410PRECAST CONCRETE BOX CULVERT

410-1Description

Provide precast four -sided concrete box culverts as an alternative to the structure shown in the Contract Documents. Only monolithic segments, or two -piece segments with three-sided bottom sections and a simple support top slab section, are permitted. Two -piece segments are limited to installations with a minimum of two feet fill height above the top slab. Construct headwalls, wingwalls and other special features using ca st-in-place concrete. Precast wingwalls, cut -off walls or headwalls are not permitted unless otherwise noted in the Contract Documents. Meet the requirements in 449 -1.

410-2Materials

Ensure that the materials used for the construction of precast box cu lverts have certification statements from each source, showing that they meet the applicable requirements of the following: Portland Cement Concrete ................................ ..Section 346 Reinforcing for Concrete ................................ ....Section 415 Precast Concrete Drainage Products ................... Section 449 Wire for Site Cage Machines .............................. Section 931 Coarse Aggregate * ................................ ..............Section 901 Fine Aggregate * ................................ .................. Section 902 Curing Materials for Concrete ............................ Section 925 Materials For Concrete Repair ** ........................ Section 930 Non-Shrink Grout ** ................................ ...........Section 934 Liner Repair Systems ................................ ..........Section 948 Joint Materials ............................ ASTM C443, ASTM C877 ................................ ................................ ..... or ASTM C990 Geotextile Fabrics ................................ ............... Section 985 * The gradation requirements of aggregates ar e not applicable when using dry-cast concrete. ** Use products listed on the Department’s Approved Product List ( APL).

410-3Materials Acceptance and Testing of Precast Box Culverts

410-3.1General: Meet the requirements of Section 346, except as modified herein:

Prepare, cure, and test the test cylinders in accordance with ASTM C31 and ASTM C39 test methods. Follow the alternative method of compaction, in accordance with ASTM C497, if the consistency of concrete is too stiff for compaction by rodding or internal vibrations. Expose shipping strength test cylinders to the same curing conditions as the precast concrete box sections. Performal l concrete quality control testing and inspections in accordance with 346-9.2. For training and other qualifications meet the requirements of Section 105. Test all QC samples for compressive strength in a laboratory meeting the requirements of 430 FY 2023-24 Return to Table of Contents

410-3.2Quality Assurance Inspection and Testing: The Engineer will perform

periodic inspections, sampling, and testing to ensure of the quality and acceptability of the materials, methods, techniques, procedures and processes being utilized by the man ufacturing facility in the fabrication of precast concrete box culverts.

410-3.3Special Requirements for Dry -Cast Concrete: Dry-cast concrete is defined as

a very low slump concrete that requires continuous and intense vibration to compact the concrete, enabling immediate removal of the side forms without detrimental effects to the concrete when used in a dry -cast manufacturing process. The target slump , air content ranges , and the plastic property tolerances of Section 346 are not applicable to dry -cast concrete. Perform absorption tests on specimens from each LOT of dry -cast production in accordance with the test methods in ASTM C497. The absorption of each specimen must not exceed 9.0 percent of the dry mass for Test Method A procedure or 8.5 percent for Test Method B procedure. All specimens must be free of visible cracks and must represent the full thickness of the product. Test specimens after 28 days of standard curing, or prior to the date of shipping if the precast box sections are to be shippe d before the completion of the 28 day curing period. Core three specimens for Test Method B in accordance with ASTM C42 and meet the sampling location and size requirements of ASTM C497. Prepare or core a minimum of one specimen for Test Method A in accordance with the test cylinder requirements of ASTM C497. When the initial absorption specimen from a concrete box section fails to conform to this Specification, the absorption test may be made on another specimen from the same box section and the resu lts of the retest may be substituted for the original test results for acceptance of the LOT. The manufacturer may test each box section within a LOT and cull the box sections not meeting absorption requirements marking them as deficient with waterproof pa int or other approved means. Deficient box sections must not be shipped to the project site. Reduce the frequency of absorption tests to one test every five LOTs when the results of five consecutive LOTs meet the specified limit.

