462-1Description
manufacturer’s recommendations. Constituent components of PT systems include, but are not limited to, anchorage assemblies, filler containment assemblies, filler material, and related steel reinforcement. Use the most stringent requirements, as determined by the Engineer, of those specified in this Section or the component manufacturer’s recommendations for protecting components from damage due to environmental exposure, improper handling, or improper installation.
components from a single supplier (vendor).
testing in accordance with Section 960. Include in the PT system testing all possi ble combinations of components to be incorporated into the structure.
Engineer in accordance with Section 5 .
shown in the Contract Documents.
in 960-2, that were used in system testing and as listed on the approved PT system shop drawings.
delete any major components , as defined in 960 -2, of a PT system approved by the Engineer for use on the project .
may be performed concurrent with mockup testing if performed prior to installation of any PT system hardware .
D4285 through the duct . Provide visual confirmatio n that the duct is free of water and moisture.
predetermined load, anchor ends directly against hardened concrete and install permanent anchorage caps.
D4285 through the duct. Provide visual confirmation that the duct and tendon are free of water and moisture.
Engineer for review and written approval.
blockages, and voids. Submit test data to the Engineer to verify that the work meets the requirements of this Section. Perform filler injection operations in accordanc e with 462 -7.4. 664 FY 2023-24 Return to Table of Contents
462-2Materials
462-2.1General:
Approval of any material by the Engineer will not preclude subsequent rejection if material is damaged or otherwise found to not meet the requirements of this Section or
462-2.2Steel Reinf orcing:
462-2.2.1 Mild Steel:
and are the responsibility of PT system supplier (vendor). Design system specific local zone reinforcement for the number of strands or wires a particular PT system can accommodate at maximum allowable strand or wire force; do not design project specific local zone reinforcement for a reduced system capacity.
details to the Engineer for review and written approval. 462-2.2.2 Prestressing: 462-2.2.2.1 Strand:
462-2.2.2.2 Bar:
subject to written approval by the Engineer. 462-2.2.2.3 Parallel Wire :
462-2.3Duct Filler: Use only grout and flexible filler meeting the requirements of
Section 938 and are listed on the Department’s Approved Product List (APL). 462-2.3.1 Grout:
vertical.
requirements of Section 923.
462-2.3.2 Flexible Filler: Prepare flexible filler for installation in accordance with the manufacturer’s instructions. Do not combine different flexible filler products.
462-2.4Other Material References:
Meet the requirements of this Section, as well as the following: Class 5 Applied Coating* ................................ ...............Section 975 Elastomeric Coating System* ................................ .........Section 975 Epoxy Compound* ................................ ......................... Section 926 Magnesium Ammonium Phosphate Concrete* ..............Section 930 Methacrylate* ................................ ................................ .Section 413 Water ................................ ................................ ...............Section 923 *Use products listed on the Department’s Approved Product List ( APL).
462-2.5Component Samples:
665 FY 2023-24 Return to Table of Contents 462-2.5.1 Prestressing Steel:
prestressing strand, wire, and bar to be used on project.
for PT operations on the Project.
Engineer. 462-2.5.2 Grout:
total quantity of one bag per L OT or shipment. A LOT is defined as a quantity of material from a single production batch or shipment
Engineer will determine at what frequency, interval, sample phase (powder, liquid or solid) and location those samples will be recovered from the project.
Engineer.
production LOT of gro ut to be used on the project. These samples will be used by the State Materials Office for product testing.
trial batch using the same water source and grout to be used for production grouti ng.
Submit samples a minimum of four weeks prior to initial production grouting. Do not commence grouting operations until grout test results are available and approved by the Engineer. Mock -up testing per section 462 -7.4.1.1 (5) m ay proceed prior to grout approval. 462-2.5.3 Flexible Filler:
quantity of one gallon per LOT. A LOT is defined as a quantity of material from a single production batch or shipment not to exceed 1,000 gallons.
Engineer will determine at what frequency, interval, sample phase (liquid or solid) and location those samples will be recovered from the projec t.
Engineer.
462-3Alternate PT System Designs
Designs using a PT scheme different from that shown in the Contract Documents may be submitted for the Engineer’s approval provided proposed scheme fulfills the design requirements, and the Contractor demonstrates compliance with these requirements:
or greater than that provided by the PT scheme shown in original Contract Documents.
the distribution shown in original Contract Documents.
Association of State Highway and Transportation Officials Load and Resistance Factor Design, 666 FY 2023-24 Return to Table of Contents AASHTO LRFD Bridge Design Specifications Section 5, and is equivalent to or greater than service and strength limit states provided in original Contract Documents.
meet requirements of the Design Criteria shown in original Contract Documents.
satisfied.
alternate PT scheme.
steel, and concrete cover
quantity from that shown in the Co ntract Documents is paid based on comparison of the following:
is less, and
If approved alternate PT scheme or system is under a Cost Savings Initiative Proposal (CSIP), method of payment will be in compliance with CSIP agreement.
Record.
