451PRESTRESSED SOIL ANCHORS

451-1Description

Construct prestressed soil anchors consisting of a high strength steel tendon anchored to the retaining wall on one end and to the soil on the other end through a bulb of pressure injected portland cement concrete grout. Test each anchor by prestressing to the load indicated in the Contract Documents before locking off to the retaining wall. Select the prestressed soil anchor type and the installation method, and determine the bond length a nd anchor diameter. Assume responsibility for installing prestressed soil anchors that develop the load -carrying capacity indicated in the Plans in accordance with 451 -7. Provide corrosion protection for permanent prestressed soil anchors. The Engineer will not require corrosion protection for temporary prestressed soil anchors. Protect anchor tendons from corrosion as shown in the Plans in accordance with 451 -8.

451-2Definitions

structure.

and transmits the tensile force to the soil or rock. For a compression prestressed soil anchor, the bond length will be different from the tendon bond length.

prestressed soil anchor during its service life after completing stressing and testing. The factored design load includes appropriate load factors to ensure that the overall structure has adequate strength for its intended use.

sieve size.

prestressing steel with sheathing and coating when required.

partial-length of prestressing tendon to another.

bond between the prestressing steel and the surr ounding grout or to provide corrosion protection.

anchorage at the bond l ength of the tendon.

purposes.

immediately after the force has been transferred from the jack to the stressing anchorage.

keep the testing equipment positioned.

recording the movement of the tendon at each increment. 521 FY 2023-24 Return to Table of Contents

the tendon at each increment.

certain period of time.

10% of the desired transfer load. This check is made immediately after transferring the load to the stressing anchorage.

measured during soil anchor testing .

anchor testing .

to transfer tensile loads to soil or rock. A prestressed soil anchor includes all prestressing steel, anchorage devices, bearing plates, grout, coatings, corrosion protection, sheathings and couplers if used.

the prestressing steel as defined by the specified standard.

grout surroun ding the unbonded length is a void filler and provides corrosion protection.

its service life after completing stressing and testing in order to limit deflection . The service load does not include load factors.

jack up to the anchorage devices during any anchor acceptance test (i.e. Performance Test, Proof Test or Creep Test ).

451-3Qualifications

The Contractor or subcontractor performing the work described in this Section shall have installed prestressed soil anchors for a minimum of five years. At the preconstruction conference, the Contractor shall submit a list containing at least five projects, completed within the last five years, where the Contractor has installed prestressed soil anchors. Include a brief description of each project and a reference for each project listed. As a minimum, include with the reference an individual's name and current phone number. Prior to the start of work, the Contractor shall submit a list identifying his engineer, drill operators, and on -site supervisors who will be assigned to the project. Include in the list a summary of each individual ’s experience. Assign a Specialty Engineer to supervise the work with at least five years of experience in the design and construction of permanently -anchored structures. Do not use manufacturers' representatives in order to meet the requirements of this Section. Provide drill operators and on - site supervisors that have a minimum of one year experience installing permanent prestressed soil anchors with the Contractor’s organization. The Engineer will approve or reject the Contractor ’s qualifications and staf f within 15 working days after receipt of the submission. Do not start work on any prestressed soil anchor wall system or order materials until receiving approval of the qualifications. The Engineer may suspend the prestressed soil anchor work if the Contr actor or subcontractor substitutes 522 FY 2023-24 Return to Table of Contents unqualified personnel for approved personnel during construction. If work is suspended due to the substitution of unqualified personnel, the Contractor is fully liable for additional costs resulting from the suspension of work and the Department will not allow any adjustment in Contract Time resulting from the suspension of work.

451-4Materials

451-4.1General: Meet the following requirements:

Concrete ................................ .............................. Section 346 Prestressed Construction ................................ .....Section 450 Structural Steel an d Miscellaneous Metals .........Section 460

451-4.2Prestressing Steel: Use prestressed soil anchor tendons fabricated from single or

multiple elements of one of the following prestressing steels , unless otherwise shown in the Plans:

ASTM A779.

451-4.3Anchorage Covers ( include for temporary anchors only whe n shown in the

Plans): Use exposed anchorage covers fabricated from steel or ductile cast iron with a minimum thickness of 0.10 inches. Ensure that the cover is securely attached to the anchorage device or bearing plate. If the cover is to be grease filled , ensure the cover forms a permanent watertight enclosure for the anchorage device.

451-4.4Anchorage Devices: Use anchorage devices capable of developing 95% of the

minimum specified ultimate tensile strength of the prestressing steel tendon. Use anchora ge devices that meet the static strength requirements of Section 3.1.6(1) and Section 3.1.8(1) of the Post Tensioning Institute “Guide Specification for Post -tensioning Materials ”. Use couplers for tendon sections capable of developing 95% of the minimums pecified ultimate tensile strength.

451-4.5Cement Grout: Use grout for anchorage consisting of a pumpable mixture of

portland cement meeting the requirements of Section 921, sand, water, and admixtures. The Contractor may use admixtures which control bleed, improve flowability, reduce water content, and retard set in the grout subject to the approval of the Engineer. The Contractor may only add expansive admixtures to the grout used for filling sealed encapsulations, trumpets, and anchorage covers. Do not use accelerators. Use admixtures compatible with the prestressing steels and mixed in accordance with the manufacturer's recommendations. Do not perform strength testing as system performance will be measured by proof-testing each anchor. The Department may require cylinder testing if the Contractor uses admixtures or irregularities occur in anchor testing. Cast a set of three 4 inches x 8 inches grout cylinders for each LOT in accordance with ASTM C31, except fill the cylinder molds in one layer without rodding. Use grout that attains a minimum compressive strength of 3,400 psi within seven days, when tested in accordance with ASTM C39.

451-4.6Bearing Plate: Use bearing plates fabricated from steel meeting the

requirements of AASHTO M 270 or AST M A709.

451-4.7Bondbreaker: Use bondbreaker fabricated from a smooth plastic tube or pipe

having the following properties:

523 FY 2023-24 Return to Table of Contents

installation

451-4.8Centralizers: Use centralizers fabricated from plastic, steel, or material that is

nondetrimental to the prestressing steel. Do not use wood. Ensure that the centralizer is able to support the tendon in the drill hole, and position the tendon so a minimum of 0.5 inches of grout cover is provided over the tendon bond length. In addition, locate the upper centralizer a maximum of 5 feet from the top of the tendon bond length, and locate the l ower centralizer a maximum of 12 inches from the bottom of the tendon bond length. The Engineer will not require centralizers on pressure injected tendons if the Contractor installs the anchor in coarse grained soils using grouting pressures greater than 1 50 psi. The Engineer will not require centralizers if the Contractor installs the anchors and grouts them through a hollow stem auger and maintains the hole full of stiff grout (slump less than 9 inches) during extraction of the auger.

451-4.9Corrosion I nhibiting Grease ( include for temporary anchors only when

shown in the Plans): For corrosion inhibiting grease, meet the requirements of Section 3.2.5 of the Post Tensioning Institute Specification for Unbonded Single Strand Tendons.

451-4.10Heat Shrinka ble Tubes: Use heat shrinkable tubes fabricated from a radiation

cross-linked polyolefin tube internally coated with an adhesive sealant. Prior to shrinking, ensure

that the tube has a nominal wall thickness of 24 mils. Ensure that the adhesive sealant inside the

tube has a nominal thickness of 20 mils.

451-4.11Sheath (include for temporary anchors only when shown in the Plans): Use

a sheath as part of the corrosion protection system for the unbonded length portion of the tendon

fabricated from one of the following:

polyethylene Type II, III, or IV as defined by ASTM D1248 or approved equal, with a minimum

wall thickness of 60 mils, plus or minus 10 mils.

PP 210 B5554211 as defined by ASTM D4101 or approved equal, with a minimum wall

thickness of 60 mils, plus or minus 10 mils.

as defined by ASTM D3350 and ASTM D1248 (or approved equal), with a minimum wall

thickness of 60 mils, plus or minus 10 mils.

thickness of 0.20 inches.

encapsulation.

451-4.12Spacers: Use spacers to separate elements of a multi-element tendon and which

permit grout to flow freely up the drill hole. Use spacers fabricated from plastic, steel, or

material which is nondetrimental to the prestressing steel. Do not use wood. The Contractor may

use a combination centralizer-spacer.

451-4.13Tendon Bond Length Encapsulations (include for temporary anchors only

when shown in the Plans): When the Contract drawings require the tendon bond length to be 524FY 2023-24Return to Table of Contents

encapsulated to provide additional corrosion protection, use encapsulation fabricated from one of

the following:

AASHTO M 252, with a minimum wall thickness of 30 mils

requirements of ASTM D1784, Class 13464-B.

451-4.14Trumpet (include for temporary anchors only when shown in the Plans):

Use a trumpet to provide a transition from the anchorage to the unbonded length corrosion

protection fabricated from a steel pipe or tube meeting the requirements of ASTM A53 for pipe

or ASTM A500 for tubing. Use a trumpet that has a minimum wall thickness of 0.125 inches for

diameters up to 4 inches and 0.20 inches for larger diameters.

451-4.15Water: Use potable water for mixing grout

451-4.16Grout Tube: Use a grout tube fabricated from a high density polyethylene

tube, or a PVC pipe, or a steel pipe with a 0.5 inches minimum inside diameter.

451-5Tendon Fabrication

Provide tendons that are either shop or field fabricated. Fabricate the tendon as shown on

the approved shop drawings.

Ensure that tendons are free of dirt, rust, or any other deleterious substance. Degrease the

bond length.

Handle and protect tendons, prior to installation, in a manner to avoid corrosion and

physical damage. The Engineer will consider damage such as abrasion kinks, welds and weld

splatters, cuts, and nicks which impair the proper performance of the tendon cause for rejection.

Sheath tendons in the stressing length to prevent contact of the anchor tendon with the

drill hole wall. The Contractor may use sheathing that consists of tubes surrounding individual

tendon elements or a single tube surrounding the elements altogether.

The Contractor may use sheathing material of either steel, plastic, or any other material

nondetrimental to the high strength prestressing steel. The Contractor may use tape to prevent

grout from entering under the sheath on individually sheathed elements.

Select the type of tendon to be used. Unless otherwise shown in the Plans, size the tendon

so the factored design load does not exceed 80% of the minimum specified ultimate tensile

strength of the tendon. Increase the tendon size by the sacrificial steel thickness shown in the

Plans. In addition, size the tendon so the maximum test load does not exceed 90% of the

minimum yield strength of the tendon.