410-4Design of Precast Co ncrete Box Sections

410-4.1General: In lieu of a cast -in-place concrete box section or if specified in the

Contract Documents, provide precast box culverts in accordance with Standard Plans, Index 400-291 and the following: Segment lengths must be bet ween 4 feet and 16 feet. Short -side wall lengths for end segments of skewed culverts, may be less than 4 feet when approved by the Engineer. Provide tongue and groove joints at the ends of segments. For two -piece box culvert segments, provide keyed joints for the top slab -to-wall connection to prevent lateral displacement at the top of the walls, and double -sided tongue and groove joints in the bottom slab to minimize differential settlement between segments. Alternate methods to prevent differential sett lement may be used when included in the Contract Documents or approved by the Engineer. Concrete cover at the joints may be reduced from the nominal cover shown in the Contract Documents, in accordance with the Standard Plans , but not less than 1 inch clear to the ends or inside mating surfaces of the joints or 1 -1/2 inches clear to the outside surface of the joint for slightly and moderately aggressive environments, or 2 inches clear to the outside surface for extremely aggressive environments. Meet one of the following design options: 431 FY 2023-24 Return to Table of Contents 410-4.1.1 Equivalent to Cast -In-Place Designs: Provide precast box segments identical to the plan details, including reinforcing steel grade or FRP reinforcing type , sizes and spacings, concrete cover, concrete class, and slab and wall dimensions. Reinforcing bar sizes and spacings may be reduced provided the equivalent area of reinforcing is provided in each layer. Haunch dimensions may be increased with the approva l of the Engineer, but not greater than 8 inches for box culverts with internal spans less than 6 feet, or 12 inches for box culverts with larger internal spans. 410-4.1.2 Standard Precast Designs: Provide precast box segments in accordance with Standard Plans, Index 400-292 with the same hydraulic opening, fill height and reinforcing bar cover as shown in the P lans, for the most critical design loading combination. Perform a bridge load rating in accordance with the Structures Design Guidelines, for any multiple barrel culverts with a total span equal to or greater than 20 feet, when measured between the inside face of end supports, along the centerline of the roadway crossing. 410-4.1.3 Modified or Special Designs: Submit Modified Designs which differ from the standard precast designs in 410 -4.1.2 with modifications to the wall and slab thickness haunch dimensions , or the use of FRP reinforcing . Submit Special Designs for sizes, elements and loads other than those referenced in 410 -4.1.2. Redesign box c ulverts using the same AASHTO design specification, live load, hydraulic opening, fill height, minimum concrete class and concrete cover as shown in the Contract Documents. Special Designs will be required for all two-piece concrete box culvert segments. P rovide a minimum member thickness not less than 75% of the thickness of the corresponding member of an equivalent Standard Plans, Index 400- 292 box culvert, but not less than 7 inches for culverts with 2 inch concrete cover or 8 inches for 3 inch concrete cover. Perform a bridge load rating in accordance with the Structures Design Guidelines, for any redesign with a total span equal to or greater than 20 feet, when measure between the inside face of end supports, along the centerline of the roadway crossing .

410-4.2Design Submittals: Submit shop drawings for all design options in accordance

with 410-12. Submit design calculations, revised plans and load rating when required for approval in accordance with Section 5 for Modified or Special Designs. Ensure that a Specialty Engineer performs the design for Modified Designs of the box culvert and signs and seals the calculations. Ensure that the Contractor’s Engineer of Record performs any bridge load rating and the design for any Special Designs and signs and seals the revised plans, calculations and load rating.