462-4Qualifications
Provide all project personnel and crew foreman in accordance wi th Section 105.
462-5Submittals
drawings, and manuals in accordance with this Section and Section 5. Submit to the Engineer signed and sealed PT related shop drawings designed by the Contractor’s Engineer of Record.
Documents and requirements of this Section. Show details of PT hardware components, tendon geometry and locations complying with the Cont ract Documents and limitations of selected PT system. Include all inlets, outlets, high point inspection port details, anchorage inspection details, permanent anchorage caps, protection system materials, and application limits. If applicable, include detai ls of the duct dehumidification system.
462-6Transport, Handling and Storage
462-6.1General:
Store all materials in a weatherproof building, shed, covering, or container until time of use.
462-6.2LOT Identification:
that allows each LOT to be clearly identified at project site for all PT system components, filler, bars of each size from each mill heat of steel, and all strands from each manufactured re el.
reel of material represented if applicable. 667 FY 2023-24 Return to Table of Contents
at the site will be rejected.
rejection.
Engineer for each LOT of filler on the project.
462-6.3Prestressing Steel:
damage and corrosion during shipping and storage.
incorporate it into a corrosion inhibitor carrier type packaging material.
concrete, or bond strength of steel to concrete.
Federal Specification MIL-P-3420.
condition.
high-strength prestressing steel, care to be used in handling, include type, kind, and amount of
corrosion inhibitor used, date when placed, safety orders, and instructions for use.
its surface.
462-6.4Filler:
humidity) in strict conformance with manufacturer’s recommendations at all times from
manufacture to installation.
covering to protect the filler.
maximum period of one week. The allowable on site storage time may be extended by the
Engineer if the grout filler is in a climate-controlled structure. Grout filler material with a total
time from manufacturer in excess of six months must be removed from the jobsite and replaced
with new material.
manufacturer’s expiration date. Do not use flexible filler that has exceeded the manufacturer’s
recommended usage date. Remove all such filler from the jobsite and replace with new material.
462-6.5Duct and Pipe:
contamination, corrosive elements, or any other damage or contamination during transport,
storage, and handling.
remove duct end caps until duct is incorporated into the bridge component.
668FY 2023-24Return to Table of Contents
462-7.2.4 before use.
462-7Construction
462-7.1General:
requirements of Section 960-3.6.
major components, as defined in 960-2, furnished to the project and shown on the approved PT
system shop drawings exactly match the major components used in PT system testing.
any PT ducts, anchorage assemblies, splices and connections, reinforcement, or other embedded
items.
Engineer.
462-7.2System Installation:
Accurately and securely fasten all PT anchorages, ducts, inlet and outlet pipes,
miscellaneous hardware, reinforcing bars, and other embedded items at locations shown in the
Contract Documents or on approved shop or working drawings or as otherwise approved by the
Engineer in writing.
462-7.2.1 Ducts:
practical.
Documents, or according to approved shop or working drawings, or as approved in writing by
the Engineer.
30 inches for steel pipes, 24 inches for round plastic ducts, and 12 inches for flat ducts to prevent
movement, displacement, or damage from concrete placement and consolidation operations.
drawings.
internal ducts at anchorages, diaphragms, and deviation saddles and are supported at intermediate
locations according to the Contract Documents including approved shop drawings.
smooth and continuous with no lips, kinks, or dents. This also applies to curves in pre-bent steel
pipe.
before placing any concrete.
drains, and all other duct openings are sealed at all times after installing ducts and until tendon
installation is complete.
per the approved system drawings. 669FY 2023-24Return to Table of Contents
connections or sealing for any reason.
instructions, to make splices between sections of smooth plastic duct or make connection with
electrofusion duct coupler as shown on the approved PT system shop drawings.
3/8 inches wide power seated band and clamps in accordance with 960-2.2 on each end of a duct
boot to seal against filler leakage. Install band per manufacturer’s instructions.
PT will be removed from structure are not required to be coupled across segment joints.
may be present within the duct.
462-7.2.1.1 Installation Tolerances:
following table:
Table 462-1
Duct Installation Tolerances
Type Vertical Position (inches) Horizontal Position (inches)
Horizontal tendons in slabs or in slab
regions of larger members ±1/4 ±1/2
Longitudinal draped superstructure
tendons in webs: Tendon over supports
or in middle third of span
±1/4 ±1/4
Tendon in middle half of web depth ±1/2 ±1/4
Longitudinal, generally horizontal,
superstructure tendons usually in top or
bottom of member
±1/4 ±1/4
Horizontal tendons in substructures and
foundations ±1/2 ±1/2
Vertical tendons in web Longitudinal
Position ±1
Transverse
Position ±1/4
Vertical tendons in pier shafts ±1/2 ±1/4
All other cases ±1/4 ±1/4
duct joints, and/or at faces of concrete are within plus or minus 3 degrees of desired angle
measured in any direction.
transitions.
position laterally and plus or minus 1 inch along tendon except that minimum cover requirements
must be maintained.
form of spirals, multiple U-shaped bars, or links centered around duct and anchorage
(±1/4 inch tolerance) and starting within 1/2 inch of the back of the main anchorage plate. 670FY 2023-24Return to Table of Contents
duct/anchorage and other non-local zone reinforcement, the position of duct prevails. Adjust the
non-local zone reinforcement with the Engineer’s written approval.