Assume responsibility for determining the bond length necessary to develop the design

load indicated in the Plans or the shop drawings. Use a minimum bond length of 10 feet in rock

and 15 feet in soil. Ensure that the minimum tendon bond length is 10 feet.

451-6Installation

451-6.1General:

451-6.1.1 Drilling: Core drilling, rotary drilling, percussion drilling, auger

drilling, or driven casing may be used. At the ground surface, locate the drill hole within

12 inches of the location shown in the Plans or the approved shop drawings. Locate the drill hole

so that the longitudinal axis of the drill hole and the longitudinal axis of the tendon are parallel.

In particular, do not drill the prestressed soil anchor hole in a location that requires the tendon to

be bent in order to connect the bearing plate to the supported structure. At the point of entry, 525FY 2023-24Return to Table of Contents

install the prestressed soil anchor within plus or minus 3 degrees of the inclination from

horizontal shown in the Plans or the approved shop drawings. At the point of entry, make the

horizontal angle formed by the prestressed soil anchor and the structure to within plus or minus

3 degrees of a line drawn perpendicular to the plane of the structure unless otherwise shown in

the Plans or approved shop drawings. Do not allow the prestressed soil anchors to extend beyond

the right-of-way or easement limits shown in the Plans.

451-6.1.2 Tendon Insertion: Insert the tendon into the drill hole to the desired

depth. When the tendon cannot be completely inserted, remove the tendon from the drill hole,

and then clean or redrill the hole to permit insertion. Do not drive or force partially inserted

tendons into the hole.

451-6.1.3 Installation of Trumpet and Anchorage: When corrosion protection

is required, extend that portion of the corrosion protection surrounding the unbonded length of

the tendon, up beyond the bottom seal of the trumpet or 12 inches into the trumpet if no trumpet

seal is provided. If the protection does not extend beyond the seal or sufficiently far enough into

the trumpet, extend the corrosion protection, or lengthen the trumpet.

When required, ensure that the corrosion protection surrounding the

unbonded length of the tendon does not contact the bearing plate or the anchor head during

testing and stressing. If the protection is too long, trim the corrosion protection to prevent

contact.

Place the bearing plate and anchor head so the axis of the tendon is

perpendicular to the bearing plate within plus or minus 3 degrees and the axis of the tendon

passes through the center of the bearing plate.

If using grout protected tendons, electrically isolate the bearing plate,

anchor head, and trumpet from the surrounding concrete, soldier pile, or any metallic element

embedded in the structure.

Completely fill the trumpet with corrosion inhibiting grease or grout.

Trumpet grease may be placed any time during construction. Place trumpet grout after the

prestressed soil anchor has been tested and stressed. Demonstrate to the Engineer that the

procedures selected for placement of either grease or grout will produce a completely filled

trumpet.

For permanent soil anchors, cover all anchorages permanently exposed to

the atmosphere with a corrosion inhibiting grease-filled or grout-filled cover. Demonstrate to the

Engineer that the procedures selected for placement of either grease or grout will produce a

completely filled cover. If the Plans require restressable anchorages, use corrosion inhibiting

grease to fill the anchorage cover.

451-6.2Anchor Grouting: Provide grouting equipment that produces a grout free of

lumps and undispersed cement. Use a positive displacement grout pump equipped with a

pressure gauge to monitor grout pressures. Ensure that the pressure gauge is capable of

measuring pressures of at least 150 psi or twice the actual grout pressures used, whichever is

greater. Size the grouting equipment to enable the grout to be pumped in one continuous

operation. Ensure that the mixer is capable of continuously agitating the grout.

Inject the grout from the lowest point of the drill hole. Grout may be pumped

through grout tubes, casing, hollow-stem-augers, or drill rods. The grout may be placed before or

after insertion of the tendon. Record the quantity of the grout and the grout pressures. Control the

grout pressures and grout takes to prevent excessive heave or fracturing. 526FY 2023-24Return to Table of Contents

Except where indicated below, the grout may be placed above the top of the bond

length at the same time as the bond length grout but may not be placed under pressure. Ensure

that the grout at the top of the drill hole does not contact the back of the structure or the bottom

of the trumpet.

If the prestressed soil anchor is installed in a fine-grained soil using drill holes

larger than 6 inches in diameter, place the grout above the top of the bond length after testing and

stressing the prestressed soil anchor. The Engineer will allow the entire drill hole to be grouted at

the same time if it can be demonstrated that the particular prestressed soil anchor system does not

derive a significant portion of its load-carrying capacity from the soil above the bond length

portion of the prestressed soil anchor.

If using grout protected tendons for prestressed soil anchors anchored in rock, use

pressure grouting techniques. For pressure grouting, seal the drill hole, and inject grout until a

50 psi grout pressure (measured at the top of the drill hole) can be maintained on the grout for

five minutes.

Upon completion of grouting, the grout tube may remain in the hole, but it must

be filled with grout.

After grouting, do not load the tendon for at least three days.

Record the following data concerning the grouting operation:

451-7Prestressed Soil Anchor Testing and Stressing

451-7.1General: Test each prestressed soil anchor. The Engineer will select the

prestressed soil anchors to be performance tested and those to be creep tested, and at his

discretion, may increase or decrease the number of tests.

Perform creep testing and performance testing at the beginning of the anchor

installation, prior to installation of the remaining soil anchors, unless directed otherwise by the

Engineer. In projects with multiple anchor row levels, the Engineer may request performance

and creep testing at the beginning of the installation of soil anchors for subsequent levels. The

purpose of these initial tests is to verify the Contractor’s installation procedures, the performance

of the bond length, and the calibration of testing equipment.

Perform creep testing as follows:

Perform performance testing as follows:

whichever is greater.

Perform proof tests on all prestressed soil anchors, not subjected to a performance

test or a creep test. Record the results of each test on form 700-020-04 Soil Anchor Forms.

Submit a separate form for each test. Submit the test results to the Engineer on a weekly basis

within one week of testing. Do not apply a load greater than 10% of the factored design load to 527FY 2023-24Return to Table of Contents

the prestressed soil anchor prior to testing. For the maximum test load, do not exceed 90% of the

minimum yield strength of the tendon. Simultaneously apply the test load to the entire tendon.

Do not perform stressing of single elements of multi-element tendons.

Provide testing equipment that consists of:

measure the ground anchor movement. Use a movement-measuring device that has a minimum

travel equal to the theoretical elastic elongation of the total anchor length at the maximum test

load and that has adequate travel so the prestressed soil anchor movement can be measured

without resetting the device.

minimum ram travel of not less than the theoretical elastic elongation of the total anchor length

at the maximum test load, and a calibrated pressure gauge, graduated in 100 psi increments or

less, or calibrated load cell with readout box, to measure the applied load. Ensure that the jack

and pressure gauge are calibrated by an independent firm as a unit, and that the calibration is

performed within 60 calendar days of the date submitted.

performing a creep test. Load cell may also be used in performance and proof tests, at the

Contractor’s discretion. Ensure that the load cell is calibrated by an independent firm and that the

calibration is performed within 60 calendar days of the date submitted. Obtain the Engineer’s

approval of the calibration before testing commences.

the Engineer. Ensure that the reference gauge is calibrated with the test jack and pressure gauge.

during each performance test and creep test.

such a manner that the jack, bearing plates, load cells and stressing anchorage are axially aligned

with the tendon and the tendon is centered within the equipment.

If, during the performance of any load test (proof, performance, or creep), the

load determined by the load cell or the load determined by the reference gauge differs by more

than 10% from the load determined by the pressure gauge when the pressure gauge measures

80% of the Factored Design Load (0.80 DL), suspend the test, unload the anchor being tested,

recalibrate the load cell, jack, pressure gauge, and reference pressure gauge, and repeat the test at

no expense to the Department. Obtain the Engineer’s approval of the recalibration data prior to

resuming testing.

If, at any time, a pressure gauge, reference pressure gauge, or load cell is repaired

or replaced, obtain the Engineer’s written approval of calibration data of the repaired or the new

measuring device (load cell or pressure gauge, or reference gauge) prior to resuming testing.

Perform additional performance tests, at no expense to the Department, on the first two soil

anchors using the repaired or new measuring device to verify the calibration of the equipment.

451-7.2Criteria for Performing a Performance Test and a Proof Test: Raise the load

from one increment to another immediately after recording the prestressed soil anchor

movement. Measure and record the prestressed soil anchor movement to the nearest 0.001 inch

with respect to an independent fixed reference point at the alignment load and at each increment

of load. Monitor the load with a pressure gauge or load cell. At load increments other than the

maximum test load, hold the load just long enough to obtain the movement reading. 528FY 2023-24Return to Table of Contents

Hold the maximum test load for at least 10 minutes. Pump the jack as necessary in

order to maintain a constant load. Start the load-hold period as soon as the maximum test load is

applied, and measure and record the prestressed soil anchor movement, with respect to an

independent fixed reference, at 1, 2, 3, 4, 5, 6, and 10 minutes. If the prestressed soil anchor

movement between 1 minute and 10 minutes exceeds 0.04 inches, hold the maximum test load

for an additional 50 minutes. If extending the load-hold, record the prestressed soil anchor

movements at 15 minutes, 20, 25, 30, 40, 50 and 60 minutes.

451-7.2.1 Performance Test: Perform the performance test by incrementally

loading and unloading the prestressed soil anchor in accordance with the following schedule:

Performance Test Schedule

Load Load

AL AL

0.20DL* 0.20 DL

AL 0.40 DL

DL 0.60 DL

0.40DL* 0.80 DL

AL 0.90 DL*

DL 0.20 DL

0.60DL* 0.40 DL

AL 0.60 DL

DL 0.80 DL

DL 0.90 DL

DL 1.00 DL*

0.80DL* Reduce to lock-off load

AL - is the alignment load.

DL - is the prestressed soil anchor factored design load.

Plot the prestressed soil anchor movement versus load for each load

increment marked with an asterisk (*) in the performance test schedule, and plot the residual

movement of the tendon at each alignment load versus the highest previously applied load.

451-7.2.2 Proof Test: Perform the proof test by incrementally loading the

prestressed soil anchor in accordance with the following schedule:

Proof Test Schedule

Load Load

AL 0.80 DL

DL 0.90 DL

DL 1.00 DL

DL Reduce to lock-off load

Compare the proof test results to the performance test results. If there is

any significant variation from the performance test results, perform a performance test on the

next anchor. 529FY 2023-24Return to Table of Contents

Plot the prestressed soil anchor movement versus load for each load

increment in the proof test.