410-5Other Elements of a Precast Box Culvert System

Extend reinforcing from precast sections to provide adequate splice lengths or utilize a mechanical rebar splicing system (steel reinfor cing only) listed on the Department’s Approved Product List ( APL) for securing reinforcing dowels for headwalls, toe walls and wingwalls. Cast all elements of the headwalls and wingwalls (footing and stem) in -place, unless otherwise noted in the Contract Documents. Cast all cut -off or toe walls for precast box end segments in -place only. Extend the depth of cut -off or toe walls an additional 6 inches with the limits of the bedding material. Bedding material and compaction requirements for wingwalls are the same as required for precast box sections, except that the granular material may be placed to the inside edge of the toe wall, unless otherwise specified in the Contract Documents. Bedding material is not required for cast -in-place wingwall footings. 432 FY 2023-24 Return to Table of Contents All requirements of Section 400 and Section 415 apply to the fabrication of these elements. Backfill the locations behind the walls in accordance with the requirements of Section 125.

410-6Fabrication

410-6.1Casting: Cast precast elements in unyielding be ds and forms. Ensure bearing

surfaces in casting forms are level and straight, and vertical surfaces are plumb prior to casting. Ensure surfaces within the forms against which concrete will be cast, are clean and free from rust and hardened residual concre te. Provide full concrete cover clearance to all form wires and other miscellaneous pieces of metal, except as permitted by Section 415. Bend all tie wires away from the form surface to provide maximum concrete cover. Provide inserts and lifting devices in accordance with 450 -9.2.1.

410-6.2Surface Finish: Finish the precast elements in accordance with 400 -15.1

410-6.3Curing: Perform the curing by any method prescribed in Sections 400 and 450,

or by any other Department approved alternate curing method included in the approved Producer QC Plan, or combinations thereof that have provided satisfactory results.

410-6.4Fabrication Tolerances:

410-6.4.1 Internal Dimensions: Ensure the internal dimensions do not vary more than 1% from the design dimensions, with a maximum of 3/4 inch. Ensure the haunch dimensions do not vary more than 1/4 inch from the design dimensions. 410-6.4.2 Slab and Wall Thickness: Ensure the slab and wall thickness are not

be less than that shown in the Plans or approved shop drawings by more than 5 percent or

3/16 inch, whichever is greater. A thickness more than that required in the design will not be a

cause for rejection although payment will be for plan quantity only.

410-6.4.3 Length of Opposite Surfaces: Ensure the variations in laying lengths

of two opposite surfaces of the box section are not more than 1/8 inch per foot of clear span, with

a maximum of 5/8 inches for precast boxes with a clear span of up to 7 feet and a maximum of

3/4 inches for boxes with a clear span greater than 7 feet. The exception to this is when beveled

ends, for the purpose of laying curves, or skewed ends are specified by the Engineer.

410-6.4.4 Length of Section: Ensure the under run in length of sections is not

more than 1/8 inch per foot of length with a maximum of 1/2 inches in any box section.

410-6.4.5 Tongue and Groove Joints or Ends: Ensure the planes formed by the

ends of box sections do not vary perpendicular from the joint axis by more than the following:

internal span with a maximum 5/8 inches for internal spans or heights less than or equal to 7 feet,

and a maximum of 3/4 inches for internal spans greater than 7 feet.

or heights less than 5 feet, or more than 3/8 inches for internal spans or heights of 5 feet or

greater.

410-6.4.6 Position of Reinforcement: Meet the requirements of 415-5.10.2 for

the maximum variation in the position of slab reinforcing. Meet the requirements of 415-5.8.2

for the maximum variation of wall reinforcing, except that the concrete cover must not be less

than 1/4 inches nor more than 1/2 inches from the design dimensions.

410-6.4.7 Area of Reinforcement: Provide the area of reinforcement as indicated

in the Plans or approved shop drawings as a minimum. If welded wire reinforcement is utilized

in lieu of mild steel reinforcement, the provisions of 415-6 apply. 433FY 2023-24Return to Table of Contents

410-6.5Removal of Forms: Remove forms after the concrete has attained the minimum

compressive strength requirements included as part of the Producer QC Plan, but not less than

the following:

Table 410-1

Vertically cast walls and slabs for four-sided sections 1,000 psi

Three-sided box culvert bottom section 2,500 psi

Horizontally cast self-supporting slabs or walls 2,500 psi

Products manufactured with dry-cast concrete, are exempt from these

requirements.

