “#4”
Concrete Specifications
Ready-Mix Concrete
- Minimum strength: 3,000 PSI at 28 days
- Recommended: 4,000 PSI for better durability
- Slump: 4 inches ±1 inch
- Maximum aggregate size: 3/4”
- Air entrainment: 5-7% (if freeze-thaw exposure)
- Water-cement ratio: 0.50 maximum
When ordering, tell supplier:
- “3,000 PSI concrete, 4-inch slump”
- “For foundation/structural work”
- “Need 2.0 cubic yards”
- Delivery time and location
AB3 Aggregate Specifications
AB3 (Aggregate Base Course)
- California specification for base aggregate
- Well-graded crushed stone
- Sizes: 3/4” down to fines
- Compaction: 95% Modified Proctor minimum
- Alternative names:
- Class 2 Base Rock
- Dense Grade Aggregate
- Road Base Material
Steel Plate Specifications
Bearing Plates
- Material: ASTM A36 structural steel
- Dimensions: 12” × 12” × 1/2” thick
- Minimum yield: 36,000 PSI
- Holes: Not required (embedded in concrete)
- Finish: Mill finish (no coating needed)
- Tolerances: ±1/16” on dimensions
Where to get:
- Local steel fabricator
- Online: metalsdepot.com, onlinemetals.com
- Alternative: Use steel service center
🏪 Where to Buy
Local Suppliers
Big Box Stores (Home Depot, Lowe’s)
- Rebar (usually in stock)
- Concrete accessories
- Form lumber
- PVC pipe
- Hand tools
- Safety equipment
Concrete Supply Stores
- Rebar chairs and accessories
- Form oil
- Specialized concrete tools
- Ground anchors
- Wire ties
Ready-Mix Concrete
- Search: “ready mix concrete near me”
- Call for pricing and delivery
- Schedule 2-3 days in advance
- Minimum order may be 1 CY
Aggregate Suppliers
- Search: “landscape supply” or “rock yard”
- AB3/Class 2 base rock
- Delivered or pickup
- Need truck or trailer for pickup
Steel Fabricators
- Search: “steel fabrication near me”
- Custom bearing plates
- Usually 1-2 week lead time
- Can cut to exact size
Online Suppliers
For Rebar:
- homedepot.com - Delivery available
- lowes.com - In-store pickup
- rebarmart.com - Bulk orders
For Steel Plates:
- metalsdepot.com - Cut to size
- onlinemetals.com - Small quantities
- Local steel service center (cheaper)
For Specialty Items:
- concreteproducts.com - Ground anchors
- grainger.com - Industrial supplies
📦 Delivery & Storage
Receiving Deliveries
Rebar Delivery:
- Check quantity (count bars)
- Check length (measure)
- Inspect for damage/rust
- Store off ground on 2×4s
- Cover with tarp if storing >1 week
Concrete Delivery:
- Have site prepared and crew ready
- Clear path for truck
- Test cylinders ready
- Vibrator ready
- Forms complete and inspected
AB3 Delivery:
- Have dump location prepared
- Level ground for pile
- Cover with tarp if rain expected
Material Storage
Before Construction:
- Store rebar off ground (prevents rust)
- Keep form lumber dry
- Protect cement from moisture
- Store tools securely
During Construction:
- Keep concrete area clean
- Stage materials for easy access
- Protect partially completed work
- Remove trip hazards daily
🧮 Material Calculators
How Much Do I Need for TWO Abutments?
| Material | One Abutment | Two Abutments |
|---|---|---|
| #4 Rebar (10’ bars) | 14 | 28 |
| Concrete | 2.0 CY | 4.0 CY |
| AB3 Base | 0.75 ton | 1.5 ton |
| Bearing Plates | 2 | 4 |
| Ground Anchors | 6 | 12 |
| Drainage Pipe (4”) | 6 ft | 12 ft |
| Total Cost | ~$1,100 | ~$2,200 |
Waste Factors
Add these percentages for waste/mistakes:
- Rebar: +10% (2 extra bars)
- Concrete: +15% (included in 2.0 CY order)
- Form lumber: +20% (mistakes happen)
- Wire ties: +50% (they’re cheap, buy extra)
✅ Pre-Purchase Checklist
Before you order, verify:
- Exact quantities calculated
- Local suppliers identified
- Delivery dates coordinated
- Storage location prepared
- Tools rented/purchased
- Crew availability confirmed
- Weather forecast checked
- Permits obtained (if required)
💡 Money-Saving Tips
- Buy in bulk: If building 2 abutments, order all at once
- Rent vs. buy: Rent expensive tools (compactor, vibrator)
- Shop around: Get quotes from 3 concrete suppliers
- Timing: Order concrete mid-week (cheaper than weekends)
- Pick up: Save delivery fees on small items
- Reuse forms: If building 2 abutments, reuse lumber
- Group orders: Coordinate with neighbors for bulk pricing
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