451-7.3Criteria for Performing a Creep Test: Perform the creep test by incrementally

loading and unloading the prestressed soil anchor in accordance with the performance test

schedule given above. At the end of each loading cycle, hold the load constant for the

observation period indicated in the creep test schedule below. Use the following times for

reading and recording the prestressed soil anchor movement during each observation period: 1,

2, 3, 4, 5, 6, 10, 15, 20, 25, 30, 40, 50, 60, 75, 90, 100, 120, 150, 180, 210, 240, 270, and

300 minutes as appropriate. Start each load-hold period as soon as applying the test load. Pump

the jack as necessary in order to maintain a constant load.

Plot the prestressed soil anchor movement and the residual movement measured

in a creep test as described for the performance test above, and plot the creep movement for each

load-hold as a function of the logarithm of time.

Creep Test Schedule

Load Observation Period (minutes.)

AL

0.90DL 60

1.00DL 300

451-7.4Lock-Off: Upon satisfactory completion of all testing, reduce the load to the

lock-off load, and transfer the load to the anchorage device. Use a lock-off load that is 80% of

the prestressed soil anchor service load. The Contractor may completely unload the prestressed

soil anchor prior to lock-off. After transferring the load and prior to removing the jack, take a

lift-off reading. Use a lift-off reading that is within 10% of the specified lock-off load. If the load

is not within 10% of the specified lock-off load, reset the anchorage, and take another lift-off

reading. Repeat this process until obtaining the desired lock-off load.

451-7.5Cutting of Tendon Protrusions: After an anchor has been accepted by the

Engineer, saw cut the portion of the anchor tendon extending beyond the anchorage. Take care

not to damage the tendon or the tendon anchorage.

451-7.6Prestressed Soil Anchor Load Test Acceptance Criteria: The Engineer will

accept a performance or proof-tested prestressed soil anchor with a 10 minute load hold if the:

0.04 inches of movement between 1 minute and 10 minutes; and

(movement between alignment load after 0.90 DL and the final movement reading at 1.00 DL)

exceeds 80% of the theoretical elastic elongation of the test stressing length. For proof tests, net

movement at the maximum test load (movement between alignment load and the final movement

reading at 1.00 DL) exceeds 80% of the theoretical elastic elongation of the test stressing length.

The Engineer will accept a performance or proof-tested prestressed soil anchor

with a 60 minute load hold if the: 530FY 2023-24Return to Table of Contents

deformation rate that does not exceed 0.08 inches in the last log cycle of time; and

(movement between alignment load after 0.90 DL and the final movement reading at 1.00 DL)

exceeds 80% of the theoretical elastic elongation of the test stressing length. For proof tests, net

movement at the maximum test load (movement between alignment load and the final movement

reading at 1.00 DL) exceeds 80% of the theoretical elastic elongation of the test stressing length.

The Engineer will accept a creep tested prestressed soil anchor if the:

that does not exceed 0.08 inches/log cycle of time; and

alignment load after 0.90 DL and the final movement reading at 1.00 DL) exceeds 80% of the

theoretical elastic elongation of the test stressing length.

If the total movement of the prestressed soil anchors at the maximum test

load does not exceed 80% of the theoretical elastic elongation of the test stressing length, replace

the prestressed soil anchor at no cost to the Department.

Stop the creep test as soon as the creep rate exceeds 0.08 inches/log cycle

of time. Incorporate prestressed soil anchors which have a creep rate greater than 0.08 inches/log

cycle of time in the finished work at a load equal to one-half its failure load. The failure load is

the load carried by the prestressed soil anchor after the load has been allowed to stabilize for

10 minutes without exceeding 0.04 inches of movement between 1 and 10 minutes.

When a prestressed soil anchor does not satisfy the load test acceptance

criteria, the Contractor may modify the design and/or the construction procedures. These

modifications may include, but are not limited to, installing replacement prestressed soil anchors,

reducing the factored design load by increasing the number of prestressed soil anchors,

modifying the installation methods, increasing the bond length or changing the prestressed soil

anchor type. Obtain the Engineer’s approval prior to making any modification which requires

changes to the structure. Perform any modifications at no additional cost to the Department. The

Department will not allow additional Contract Time for modifications. The Engineer will not

allow retesting of the failed prestressed soil anchor except to determine the anchor failure load.

451-8Corrosion Protection (include for temporary anchors only when shown in the Plans)

451-8.1General: Protect prestressed soil anchors against corrosion using materials and

procedures described herein. The following materials may be used independently or in various

combinations:

Use corrosion protection materials with properties that are not detrimental to the

prestressing steel and that prevent the intrusion of corrosive environments. Use coating materials

that also have the following properties:

of temperature

531FY 2023-24Return to Table of Contents

or sheathing

When acidic water can enter the bore hole during the period subsequent to the

drilling and flushing operation and prior to tendon insertion and grouting, introduce chemical

additives for neutralizing purposes. Maintain a minimum pH of 9.0 when the prestressing steel is

in contact with this water. During prolonged periods, monitor the pH at regular intervals, and add

additional neutralization as required. Concentrated sodium hydroxide and calcium hydroxide

have proven effective for this purpose.

451-8.2Protection Systems:

451-8.2.1 Bond Length:

meet the following requirements:

cement grout cover.

tendons to separate each of the individual elements of the tendon so the prestressing steel will

bond to the grout. Position spacers so their center to center spacing does not exceed 10 feet. In

addition, locate the upper spacer a maximum of 5 feet from the top of the tendon bond length,

and locate the lower spacer a maximum of 5 feet from the bottom of the tendon bond length.

cover over the tendon bond length. Position centralizers so their center to center spacing does not

exceed 10 feet. In addition, locate the upper centralizer a maximum of 5 feet from the top of the

tendon bond length, and locate the lower centralizer a maximum of 12 inches from the bottom of

the tendon bond length.

prestressed soil anchor tendons if the prestressed soil anchor is installed in coarse-grained soils

using grouting pressures greater than 150 psi.

augured prestressed soil anchor tendons if the prestressed soil anchor is grouted through the

auger and the hole is maintained full of a stiff grout, (9 inches slump or less) during extraction of

the auger.

corrosion by encapsulating the tendon in a grout-filled corrugated plastic or deformed steel tube.

Grout the tendon inside the encapsulation prior to inserting the tendon in the drill hole or after

the tendon has been placed in the drill hole. Mix expansive admixtures with the encapsulation

grout if the tendon is grouted inside the encapsulation prior to inserting it in the drill hole.

Centralize the tendon within the tendon bond length encapsulation with a minimum of

0.10 inches of grout cover. Use spacers along the tendon bond length of multi-element tendons to

separate the elements of the tendon so the prestressing steel will bond to the encapsulation grout.

cover over the tendon bond length encapsulation. Position centralizers so their center to center

spacing does not exceed 10 feet. In addition, locate the upper centralizer a maximum of 5 feet 532FY 2023-24Return to Table of Contents

from the top of the tendon bond length, and locate the lower centralizer a maximum of 12 inches

from the bottom of the tendon bond length.

pressure-injected prestressed soil anchor tendons if the prestressed soil anchor is installed in

coarse-grained soils using grouting pressures greater than 150 psi.

hollow-stem-augured prestressed soil anchor tendons if the prestressed soil anchor is grouted

through the auger and the hole is maintained full of a stiff grout (9 inches slump or less) during

extraction of the auger.

451-8.2.2 Unbonded Length: For the minimum unbonded length of the tendon,

use 15 feet or as indicated in the Plans or the approved shop drawings, whichever is greater.

If grouting the entire drill hole (tendon bond length and unbonded length)

in one operation, provide the corrosion protection of the unbonded length by a sheath completely

filled with corrosion inhibiting grease or grout, or a heat shrinkable tube internally coated with

an elastic adhesive. If using grease under the sheath, make provisions to prevent the grease from

escaping at the ends of the sheath. With grease, completely coat the tendon, fill the void between

the tendon and the sheath, and fill the interstices between the wires of the 7-wire strands. Ensure

that the shop drawings show how to provide a transition between the bond length and the

unbonded length corrosion protection. If the sheath is grout filled, provide a separate

bondbreaker that prevents the tendon from bonding to the grout surrounding the unbonded

length.

If providing grease-filled sheath corrosion protection and the drill hole

above the bond length is grouted after locking off the prestressed soil anchor, grout the tendon

inside a second sheath.

451-8.2.3 Anchorage and Trumpet: Use non-restressable anchorage devices

except where indicated in the Plans. Provide restressable anchorages on those prestressed soil

anchors designated as restressable in the Plans. Ensure that the post-tensioning supplier provides

a restressable anchorage compatible with the post-tensioning system provided along with written

recommendations concerning the restressing of the tendons.

If using strand tendons, submit written recommendations from the post-

tensioning supplier for seating the wedges. Include with the recommendations the minimum load

required to properly seat the wedges in the anchor head.

Size the bearing plates so that:

of the steel when applying a load equal to 95% of the minimum specified ultimate tensile

strength of the tendon; and

recommended in Section 3.1.7 of the Post Tensioning Institute Guide Specification for Post-

Tensioning Materials.

Weld the trumpet to the bearing plate. Provide a trumpet that has an inside

diameter equal to or larger than the hole in the bearing plate. Ensure that the trumpet is long

enough to accommodate movements of the structure during testing and stressing. For strand

tendons with encapsulation over the unbonded length, provide a trumpet that is long enough to

enable the tendon to make a transition from the diameter of the tendon in the unbonded length to

the diameter of the tendon at the anchor head without damaging the encapsulation. Ensure that

trumpets filled with corrosion-inhibiting grease have a permanent Buna-N synthetic rubber or 533FY 2023-24Return to Table of Contents

approved equal seal provided between the trumpet and the unbonded length corrosion protection.

Ensure that trumpets filled with grout have a temporary seal provided between the trumpet and

the unbonded length corrosion protection or that the trumpet overlaps the unbonded length

corrosion protection by a minimum of 12 inches and fits tightly over the unbonded length

corrosion protection.

451-9Submittals

Prepare and submit Shop drawings and a design submission describing the prestressed

soil anchor system or systems intended for use to the Engineer for review and approval

30 working days prior to the commencement of the prestressed soil anchor work. Include the

following in the shop drawings and design submission:

system. Include details for the following:

material or assemblies to be provided will fully comply with the requirements of the Contract.