410-6.6Lifting and Removal From Casting Area: Handle all products, including those

manufactured with dry-cast concrete, after the concrete attains sufficient compressive strength as

determined by the manufacturer but not less than the following, unless otherwise approved in the

Producer QC Plan:

Table 410-2

Vertically cast and stored elements (walls and slabs) 1,000 psi

Form/pallet supported elements (walls or slabs) 1,000 psi

Self-supporting four-sided sections 1,000 psi

Self-supporting horizontal slabs or three-sided sections 2,500 psi

Limit the flexural tension stresses from handling to a maximum allowable stress

of three times the square root of the concrete compressive strength in psi, prior to the concrete

attaining the required 28-day strength.

410-7Handling, Storage, and Shipping

Handle, store, and ship precast box culverts in a manner that prevents chipping, cracks,

fractures, and excessive bending stress. Do not ship precast box culverts before the concrete

attains the required 28-day strength.

The manufacturer is permitted to verify the shipping strength test, before 28 days, by

testing compressive strength cylinders that are cured under the conditions similar to the product

or by testing temperature match cured cylinders. The manufacturer may use the maturity method,

ASTM C 1074, pulse velocity method in accordance with ASTM C 597, or any other approved

nondestructive test method to estimate the strength of concrete for determining form removal and

handling strengths or before verification of shipping strength by test cylinders.

Curing temperature and cycle must be monitored on a minimum of one box culvert

curing cell from each day of production when nondestructive test methods or temperature match

cured cylinders are used to determine concrete strengths.

The shipping strength test is the average compressive strength of two test cylinders. Do

not ship any products until the QC Manager’s stamp is affixed to the product.

410-8Repairs and Rejection

Evaluate cracks, spalls and other deficiencies in accordance with 450-12. Classify

fractures and cracks passing through the wall or slab, except for a single end crack with a length

that does not exceed the depth of the joint, as major cracks. Walls and slab areas outside the 434FY 2023-24Return to Table of Contents

middle half of the internal span will be considered non-critical locations for the purpose of

evaluating cracks. Repair cracks and all other deficiencies in accordance with 450-13 or the

plant’s approved repair methods that are included as part of the Producer QC Plan. Ensure that

the original performance and durability of the repaired box culverts are maintained.

Use materials for concrete repair that will meet or exceed the strength requirement of the

class of concrete used. Materials meeting the requirements of Section 930 may be substituted for

non-shrink grout when required by 450-13. Precast box culvert elements are subject to rejection

if they fail to conform to any of the Specification requirements after repair or when damaged

ends would prevent making a satisfactory joint.

410-9Marking

Ensure each section of Precast Box Culvert has permanently and clear marking on an

inside face by indentation, waterproof paint, or as specified in the Producer QC Plan, showing

the manufacture date, serial number, project number, and manufacturer’s name or symbol. The

top of the box culvert must also be clearly indicated with waterproof paint or as specified in the

Producer QC Plan.

410-10Trench, Foundation, Laying, and Backfill

410-10.1General: Meet the requirements of Section 125 and/or Section 121, for trench

excavation, foundation construction, laying and backfilling and the following:

Lay all precast box culvert sections on a dry, slightly yielding foundation, to

ensure uniform bearing across the full width of the bottom slab. Provide dewatering devices, if

applicable, in accordance with 455-29, capable of maintaining a stable and surface-dry trench

bottom. Construct any temporary sheet piling used in cofferdams, retaining walls and to

incorporate the Contractor’s specific means and methods, in accordance with 125-3.

410-10.2Bedding: Provide bedding that consists of a minimum 6 inch depth of select

material, with not more than 15% fines passing the No. 200 U.S. Standard sieve, in accordance

with Standard Plans, Index 120-001 or other granular material approved by the Engineer. Place

bedding in maximum 6 inch compacted layers below the culvert to a minimum width of

12 inches outside the exterior walls of the culvert and meet the density requirements of 125-9.2.