The Engineer will approve or reject the shop drawings and design submission within

30 working days after receipt of the submission.

Submit to the Engineer for review and approval or rejection mill test reports for the

prestressing steel and the bearing plate steel. The Engineer may require the Contractor to provide

samples of any prestressed soil anchor material intended for use on the project. The Engineer

will approve or reject the prestressing steel and bearing plate steel within five working days after

receipt of the test reports. Do not incorporate the prestressing steel and bearing plates in the work

without the Engineer’s approval.

Submit to the Engineer for review and approval or rejection calibration data for each test

jack, pressure gauge, and reference pressure gauge to be used. The Engineer will approve or

reject the calibration data within five working days after receipt of the data. Do not commence

testing until the Engineer has approved the jack, pressure gauge, and reference pressure gauge

calibrations. 534FY 2023-24Return to Table of Contents

Submit to the Engineer within 20 calendar days after completion of the prestressed soil

anchor work a report containing:

in the installation

pressures

451-10Tendon Storage and Handling

Handle and store tendons in a manner to avoid damage or corrosion. The Engineer will

consider damage to the prestressing steel as a result of abrasions, cuts, nicks, welds and weld

splatter cause for rejection. Protect the prestressing steel if performing welding in the vicinity.

Do not ground welding leads to the prestressing steel. Protect prestressing steel from dirt, rust, or

deleterious substances.

The Engineer will allow a light coating of rust on the steel. If heavy corrosion or pitting is

noted, the Engineer will reject the affected tendons.

Use care in handling and storing the tendons at the site. Prior to inserting a tendon in the

drill hole, examine the tendon for damage to the encapsulation and the sheathing. If, in the

opinion of the Engineer, the encapsulation is damaged, repair the encapsulation in accordance

with the tendon supplier’s recommendations. If, in the opinion of the Engineer, the smooth

sheathing has been damaged, repair it with ultra high molecular weight polyethylene tape. Spiral

wind the tape around the tendon to completely seal the damaged area at a pitch that ensures a

double thickness at all points.

451-11Method of Measurement

Unless otherwise shown in the Plans, the quantity to be paid for will be the number of

prestressed soil anchors, based on the maximum anchor spacing shown in the Plans, installed and

accepted. For prestressed soil anchors that do not meet the acceptance criteria, the original

prestressed soil anchor and any required additional work or prestressed soil anchors will be, in

sum, considered to be one prestressed soil anchor for payment purposes.

451-12Basis of Payment

Prices and payments will be full compensation for all work specified in this Section,

including furnishing the materials necessary to complete the anchors in place and accepted. The

quantity of performance and creep tests to be paid for will be the number of tests performed on

accepted anchors.

The cost of proof testing will be included in Item No. 451-70.

No payment will be made for tests performed on unaccepted anchors.

Payment will be made under:

Item No. 451- 70- Prestressed Soil Anchors - each.

Item No. 451- 70- 1 Prestressed Soil Anchor (Performance Tests) - each.

Item No. 451- 70- 2 Prestressed Soil Anchors (Creep Tests) - each. 535FY 2023-24Return to Table of Contents

PRECAST SEGMENTAL BRIDGE CONSTRUCTION

452-1Description

Fabricate, store, transport and erect precast structural concrete superstructure and/or substructure segments on a prepared foundation, to the established lines and grades, in accordance with the design, dimensions and details shown on the Plans and in accordance with this Section. Reinforcing steel, embedded items and all appurtenant items are included. Base the bid on the design shown in the Plans. The work in this Section does not include longitudinally post -tensioned beams upon which a concrete sl ab is cast-in-place.

452-2Qualification of Contractor’s Personnel

Meet the requirements of Section 105. When mixing, handling and applying an epoxy bonding agent, provide direct supervision by a person with knowledge and experience, or trained by a tec hnical representative of the manufacturer in the use of this material. Arrange for a technical representative of the manufacturer to be at the site as an advisor at the beginning of this work. Ensure that all personnel who will be working with an epoxy bo nding agent are thoroughly familiar with the safety precautions necessary for use of this material.

452-3Definitions

The following definitions apply to segmental bridge construction:

452-3.1Segment: A modular section of the superstructure and/or subs tructure

consisting of a certain cross -section shape and length as detailed in the Plans.

452-3.2Match Cast: A precast concrete fabrication process whereby a segment

is cast against the preceding segment producing a matching interface which permits the re-establishment of the cast geometry at erection time. Match casting is accomplished by either the short line or long line casting method.

452-3.3Short Line Casting: Casting segments one at a time in a casting cell

between a bulkhead at one end and a p reviously cast segment at the other. The first segment is cast between the bulkhead and another, temporary bulkhead.

452-3.4Long Line Casting: Casting segments on a casting bed of sufficient

length to permit the cumulative casting of segments for the en tire length of a span or cantilever between field closure pours without repositioning the segments on the casting bed. With this method, the first segment is cast between bulkheads and successive segments are cast between a movable bulkhead on one end and the previously cast segment on the other.

452-3.5Casting Cell: A special formwork arrangement usually consisting of a

fixed vertical bulkhead of the cross section shape at one end and adjustable soffit, side and core forms all designed and assembled int o a machine for making a single superstructure segment. A casting cell for a substructure pier shaft segment consists of exterior and interior side forms and a soffit form of the cross section shape.

452-3.6Wet Joint System: Where segments are made in a casting cell between

two bulkheads and are not match cast. The segments are then erected in the superstructure with a narrow cast -in-place joint between each segment. (During erection, all the segments of a span or 536 FY 2023-24 Return to Table of Contents

multiple spans are supported by falsewor k, truss or other technique until the joints have gained strength and the longitudinal post -tensioning installed to make them self supporting.)

452-3.7Span by Span (Erection): Placing a specified number of segments on a

temporary support system, aligned and post-tensioned longitudinally forming a completed span of the superstructure.

452-3.8Balanced Cantilever (Erection): The segments are sequentially erected

alternately on either side of the pier in cantilever to a point where a closure is cast -in-place.

452-3.9Progressive Cantilever: (Erection): The segments are erected

progressively in cantilever, in one direction, from one pier to the next, using temporary intermediate piers, or other systems as required to support the advancing cantilever betwe en piers.

452-3.10Casting Curve: The curve of casting geometry that has to be followed

in the casting cell or bed for achieving the theoretical bridge profile and alignment after all the final structural and time dependent (creep and shrinkage) deformations have taken place. The casting curve is a combination of the theoretical bridge geometrical profile grade, alignment and the camber.

452-3.11Camber: The amount by which the concrete profile at casting time must

differ from the theoretical geometric profile grade to compensate for all structural dead load, post-tensioning, all long term and time dependent deformations (creep and shrinkage) including all the intermediate erection stages and effects. (The opposite of deflections).

452-3.12Erection El evation: The elevation at which a segment is set in the

structure at the time it is erected. (This is profile grade corrected by the amount of deflection calculated to occur from that stage onwards.)

452-4Shop Drawings, Calculations and Manuals

452-4.1General: Use methods and procedures providing adequate safety to the general

public from construction/erection activities and/or falsework placed over or adjacent to traveled roadways, navigational or recreational waterways or any existing commercial, indu strial or other facility.

452-4.2Information Required: Submit integrated detailed shop drawings, calculations,

manuals and other information, including, but not limited to, the following: 452-4.2.1 Segment Shop Drawings:

reinforcing steel, prestressing steel, duct filler, and other similar items.

fillets, radii, working points, post -tensioning, clearances, rebar dimensions and spacing, embedded items, holes, anchorage po sitions, and other similar items.

outlined in Section 462.

tensioning in each precast segment and the total weigh t for reinforcement and post -tensioning for both the superstructure and substructure summarized and tabulated on the shop drawings.

supports and loads or reactions from any spe cial erection equipment placed in locations not already allowed for in the Plans. 537 FY 2023-24 Return to Table of Contents

geometry, cross section dimensions, or segment length including any required changes to reinforcing and post-tensioning.

blockouts, temporary openings, holes, and other similar items; and any localized required strengthening and the materials and methods to fill and finish the ho les. 452-4.2.2 Casting Yard:

set up and operation of the casting cells, movable rain and sun shades, geometry control stations, the storage and handling of rebar cages. the preparation of as built geometry data, placing and finishing concrete, curing of concrete, form stripping, bond breaking, and other similar items.

Additional strengthening of the segments to accommodate stacking will be at no expense to the Department.

casting cells for the manufacture of the segments, surveying the segment, lifting and transportation of the segment in the yard, and other sim ilar items.

supporting the segments, single or double stacking, placing erection marks and segment identification , and other similar items.

452-4.2.3 Erection Manual: Meet the requirements in 452 -8. 452-4.2.4 Manual for Geometry Control and Casting Curves: Meet the requirements in 452 -6.3.

452-5Materials

452-5.1General: Use materials which conform to this Section and the requirements

prescribed in Division III, Materials, for the particular kind and type of material specified.

452-5.2Concrete: Use concrete as specified in Section 346 except as specifically

modified herein. Use No. 67 coarse aggregate in the concrete for segments. Screenings are not allowed as a substitute for silica sand for use in concrete for Precast Superstructure Segments.

452-5.3Reinforcing Steel: Use ASTM A615, Grade 60 reinforcing steel which meets

the requirements of Section 415. When welding reinforcing steel, meet the requirements of the American Welding Society’s Structural Welding Code D1.4. The Engineer may allow shop prepared welded reinforcing grillages. Field welding of reinforcing steel is not allowed.

452-5.4Post-Tensioning Syst ems: Use post-tensioning hardware components meeting

the requirements of Section 462 and used in field mock -up testing. Components are not interchangeable and must comply with the details of the approved shop drawings.

452-5.5Epoxy Bonding Systems : Use only epoxy systems comprised of two

components, a resin and a hardener, with each component distinctly pigmented so that mixing produces a third color similar to the color of the precast segments and are listed on the Department ’s Approved Product List (APL). Manufacturers seeking evaluation of their products must submit an application conforming to the requirements of Section 6. In its workable state, or open time, the epoxy bonding agent must function as a lubricant for joini ng the segments. In its hardened state, the epoxy bonding agent must provide a watertight seal between the precast concrete segments. The hardened epoxy bonding agent must 538 FY 2023-24 Return to Table of Contents

provide intimate contact for stress transfer by completely filling all interstitial space between the match cast segment faces. Do not use resin or hardeners from containers which are damaged or have been previously opened. Combining of resin and hardener from bulk containers will not be permitted ; use only pre-proportioned, full containers of components. Submit instructions, from the manufacturer, for the safe storage, handling, mixing, and application of the materials.

452-6Casting Requirements

452-6.1General: Ensure that all materials, details, and p rocedures are as specified

herein, as noted in the Plans, or as directed by the Engineer. Do not begin casting segments until the Engineer approves the relevant shop drawings, calculations, casting manuals, concrete forms and concreting operations and th e post- tensioning system components and layout if different from that on the Plans. (Approval of post - tensioning stressing elongations and forces for field erection operations is not required at this stage but is required prior to erection.) To use wet j oints to join cantilevers or for corrective measures, obtain the Engineer’s written approval. Give each segment an erection mark indicating its location, orientation and order in the erection sequence. Match mark abutting edges of adjacent segments. Show erection marks on the erection plans or in the erection manual.

452-6.2Forms: Take responsibility for the design and engineering of the forms as well

as their construction. Form all exposed formed surfaces of each element of the structure with the same material to produce similar concrete surface textures, color, and appearance. Obtain the Engineer’s approval of forms prior to initiating casting operations. Build the details shown on the Plans or as amended by approved shop drawings into the forms. Repair worn, damaged, or otherwise unacceptable forms and obtain the Engineer’s approval before casting any segment. Where sections of forms are joined, ensure that offsets in flat surfaces do not exceed 1/16 inches and that offsets with corners and ben ds do not exceed 1/8 inches. Ensure that all joints in the forms and contact points with bulkheads and existing segments have good fitting seals to prevent loss of fine material and cement grout. Check and inspect forms on a regular weekly basis to ensure proper alignment and geometric accuracy. Do not use forms which fail to meet the specified casting tolerances until such corrections are made to produce segments within the specified tolerances. Use a small blockout at all locations where an external ten don enters or exits the face of the concrete at deviation blocks and diaphragms except at anchorage locations. The blockout will be approximately 2 inches larger in diameter or overall dimensions than the tendon duct and have a depth equal to at least the minimum prescribed concrete cover dimension shown in the Plans.

452-6.3Casting Control (Geometry): Before commencing the casting operation, submit

the proposed method of geometry control for all segment casting operations to the Engineer for approval. Th is submittal must be in the form of a “Casting Manual” and include but not necessarily be limited to:

established on each segment. 539 FY 2023-24 Return to Table of Contents

the precasting yard.

for the precasting of segments; including survey controls and procedures, observations, checks, computational and /or graphical methods and correction techniques.

alignment, profile grade and superelevation appropriately combined with the camber. Ensure that the casting manual covers all geo metry control operations necessary and is compatible with the chosen methods of casting and erection, including erection survey, elevation and alignment control. Prepare the manual in accordance with submittal requirements of this Section. Do not begin casting without the Engineer’s approval of the geometry control method. In the precasting yard, use instruments for the geometry control which are mounted on a permanent platform of sufficient height to sight on all control points. In addition, establish and maintain permanent benchmarks and reference points throughout the casting operations. During casting, make all corrections required in the geometry of the segments from the control points established on each segment. With a match cast system, a fter casting and before bond breaking to separate the segments, check the position of the new cast and match cast segments again. If positions are not as desired, make corrections in the next segment. In general, and unless otherwise approved by the Engineer, make observations on the geometry control reference hardware cast into the segments (i.e. elevation bolts, alignment offsets and lengths) to a precision of plus or minus 0.001 foot. During casting operations, produce and maintain on a daily basis a graphical plot of the vertical and horizontal “as cast” alignments along each vertical and horizontal control line to an exaggerated scale in order to clearly highlight variations. Depict these against both the theoretical geometric vertical and horizontal alignment casting curves on a continuous layout of an entire unit of the bridge between expansion joints. Maintain this plot in good condition so that it may be used and referenced during erection. Keep all geometry control hardware cast into any segme nts, such as elevation bolts and alignment hairpins, in place during erection for reference and checking purposes. Remove the hardware after completion of erection of the unit in the bridge between expansion joints. Use experienced personnel to operate the instruments and supervise the casting operation. Prior to the commencement of casting, obtain the Engineer’s approval of the experience and/or qualifications of the supervisory and instrument operating personnel, particularly with regard to the observa tional precision required.

452-6.4Preparation for Match Casting: When match casting is used, take great care in

positioning of the match cast (previously cast) segment in relation to the segment to be cast. Ensure that the match cast segment is not twisted. Ensure that all materials to be embedded in the concrete of the new cast segment are properly positioned and supported in order to maintain their position and withstand concrete placement and consolidation without damage. Make provisions for all proj ections, recesses, 540 FY 2023-24 Return to Table of Contents

notches, openings, blockouts and the like in accordance with the Plans and approved shop drawings. Cover the abutting surface of the match cast segment with a thin film of a bond breaker consisting of flax soap and talc, or other material approved by the Engineer. Use a soap and talc mixture consisting of five parts flax soap to one part talc. The Engineer will base acceptance of a material other than soap and talc prior to casting any segments by demonstration on a large specimen consisting of a precast piece and a new cast piece with a contact facial area of at least 4 square feet .

452-6.5Embedded Items:

452-6.5.1 General: Embedded items must be in accordance with specifications for prestressed and post -tensioned construction and the requirements herein. 452-6.5.2 Embedded Post -Tensioning Ducts: Ensure that embedded ducts for post-tensioning tendons and bars are positioned accurately to their required alignment. Properly fabricate and identify all ducts so that proper positio ning is assured and can be verified after casting. Utilize positive methods to ensure that ducts will not be displaced or damaged during concrete placement and consolidation. Adequately secure all embedded post - tensioning ducts to the reinforcement cage at intervals not exceeding 30 inches for steel pipes and 24 inches for plastic ducts, (Small ducts and very flexible ducts may require closer supports). Any auxiliary ties and support bars needed for these purposes will be considered incidental and at no extra cost to the project. Prevent the concrete cover requirements from being violated by any auxiliary ties and support bars. After installation in the forms, ensure that the ends of the ducts are sealed at all times to prevent entry of water, debris and fine material. Following each pour of concrete, demonstrate that all empty ducts are free of water and are unobstructed and undamaged. Immediately prior to installation of the prestressing steel, again demonstrate to the satisfaction of the Engineer that all ducts are unobstructed and free of water and debris. 452-6.5.3 Anchorage Plates and Castings: Prior to placing concrete in the forms, fix all tendon anchorage plates and anchorage castings in their respective position in the forms, connected to their duct and sealed to prevent mortar intrusion. Ensure that anchorage plates and castings are rigidly fixed in the forms to maintain their correct alignment and position during concrete placement and consolidation. 452-6.5.4 Reinforcing Steel: Fabricate and place reinforcing steel in accordance with the Plans or as superseded by the approved shop drawings and as required herein. Do not cut out or remove reinforcing steel to permit proper alignment of post-tensioning ducts. Replace any bar that ca nnot be fabricated to clear the ducts by additional bars with adequate lap lengths and submit the details to the Engineer for approval. In the plane of the reinforcement parallel to the nearest surface of the concrete, ensure that bars do not vary from plan placement by more than 1 inch, nor by more than one-eighth of the spacing between bars, whichever is less. In the direction perpendicular to this plane of reinforcement, ensure that bars do not vary from plan placement by more than 1/4 inches. The top and bottom cover of reinforcing steel must be within 1/4 inches of the cover dimensioned in the Plans. The edge cover of the reinforcing steel must be within 1 inch of the cover dimensioned in the Plans.

452-6.6Concrete Placement, Consolidation and Fini shing:

541 FY 2023-24 Return to Table of Contents

452-6.6.1 General: Do not deposit concrete into the forms until the entire set -up of the forms, reinforcement, ducts, anchorages and embedded items have been thoroughly inspected and checked. Do not place concrete until the Engineer is satisfied t hat all the above items have been properly inspected and checked, and the rate of producing and placing the concrete will be sufficient to complete the casting and finishing operations within the scheduled time, that experienced concrete finishers are avai lable where required for finish work and that all necessary finishing tools and equipment are on hand at the site of the work and are in satisfactory condition for use. During conveying and placement, protect concrete against undue drying or rise in tem perature and inclement weather. 452-6.6.2 Concrete Placement Equipment: Use concrete placement equipment of a size and design which permits placing concrete within the specified time. Clean all equipment at the end of each operation or workday and, just prior to reuse, check the equipment again and clean off hardened concrete and foreign materials. Place concrete by belt conveyors and by pumping in accordance with

400-7.6and 400 -7.7, respectively.

452-6.6.3 Concrete Placement Sequence:

of the bottom slab between the inside edges of the internal web forms, leaving a narrow gap of 6 inches to 12 inches for inspection and consolidation of the bottom corners when the next load is placed in the webs. Then place the concrete in the bottom corners of each web to connect and consolidate with that already placed in the bottom slab. Then place concrete in the remainder of the webs in lifts not exceeding 24 inches at a time up to the top of the webs but not into the slab over the webs. Place concrete in the top slab in the outer wing and mid slab regions between webs before placing, completing and consolidating zones over the top of the webs.

vertically. Place the concrete in uniform lifts of approximately 24 inches to 36 inches and consolidate well.

above, or for any other precast compone nts. 452-6.6.4 Concrete Placement and Consolidation: Discharge individual loads of concrete into the forms, and place and consolidate in the required locations. After discharge into the forms, do not bodily move concrete from place to place within the fo rms by mechanical vibrators or other similar equipment. Place and consolidate concrete with care so that post -tensioning ducts, anchorages and any other embedded items are maintained in their proper positions and are not damaged. Consolidate all conc rete using approved vibrators together with any other equipment necessary to perform the work as specified. Use internal vibrators having a minimum frequency of 8,000 vibrations per minute and sufficient amplitude to consolidate the concrete effectively. P rovide at least two stand -by vibrators in working condition for emergency use in case of malfunction. Use of external vibrators for consolidating concrete when the concrete is inaccessible for adequate consolidation by internal means. When external vibr ation is used, construct the forms sufficiently rigid to resist displacement or damage. 542 FY 2023-24 Return to Table of Contents

Vibrate concrete in a manner which avoids displacement or damage to reinforcement, post -tensioning ducts, anchorages and other embedded items. No construction joi nts are allowed within a segment, except as detailed in the Plans. 452-6.6.5 Finishing: Strike off the roadway surface of the segment with an approved mechanical screed operated by a self contained power source. Furnish and use a straightedge at least 24 inches longer than the segment while finishing the concrete deck surface of superstructure box girder segments. Use the straightedge approximately parallel to the centerline of the segment to strike an accurate surface between the bulkhead and the top of the match cast segment at all positions across the segment width. Give all other surfaces of segments and precast components a Class 3 Finish at the precast site in accordance with 400 -15.