When coarse aggregate is approved for use as an alternate bedding material, wrap the bottom and

sides of the coarse aggregate with a layer of Type D-4 geotextile filter fabric as specified in

Section 985, and substituted the coarse aggregate with select material within 4 feet of the cut-off

or toe walls at each end of the precast box culvert. Obtain the Engineer’s approval before using

flowable fill for bedding material. Provide other special bedding material, when required by the

Contract Documents.

Set grade forms 12 inches outside each exterior wall of the box culvert. Uniformly

compact this material and then grade off using the forms. Set the grade forms approximately

1/8 inches to 1/4 inches above the theoretical grade line to allow for soil compression. Adjust

this distance to yield the proper grade, but do not use in lieu of the proper compaction of the

granular bedding material. Remove the forms after placing the precast box culvert section.

410-10.3Placement of Precast Box Culvert Sections: Obtain the Engineer’s approval

of the method of controlling line and grade during culvert installation. Use a method that allows

rapid checking of the previously laid sections. Maintain line and grade on sections previously set.

The Engineer will consider sections which do not retain the plan line within 0.10 foot or grade

within 0.10 foot during laying of subsequent sections, as not having been laid to line and grade.

Take up and relay sections not to line and grade without additional compensation. 435FY 2023-24Return to Table of Contents

410-10.4Placement of Multiple Barrel Culverts: For multiple barrel installations using

single-cell precast box sections, provide positive lateral support between the precast box culverts

consisting of non-shrink grout, concrete meeting the requirements of Section 347 or

non-excavatable flowable fill prior to backfilling. Provide partial height backfill or bracing to

maintain alignment, when approved by the Engineer.

410-10.5Backfilling: Begin backfilling only after the Engineers approval. Seal blockouts

and holes provided for lifting or joint restraint by plugging using an epoxy mortar or non-shrink

grout in accordance with Sections 926 or 934 and properly cure to ensure a sound and watertight

plug, prior to backfilling.

410-10.6Underdrain and Weep Holes: Provide a continuous underdrain in accordance

with Standard Plans, Index 400-289.

410-11Joints

410-11.1General: Make field joints for precast concrete box culvert sections with either

profile rubber gaskets or preformed joint sealants, unless otherwise detailed in the Plans or

approved shop drawings. Joint openings at the outside face must not exceed 1-1/2 inches in the

assembled position at any location along the joint perimeter. Ensure a minimum 50% overlap of

the joint tongue and groove around the entire perimeter of the box in the assembled position.

Completely wrap the outside of each joint with Type D-3geotextile filter fabric as

specified in Section 985. Provide fabric with a minimum width of 2 feet and a length sufficient to

ensure a minimum overlap of 24 inches. The filter fabric must extend a minimum of 12 inches

beyond each side of the joint. Secure the fabric tightly against the box culvert sections with metal

or plastic strapping. Other methods which will hold the fabric securely against the wall of the

culvert until the backfill is placed and compacted, may be used when approved by the Engineer.

When specified in the Plans, secure the joint by a suitable device capable of holding the sections

to line and grade as well as fully home. Remove these devices and repair locations as necessary

if intrusive into the concrete after placing and compacting sufficient backfill to secure the

sections.

410-11.2Profile Rubber Gaskets: Install field joints in accordance with the joint

manufacturer’s instructions and meet the following:

gasket required to create a soil-tight seal. Do not apply mortar, joint compound or other filler

which would restrict the flexibility of the joint.

410-11.3Preformed Flexible Joint Sealants: Install field joints in accordance with the

joint manufacturer’s instructions and meet the following:

area) of joint sealant which will create a soil-tight seal. Ensure that this amount is the minimum

quantity of bitumen sealant used. Do not brush or wipe joint surfaces which are to be in contact

with the joint sealant with cement slurry. Fill minor voids with non-shrink grout,

sealant material. When recommended by the sealant manufacturer, apply a primer of the type

recommended to all joint surfaces which are to be in contact with the sealant material. 436FY 2023-24Return to Table of Contents

protected by a removable wrapper. Do not remove the paper wrapper on the exterior surface of

the preformed flexible joint sealant until immediately prior to joining the precast sections. Apply

the joint sealant only to dry surfaces. When the atmospheric temperature is below 60°F, either

store the joint sealant in an area above 70°F, or artificially warm the joint sealant to 70°F in a

manner satisfactory to the Engineer. After assembly, ensure that there is full contact and

compression of the sealant for the entire perimeter of the joint, as evidenced by the presence of

minor bulging along any visible edges of the sealant. Neatly trim any extruded sealant flush with

the concrete surface.