452-6.7Curing:

452-6.7.1 General: Where casting cells are intended to operate on a short (daily) cycle and it can be demonstrated to the satisfaction of the Engineer that the required initial concrete strengths for the removal of the forms, application of prestress, moving and handling of the segments and that the final concrete strength can be achieved in a timely and consistent manner, then steam curing will not be required. However, take precautions to promote proper curing by methods approved by the Engineer and in accordance with Section 400. Such precautions must meet or exceed the following:

contact with a form or match cast segment) as soon as possible after casting with a moisture tight covering (wet curing bl ankets or other approved equal systems). Avoid spoiling the deck surface finish. Keep the cover on or within 12 inches of the deck surface.

succeeding operations such as geometry cont rol survey, stripping of internal forms, wing forms and shifting of and working with a segment in a match cast position. Keep the concrete surface wet throughout these operations.

concrete by the application of a Type 2 (white pigmented) membrane curing compound as specified in 925 -2 to all exposed surfaces (including segment exterior once exposed by removal from the form). Apply an approved debonding compound to match cast sur faces to serve both as a bond breaker and seal for curing.

As an alternative, steam curing may be used.

cover the match cast segment with curing blankets, or other approved equal system, to minimize the effects of differential temperature between the segments. 452-6.7.2 Steam Curing: Meet the requirements of Section 400 modified by the following requirements when steam curing is used.

temperature of three widely separated locations per casting cell. Locate the three tempe rature sensors near the top, middle and bottom of the enclosure or as otherwise approved by the Engineer. Identify the charts with the hours, dates and segment number and submit to the Engineer immediately after steam curing is completed unless otherwise a pproved. 543 FY 2023-24 Return to Table of Contents

serve both as a bond breaker and seal for curing.

(temperature and humidity) as the new cast segment until the new segment reaches the required strength to allow the removal of the forms.

452-6.8Removal of Forms: Prior to removing the forms, protect the plastic concrete

from adverse weather effects. Keep supporting forms in place until the concrete has reached the required strength for form removal as specified in the Plans, in this Section, or as approved by the Engineer. Test cylinders, made and cured in the same manner as the segment, to confirm the form release strength prior to removing form. With the Engineer’s approval, a strength curve chart may be established to determine the time necessary for achieving the required form release strength, in accordance with the specifications for form removal. Avoid cracking or damaging the segment when removing the fo rms, especially match cast surfaces and shear keys. Notify the Engineer of any damage which occurs and repair in an approved manner.

452-6.9Test Samples: Provide additional test samples and testing for compressive

strength on precast segments and field c losure joints to control the construction activities and to ensure adequate strength of these components at various stages of their manufacture and assembly. Make test cylinders, in accordance with Section 346, cured in the same manner as the structural components to ensure adequate compressive strength has been achieved in accordance with the plan requirements for the following conditions:

pretensioned.

28 days old.

stressing of longitudinal post -tensioning tendons if the component is less than 28 days old. Determine the number of cylinders in accordance with the proposed method for casting, transporting and erecting the various components. Submit the results of the compression testing of one or more test cylinders for controlling the time of execution of the various construction operations. Obtain the Engineer’s approval for meeting the Specification requirements on casting, curing and testing of concrete test cylinders. No direct payment will be made for the conc rete testing. All costs for such testing will be included in the bid items for the various precast structural components.

452-6.10Age at Erection: Unless otherwise approved by the Engineer, precast

components must be at least 14 days old prior to incorpo rating into the structure.

452-6.11Tolerances:

452-6.11.1 General: The following tolerances apply to the fabrication of precast components:

544 FY 2023-24 Return to Table of Contents

Table 452-1

Width of Web ±1/4 inch Depth of bottom slab ±3/16 inch Depth of top slab ±3/16 inch Overall depth of segment ±3/16 inch Overall width of segment ±1/4 inch Length of segment ±3/8 inch Diaphragm dimensions ±3/8 inch

Height (Individual Element) ±1/4 inch Width and Breadth (Individual Element) ±1/4 inch Thickness (wall) ±1/4 inch

Ends (deviation from a plane per 20 ft width or depth ±1/4 inch per 20 ft not to exceed 1/2 in ch. Flat Surface (deviation from a plane at any location) ±0.025 in/ft not to exceed a total of 1/4 in.

452-6.11.2 Corrections: Control dimensions from segment to segment, including cast-in-place segments, and compensate for any deviations within a single segment or series of segments so that the ov erall dimensions of the completed structure meet the dimensions and overall erection tolerances shown in the Plans and allowed by this Section. 452-6.11.3 Repairs: Repair minor breakage, spalling, or honeycomb (not over 1 inch deep) by a method approved by the Engineer. Major breakage, spalling, or honeycomb in excess of 1 inch deep is subject to the Engineer’s structural review. If found to be satisfactory, repair these areas using a method approved by the Engineer. Do not perform surface finishing or repairs on the matching joint surfaces of precast segments until after final erection of the segment, except as herein noted. If more than 20%, but less than 40% of the total contact surface of all shear keys in any single web is broken, spalled or honeycombed, grind the damaged areas to produce a cylindrical depression into sound concrete to a depth and width approximately equal to the shear key dimensions. Complete necessary repairs to shear keys damaged at the casting site prior to shipping the segment to the erection site. After erection of the segments adjacent to the damaged keys and prior to erection of additional segments, carefully pack the voids left by the depressions with an epoxy mortar as approved by the Engineer. With the Engineer’s approval, an alternate method of repair may be used. The Engineer will consider the segment unsatisfactory for use if more than 40% of the total contact surface of all shear keys in any single web is broken, spalled or honeycombed. Use an Engineer approved method for repairing damaged alignment keys located in the top and bottom slabs. The Engineer will consider a segment unsatisfactory for use if more than 50% of the total contact surface of all alignment keys in any element of the slab (wing overhang, central portion between webs, etc.) is broken, spalled or honeycombed. Remove and dispose segments found to be unsatisfactory and not repairable after structural review and cast a new segment at no expense to the Department. 545 FY 2023-24 Return to Table of Contents

452-7Precast Segment Handling, Storage and Shipment

Handle segments with care to prevent damage. Handle segments using only the devices shown on the shop drawings for this purpose. Store all precast segments level in the upright position. Firmly support all precast segments for storage and shipment on an approved three point bearing system which does not introduce a twist under self weight. Do not stack superstructure segments one upon another unless approved by the Engineer. Prior to shipment the Engineer will thoroughly inspect each segment for d amage. Thoroughly clean the faces of all joints of laitance, bond breaking compound and any other foreign material by light sand blasting prior to shipment. Make no repairs of minor spalls or chipped areas on the joint surfaces until after erection of the segment. Upon arrival at the bridge site the Engineer will inspect each segment again. If in the Engineer’s opinion, any damage has occurred during shipment that will impair the function of the segment (structurally, aesthetically, etc.), the segment will be rejected. Replace any rejected segment with an approved segment at no cost to the Department. Provide firm support at bearing locations noted above. Fully secure the segments against shifting during transport. Provide a storage area of suitable stabilit y for the segments to prevent differential settlement of the segment supports during the entire period of storage.

452-8Erection

452-8.1Erection Manual: Before commencing erection operations, submit proposals for

all segment erection operations to the Engineer for approval. This submittal must be in the form of an “Erection Manual” and include but not necessarily be limited to:

intermediate procedures relating to erecti on equipment, temporary and permanent post - tensioning and making of closures between spans and/or cantilevers and other required sequencing.

falsework, temporary towers, supports, tie-downs, counterweights, closure devices and the like.

and winch devices, gantries, trusses and the like, both on and off the structure, including the movement, introducti on and/or removal of any supports onto or connections with the structure. Include drawings and calculations for the structural effects of erection equipment on the structure.

and sequences in accordance with the segment erection and closure operations and other required scheduling.

geometry (elevations and alignments) with particular attention to the setting of critical segments such as, for example, pier segments for balanced cantilever erection. This information may be included in the Erection Manual or may be submitted later as a supplementary or separate document.

and construction method. Do not start erection with out the Engineer’s approval of the erection manual.

452-8.2Erection Geometry Control:

546 FY 2023-24 Return to Table of Contents

452-8.2.1 General: Numerical or graphical methods may be used for alignment control and checking during erection. Establish the key stages for checking of the erectio n in the erection manual and obtain the Engineer’s review and approval. Key stages would include, for example, setting a pier segment during cantilever erection and various intermediate points during subsequent segment erection, at span closure and upon co mpletion. Prepare a table of elevations and alignments required at each key stage of erection in accordance with the Plans, as cast geometry, camber and erection elevations for establishing erection controls and submit to the Engineer for approval. Carefully check elevations and alignments at each stage of erection and correct as required to avoid any possible accumulation of errors. If geometric corrective measures are necessary, the Engineer will require the Specialty Engineer to develop the means and methods to ensure the epoxy joint remains watertight and free from localized stress concentrations. The Specialty Engineer will be required to submit the corrective measures to the Engineer for approval. Use shims made of ASTM A240 Type 304 wire clot h (roving) with a maximum of 1/8 inch thickness. 452-8.2.2 Span -by-Span and Wet Joint Erection: Position each span segment according to the final longitudinal alignment, grade, camber and cross -slope. Keep the horizontal and vertical alignment of the pie r segment within 1/16 inches of that required by the approved erection plans. Correct any deviation more than the tolerance allowed above using a method approved by the Engineer. 452-8.2.3 Balanced Cantilever and Progressive Cantilever Erection: Check the alignment and elevations of the cantilevers, using two independent surveys, within one hour of sunrise on each day that segments are to be erected. Check the measurements made by each survey and ensure they agree to within 1/4 inches. When measurements do not agree, discontinue erection of segments until discrepancies in measurements are resolved to the satisfaction of the Engineer. Accurate positioning of the pier segments is very important as it will establish the line and grade for cantilevers in each direction. Position each pier segment according to the final longitudinal alignment, grade and cross -slope and ensure no further erection continues until and unless these segments are properly located on the piers by the means provided. Keep the hori zontal and vertical alignments of the pier segment within 1/16 inch of the alignment values required to control points as established by the approved erection plans. Check at each key stage of erection, in accordance with approved erection procedures, t he ends of cantilevers for required elevations and alignment. Correct any deviation from the required alignment by a method approved by the Engineer.

452-8.3Erection Tolerances:

in the erected position does not exceed 3/16 inches.

difference between two successive segment join ts not exceed 0.001 rad.

change between two successive segments does not exceed 0.003 rad.

within a single segment so that the overall dimensions of the completed structure meets the 547 FY 2023-24 Return to Table of Contents

dimensions shown in the Plans such that the accumulated maximum error does not exceed 1/1000 of the span length for either vertical profile and/or horizontal alignment. Carefully check elevations and alignments at each stage of erection and correct as required to avoid any possible accumulation of errors.

452-8.4Other Miscellaneous Erection Requirements:

452-8.4.1 Span -by-Span and Wet Joint Erection: 452-8 .4.1.1 Cl osure Joints: Use concrete meeting the same specifications and criteria as the concrete in the segments. Ensure that concrete reaches the minimum required strength as shown in the Plans or in the Specifications prior to stressing the continuity post - tensioning. Ensure that the closure joint forms provide tolerances as specified under 452 -6.11 Tolerances. 452-8.4.1.2 Wet Joints: Where forming joints between segments using cast-in-place concrete, the above conditions for closure joints also apply to wet jo ints. In addition, the cast -in-place “Wet Joints” cannot be less than 3 inches wide, nor greater than 9 inches wide unless otherwise approved by the Engineer. 452-8.4.1.3 Formwork: Adequately support formwork at all wet joints and closure joints to take all loads applied and do not remove them until the concrete in the joints has reached its required strength and the longitudinal tendons have been tensioned. 452-8.4.2 Balanced Cantilever and Progressive Cantilever Erection: 452-8.4.2.1 Deformations: For computing deformations due to time dependent stress variations, the erection time assumptions are shown in the Plans. Deformations due to creep and shrinkage and the concrete modulus of elasticity have been computed using the FDOT’s Structures Manual edition noted in the Plans. Obtain the Engineer’s approval for method of calculating the above parameters. 452-8.4.2.2 Temperature Restrictions: Meet the requirements of segments are jointed with epoxy. Measure the substrate temperature at the mid -depth of the top slab for box girder sections or 4 inches from the top surface for slabs and other sections. 452-8.4.2.3 Permissible Loads on Canti lever: During balanced cantilever erection, unbalance the cantilever by only one segment at any time. In addition to the unbalanced load due to one segment, the cantilevers are designed for loads applied by the erection equipment as listed in the Plans. Use alternate erection methods which comply with the assumptions in the Plans or otherwise approved by the Engineer. 452-8.4.2.4 Span Closure Joints: Use concrete for closure joints which comply with the same specifications and criteria as the concrete in the segments. Ensure that concrete reaches the minimum required strength as shown in the Plans or in the Specifications prior to stressing the transverse or continuity post -tensioning. Ensure that the closure joint forms provide tolerances as specified for precast segments. 452-8.4.2.5 Falsework and Formwork: Support falsework and formwork at closure pours by the cantilever ends or terminating segments of each series of segments to be joined. Secure cantilever together vertically, longitudin ally, and transversely so that the applied loads will yield equal deflections to both cantilevers. Do not remove securing devices until the closure pour concrete has reached its required strength and longitudinal continuity tendons are tensioned. Submit ca lculations and details to verify that the devices and methods have adequate rigidity and do not impose excessive loads and stresses on the structure. 452-8.4.3 Precast Box Pier Construction - Erection Tolerances: 548 FY 2023-24 Return to Table of Contents

segments in the erected position do es not exceed 3/16 inches.

line, between two successive segment joints does not exceed 0.001 rad.

vertical line does not exceed 0.003 rad. and that the maximum overall deviation from the vertical, measured in any direction, does not exceed 0.01 inches per foot of height.

452-8.5Epoxy Jointing of Precast Segments: Furnish, mix and apply a two -component

epoxy bonding system, meeting the requirements of this Section, to the match cast faces of joints between precast concre te superstructure and/or substructure segments in accordance with the Contract Documents Prior to the use of epoxy on the project, conduct a site meeting with the Engineer and epoxy manufacturer to determine the proper formulations, storage and handling, mixing and application of the epoxy. Have the necessary materials immediately available at the location of the segment joining, in the event that the segments must be separated and cleaned or epoxy reapplied. Include in the erection manual required by this Section, details of erection and post-tensioning operations which assure that the time elapsing between mixing components of the first batch of epoxy bonding agent applied to the joining surfaces of precast concrete segments and the application of a compressive contact pressure across the joint do not exceed 70% of the open time for the particular formulation of epoxy bonding agent used. Also, include details of how the minimum, closing, contact pressure of approximately 40 psi will be applied uniformly to each joint to which epoxy is applied during the epoxy curing period. Contact pressure may be attained through combinations of weight and temporary and/or permanent post - tensioning. 452-8.5.1 Cleanliness of Surfaces to be Joined: Ensure that the app lication surfaces are free from oil, form release agent, laitance or any other deleterious material that would prevent the epoxy bonding agent from bonding to the concrete surface. Remove laitance by light sandblasting, wire brushing. Do not destroy the su rface shape and profile of the mating surfaces. Ensure that the surfaces have no free moisture on them at the time the epoxy bonding agent is applied. Free moisture will be considered present if a dry rag, after being wiped over the surface, becomes damp . 452-8.5.2 Substrate Temperatures and Epoxy Formulation: Apply the epoxy bonding agent only when the substrate temperature of both surfaces to be joined is between 40°F and 115°F. The formulation of the epoxy bonding agent must have an application tempe rature range that conforms to the substrate temperature of the surfaces being joined. If the mating surfaces have different substrate temperatures, then use the formulation for the higher temperature in hot weather periods. In cold weather periods, use the formulation for the lower temperature. Thermal control precautions may be taken in accordance with 452-8.5.5. 452-8.5.3 Mixing of Epoxy Bonding Agent: Mix the two components of the epoxy bonding agent in strict accordance with the manufacturer’s instructions, using only full and undamaged containers. Only open the containers immediately before being combined and do not use any which have an expired shelf life. Thoroughly stir each container of component before combining the components. Combine the two co mponents and thoroughly mix until a uniform 549 FY 2023-24 Return to Table of Contents

color is achieved. Mix with a properly sized mechanical mixer operating at no more than 600 rpm or in accordance with the recommendations of the epoxy manufacturer. Do not mix until the segments to be joined a re within approximately 18 inches of their final position. Schedule mixing of the epoxy bonding agent so that the material in a batch is applied to the face of a joint within a maximum of 20 minutes after combining the components. The Engineer, at his d iscretion, may require a dry run to check the fit of two surfaces before applying the epoxy. 452-8.5.4 Mating of Segments: Immediately after each mating surface is covered with epoxy bonding agent, bring the segments together and apply the specified comp ressive contact pressure in accordance with the approved erection procedures. The contact pressure may be increased at any time after the epoxy has taken an initial set. Do not reduce the contact pressure until the epoxy in the joint has properly hardened and cured. If the contact pressure is reduced, do not subject the joint to tensile stress. A discernable bead line of extruded epoxy bonding agent must be apparent along the exposed edges of the joint. Fill all areas of the joint which do not show a bea d of epoxy by dispensing additional epoxy, meeting the requirements of this specification, into the joint using a pneumatic gun with epoxy cartridges. Inject epoxy to a minimum depth of 1 inch. Catch and retain epoxy which is squeezed out of the joint i n areas over waterways, roadways, buildings, etc. Clean all extruded epoxy bonding agent from external visible surfaces in a way not to damage or stain the concrete surface. Do not smear surplus extruded epoxy bonding agent over large areas (areas more than 1 inch from each side of the joint), visible surfaces or surfaces to which a cover coat, Class 5 applied finish coat or similar or texturing is to be applied later. Immediately after the segments are joined, swab all embedded (internal) post-tensioning ducts or conduits passing through the joints to smooth out any extruded epoxy bonding agent. If the time between combining the components of the epoxy bonding agent and applying the compressive contact pressure exceeds 70% of the minimum open time, immediately separate the segments and clean in accordance with 45 2-8.5.6. 452-8.5.5 Thermal Controls: 452-8.5.5.1 Cooling in Hot Weather: If the substrate temperature exceeds 115°F, do not proceed with epoxy jointing. The Contractor may take precautions to keep the mating substrate surfaces cool by shading or wetting with clean water, except that the above requirements for no moisture at th e time of application must be strictly adhered to. 452-8.5.5.2 Artificial Heating in Cold Weather: If electing to erect segments in cold weather when the substrate temperature of the mating concrete surfaces is below 40°F, an artificial environment may be used to increase the substrate temperature subject to the following:

joint through which warm air is circulated, or heating is provided by radiant heaters.

joint surface to at least 40°F.

exceeding 95°F at any point on the surface. Direct flame heating of the concrete is not allowed. 550 FY 2023-24 Return to Table of Contents

and 95°F for at least 24 hours after joining the surfaces.

optional method of raising and maintaining the substrate temperature o f the mating surfaces. Any optional method must meet the thermal restrictions above. Epoxy jointing operations may proceed if the air temperature is above 45°F and rising and the limitations above are met. 452-8.5.6 Failure to Comply with Time Limits or Incomplete Jointing: If the time limit between mixing of the epoxy -bonding agent and the application of the contact pressure is exceeded, or if the joint is incompletely filled and sealed, separate the segments and remove all epoxy from the faces using spatulas and approved solvent. Do not re -apply epoxy until the faces have been properly cleaned and solvents dispersed, for a period of 24 hours. 452-8.5.7 Removal of Support to Segments : 452-8.5.7.1 Span -by-Span Erection: Ensure that precast concrete segments remain fully supported by the erection truss or system until at least 20 hours after mixing of the last batch of epoxy bonding agent applied to any joint in the span. 452-8.5.7.2 Cantilever Erection: Independent su pport to a newly erected cantilever segment may be removed when the epoxy bonding agent in the third previous mating joint has set. It is not necessary for the epoxy bonding agent in the new joint or the immediately previous joint to be set prior to removi ng the independent support of the new segment provided that the temporary and/or permanent post -tensioning has been installed to carry the load of the new and previous segment along with any applied construction loading as per the requirements of the erection system. 452-8.5.8 Record of Jointing : Record and submit to the Engineer on a weekly basis the following information:

components.

each segment when application of the epoxy bonding agent began.

joint and completion of application.

location, volume of epoxy used, method of application, etc .