410-11.4Water-tight Joint Treatment: Provide water-tight joints when shown in the

Contract Documents. Utilize an external sealing band in accordance with ASTM C877 in

addition to the requirements of 410-11.2 or 410-11.3. Determine the minimum width of sealing

bands by substituting the larger of the clear rise or span of the precast concrete box section, for

the equivalent pipe diameter in ASTM C877 Tables 1 and 2. Install external sealing band wrap in

accordance with the manufacturer’s instructions prior to wrapping the joint with geotextile filter

fabric.

410-12Shop Drawings

Submit details of all precast box culvert elements for approval to the Engineer prior to

manufacturing in accordance with 5-1.4. These shop drawings must include the proposed layout,

lifting devices, and a note describing the casting method for the precast box culverts and details

of any modifications to cast-in-place sections or connections thereto. All details must be

submitted as a complete package including modifications to cast-in-place sections.

410-13Method of Measurement

The quantity to be paid for will be plan quantity for the structure shown in the Contract

Documents in accordance with 400-22 and 415-7.

410-14Basis of Payment

Price and payment will be full compensation for all work specified in this Section,

including the cost of special bedding material and its placement, additional cut-off or toe wall

depth, temporary sheet piling, graded forms, joint materials, filter fabric material, attachment of

the filter fabric, dewatering, excavation, channel excavation and lining, backfilling, restraining

devices and any other materials or equipment necessary to make a complete and accepted

installation.

Payment will be made under pay items for concrete (culverts), reinforcing steel

(roadway), and FRP reinforcing. 437FY 2023-24Return to Table of Contents

EPOXY INJECTION OF CRACKS IN CONCRETE STRUCTURES

411-1Description

Inject epoxy into cracks in portland cement concrete.

411-2Materials

Meet the requirements of Section 926 and as follows: Use Type E compound epoxy for injection. Use Type F-1 compound epoxy for sealing crack surfaces in preparation for injection. Use epoxy materials listed on the Department’s Approved Product List (APL).

411-3Equipment

For the equipment used to inject the epoxy, meet the recommend ations of the epoxy injection material manufacturer and the following requirements:

components within the mix ratio tolerances set by the epoxy materials manufacturer.

materials within the pump and injection apparatus. The Engineer will not allow batch mixing.

variable pressures up to 200 psi, with a pressure gauge mounted at or near the nozzle to indicate the actual working pressure.

411-4Injection Personnel Qualifications

Employ personnel trained in performing injection work similar to that required for the project to carry out the epoxy injection of cracks in concrete. Provide an on -site supervisor for the epoxy injection work who is qualified by one of the following methods:

necessary competence to accomplish the epoxy injection work in a satisfactory and safe manner in compliance with these Specifications.

years experience of on -site supervision of simila r epoxy injection work and a list of five contracts in which similar epoxy injection was acceptably completed. Ensure that the listed experience in on -site supervision and completed contracts contains the project name and location, names of contracting par ties, the owner ’s name, brief description of the work, and dates of completion of the epoxy injection work. Submit written evidence showing personnel training and the on -site supervisor ’s qualification to the Department prior to beginning any epoxy injection work.

411-5Crack Surface Preparation and Cleaning Requirements

Clean the area surrounding the cracks of all deteriorated concrete, efflorescence and other contaminants detrimental to the adhesion of the surface sealing epoxy compound. Clean the interiors of the cracks with air under sufficient pressure to remove loose materials entrapped within the crack including efflorescence. 438 FY 2023-24 Return to Table of Contents