452-8.6Packed Mortar Joints for Joints or Bearings: Where designated on the Plans,

place packed mortar after the joint or bearing has been set at the proper final elevation. Pressure grouting may be a llowed with the Engineer’s approval of the materials and method to be used. Mortar for packing consists of one part cement and one part fine aggregate, by volume, mixed with a non -shrink admixture as recommended by the manufacturer. Mix the dry 551 FY 2023-24 Return to Table of Contents

elements thoroughly to a uniform mixture. Add water to produce a mealy, slightly adhesive mixture. Pack the mortar until a water sheen is produced on the surface of the mortar. Build a form around the joint leaving one side open. Secure the form to withstand the required packing forces. Insert a small amount of mortar into the open joint to form a 2 inches thick bead on the opposite side of the form. Pack this bead by striking a special tool made of 1/2 inch by 2 inch steel having a length approximately 10 inches longer than the largest dimension of the joint being packed with a 2 pound hammer. Continue compaction until water begins to bleed out of the mortar. When bleeding has occurred, insert another bead of mortar and pack as described above. Continue this proce ss until the joint is filled to the limits shown in the Plans.

452-9Traffic Railing and Median Setting

Prior to forming the concrete traffic railings, accurately establish the as -constructed gutter line elevations at intervals not exceeding 10 feet. Then form the base of the traffic railing and median to provide an inside vertical face which extends from the surface of the concrete structure to an ele vation located 3 inches (or as shown in the Plans) above the theoretical gutter line elevations. Maintain the plan vertical height of the traffic railings as a minimum when variations exist between the plan profile and the actual profile of the gutter.

452-10Bridge Deck Surface

Provide a Class 4 Floor Finish in accordance with Section 400 for Long Bridges upon completion of superstructure segment erection and prior to opening to traffic. Install expansion joints in accordance with Section 400.

452-11Watertight Decks

Check all segment joints, closure joints and deck hole repairs to assure every location is watertight, upon completion of all milling and grinding activities on the riding surface. Repair all locations showing evidence of leaks by cutting a 3/8 inches wide x 5/8 inches deep groove along the leak interface. Clean and completely fill the groove with epoxy meeting the requirements of Section 926. Dispense the epoxy into the groove using a pneumatic gun and epoxy cartridges. Clean all excess epo xy bonding agent from external visible surfaces in a way not to damage or stain the concrete surface. Do not smear epoxy over areas located more than 1 inch from each side of the groove.

452-12Method of Measurement

Precast superstructure and substructure segment concrete, including cast -in-place concrete for closure and wet joint pours, will be measured by volume according to the quantities represented by the dimensions of the segments and cast -in-place pours on the Plans or approved shop drawings; whichever is the lesser. All reinforcement in precast superstructure and substructure segments, cast -in-place closures and wet -joints will be measured by weight according to the quantities represented by the reinforcement details in the Plans or approved shop drawings; whichever is the lesser. All permanent post -tensioning in the superstructure and substructure will be measured by weight according to the quantities represented by the details in the Plans or approved shop drawings; whichever is the lesser. 552 FY 2023-24 Return to Table of Contents

452-13Basis of Payment

452-13.1General: Payment will be in accordance with the following:

452-13.2Precast Segments -Concrete: Payment for precast superstructure and

substructure segment concrete will be at the Contrac t bid prices per cubic yard for the various classes of concrete called for. Such prices and payments will be full compensation for manufacture, storage, transport, assembly and erection of the segments complete and in place, including filling all concrete blockouts and similar miscellaneous details. These prices and payments will also include the furnishing and the application of epoxy bonding agent and Class 5 applied finish coating when specified in the Plans, providing temporary and permanent segment a ccess details, material testing, special erection equipment, temporary post -tensioning, tools, labor and incidental items necessary for completing the work in accordance with the Plans, Specifications and approved shop drawings. Cast-in-place concrete fo r closure and wet joint pours will be paid for under these items which also include the cost of all formwork, closure devices and other temporary construction needed to make these closures and joints and cast -in-place segments or portions thereof as designated in the Plans. Include the cost of providing a Class 4 floor finish on the bridge deck and approach slab surfaces in the cost of superstructure and approach slab concrete. The Bridge floor grooving will be measured and paid for separately. No additional payment will be made for extra concrete necessitated by approved modifications to the segments or structure needed to accommodate the Contractor’s construction methods.

452-13.3Precast Segments -Reinforcement: Payment for reinforcement in precast

segments, closure pours, wet joints and other cast -in-place concrete joints and details will be at the Contract bid price per pound for reinforcing steel (superstructure) and for reinforcing steel (substructure). No additional payment will be made for ex tra reinforcement necessitated by approved modifications to the segments or structure for the purposes of the Contractor’s construction methods.

452-13.4Precast Segments -Post-Tensioning: Payment for permanent post -tensioning

will be in accordance withSe ction 462. No additional payment will be made for extra permanent or temporary post - tensioning necessitated by approved modifications to the segments or structure for the purposes of the Contractor’s construction methods, nor will payment be made for tem porary tendons which are approved to be left in the structure, either stressed or unstressed, for the convenience of the Contractor’s operations.

452-13.5Precast Segments -Partial Payment: Partial payment for precast segments will

be made at 65% of the bi d price per cubic yard of concrete and per pound of reinforcement when the segment has been cast and accepted. Remaining payment will be made when the segment has been erected and accepted for incorporation into the structure. Payment for post -tensioning w ill be in accordance with Section 462.

452-13.6Precast Segment -Non-Compliance: Any penalties or deductions for non -

compliance with regard to concrete, reinforcement or post -tensioning will be applied to the work affected in accordance with the requiremen ts of the respective specifications. 553 FY 2023-24 Return to Table of Contents

452-13.7Precast Segment Production: Preparatory operations for superstructure

segment casting will be paid for separately at the Contract Lump Sum price for precast segment production. This item consists of the work n ecessary for establishing and putting into operation segment casting facilities. It includes preparatory work, operations, acquisition or lease of real property, acquisition or lease of segment manufacturing equipment, acquisition or lease of equipment for the handling, transport and storage of the segments, and all other work or operations which must be performed or costs incurred prior to the manufacture of the concrete segments, including engineering services such as shop drawings. Partial payments wil l be made as indicated below:

canceled checks or similar executed financial instruments, the cost for the acquisition of the casting forms for the precast segments by purchase, lease or manufacture will be paid up to a limit of 25% of the Lump Sum Price bid.

first operable casting form and the segment is approved and accepted by the Engineer, 25% of the Lump Sum Price bid will be paid.

out of any operable casting form and approved and accepted by the Engineer, 5% of the Lump Sum Price bid will be paid for each segment up to a limit of 50% of the Lump Sum Price bid (i.e., 5% for each of the next ten acceptable segments). The total Lump Sum Price bid under this item will not exceed the least of:

segments only (i.e., excluding any cast -in-place concrete in joints, closures or designated cast -in- place segments) or

The balance of the Lump Sum Price not paid after completion of casting the first eleven satisfactory superstructure segments will be paid after completion of the erection of the first span or closure of the first pair of cantilevers, whichever occurs first.

452-13.8Epoxy Jointing: No separate payment will be made for the work of epoxy

jointing of precast concrete segments. The cost of this work will be included in payment for the various precast concrete items.

452-13.9Payment Items:

Payment will be made under: Item No. 400 - 4- 39- Class IV Concrete (Precast Superstructure Segments) - per cubic yard. Item No. 400 - 4- 40- Class IV Concrete (Precast Substructure Segments) - per cubic yard. Item No. 400 - 8- 40- Class V Concrete (Precast Substructure Segments) - per cubic yard. Item No. 415 - 1- 4- Reinforcing Steel (Superstructure) - per pound. Item No. 415 - 1- 5- Reinforcing steel (Substructure) - per pound. Item No. 452 - 70- Precast Segment Production - lump sum.

554 FY 2023-24 Return to Table of Contents STRUCTURES FOUNDATIONS

Index

Auger Cast Piles ................................ ................................ ........ 455-38 through 455 -50

455-1General

The Contractor may examine available soil samples and rock cores obtained during the soil boring operations at the appropriate District Materials Office.

455-1.1Monitor Existing Structures: Monitor existing structures in accordance with

Section 108.

455-1.2Excavation: Complete all excavation of the foundations prior to installing piles

or shafts unless otherwise authorized by the Engineer. After completing pile/ shaft installation, remove all loose and displaced materials from around the piles/shafts, leaving a clean, solid surface. Compact the soil surface on which concrete is to be placed or which will support the forming system for the concrete to support the l oad of the plastic concrete without settling or causing the concrete to crack, or as shown in the Contract Documents. 455-1.2.1 Abutment (End Bent) Fill : Place and compact the fill before installing end-bent piling/shafts, except when driving specified t est piling in end bents or the Plans show uncased piles through proprietary retaining wall fills. When installing piles/shafts or casing prior to placing fill, take necessary precautions to prevent displacement of piles/shafts during placing and compacting fill materials within 15 feet of the piles/shafts or casing. Reference and check the position of the piles/shafts or casing at three approximately equal intervals during construction of the embankment. Place embankment material in 6 inch compacted lifts in the 15 foot area around the piles/shafts or casing. Compact embankment material within the 15 foot area adjacent to the piles/shafts or casing to the required density with compaction equipment weighing less than 1,000 pounds. When installing piles/ shafts prior to the completion of the surrounding fills, do not cap them until placing the fills as near to final grade as possible, leaving only the necessary working room for construction of the caps. When shown in the Plans, p rovide permanent casings installed prior to placement of the fill, for all drilled shafts through mechanically stabilized fills (for example, behind proprietary retaining walls) for shafts installed after fill placement. Install temporary casings through the completed conventiona l fill when permanent casings are not required. Provide permanent casings, if required, before the fill is placed extending a sufficient distance into the existing ground to provide stability to the casings during construction of the abutment fill. 555 FY 2023-24 Return to Table of Contents