462-7.2.2 Splices and Joints:
are part of approved PT system.
placement.
462-7.2.3 Inlets, Outlets, Drains and Ports:
Contract Documents including approved shop drawings.
shut-off devices (e.g., valves).
positions and those shown in Standard Plans, Index 462-001:
highest and lowest point is more than 2 feet;
girders, place drains at the geometric low points of all duct profiles, or as close as is practical to
the geometric low points of all duct profiles, except where an inlet, outlet or anchorage that can
serve as a drain is located at a low point. Locate drains, and inlets and outlets serving as drains,
at the bottom of the duct cross section. Do not locate drains within the limits of diabolos.
member to allow for proper closing of valves.
predominantly vertical surfaces of box and I-girders toward the inside face of exterior I-girders
or toward the interior of box girders.
462-7.2.4 Tendons:
free of moisture prior to installation within the duct.
within duct and completion of the stressing and filler injection operation.
within duct and completion of the stressing and filler injection operations.
calendars days allowed between the first installation of the PT tendon within the duct and
completion of the stressing and filler injection operations is 30 for PT strand and 45 for PT bars
by monitoring and continuously maintaining the relative humidity of air within the duct below
40%. Use a closed dehumidification system or other means approved by the Engineer. The
dehumidification system must be installed and operational within 24 hours of first installation of
the PT tendon within the duct and remain operational until just prior to filler injection. 671FY 2023-24Return to Table of Contents
method to increase the allowed number of calendar days between the first installation of the PT
tendon within the duct and completion of the stressing and filler injection operations.
in (1), (2), (3) or (4) of this Article will not be cause for rejection of the PT tendon.
specified, will result in stoppage of work, except when waived by the Engineer in writing.
allow for drainage of any water that may be present within the duct. Close all low point drains
and ports except the inlet and outlet ports at the anchorage caps. Blow oil-free dry compressed
air meeting ASTM D4285 through one of the anchorage cap ports until the relative humidity
measured at the inlet and outlet ends are less than 40% and continuing blowing for an additional
30 minutes. Stop blowing, wait a minimum of 15 minutes, and take humidity measurements at
the inlet and outlet ends of blowing. Further blowing is not required if both humidity readings
are less than 40%. If the humidity readings are 40% or greater, then repeat the process of
blowing and waiting for 15 minutes until the humidity measurements at the inlet and outlet end
of blowing are less than 40%. Take humidity measurements of air within the duct at the inlet end
and outlet end of blowing using separate humidity meters. Use humidity meters approved by the
Engineer.
debris at the anchorages and low points of the tendon profile before installing the PT tendon
within the duct.
Engineer and is only permitted as defined in this Article.
and blockages as subject to provisions of 462-8.3.2. For flexible filler operations, use the repair
procedure described in the approved Wax Injection Operations Plan.
uncapped ducts that have been subjected to salt spray), flush duct with potable water containing
slack lime (i.e., calcium hydroxide) or quicklime (i.e., calcium oxide) in the amount of
0.17 pounds per gallon.
before placing tendon.
continue to flush duct until chloride level in flush water outflow is below 250 ppm.
low point drains to allow for drainage of flush water within the duct. Perform the blowing
process described in (8) of this Article. Provide visual confirmation that the duct is free of water
and moisture for its entire length before installing the PT tendon within the duct.
using methods that will not snag on any lips or joints in ducts.
end with smooth protective cap.
during installation of PT strand into duct. 672FY 2023-24Return to Table of Contents
beyond dead end anchorages to allow for second end stressing as needed for reconciliation of
jacking force versus measured elongation.
wire sock or other device attached to advancing end. Strands may be brazed together for pulling
as long as one foot of strand from the brazed end is removed by cutting after installation. Do not
electric arc weld strand ends together for this purpose.
strand spacers, etc.) must be removed prior to stressing
required by this Section or the Contract Documents. The only two exceptions are:
may be installed for test; and,
boxes prior to concrete casting such that they meet 462-8.3.1.
462-7.3Post-Tensioning Operations:
specified in the Contract Documents.
force is in agreement with the Contract Documents.
462-7.3.1 Stressing Equipment:
Only use equipment furnished by supplier of PT system.
462-7.3.1.1 Jacks and Gauges:
Equip each jack with pressure gauge for determining jacking
pressure that has a minimum dial diameter of six inches.
462-7.3.1.2 Calibration:
extension of jack in various positions (e.g., two-inch, four-inch, eight-inch stroke).
to obtain an average force.
etc.) setup in same configuration intended for use on Project.
supplier or an independent laboratory.
stressing equipment.
and tractability to National Institute of Standards and Technology (NIST) along with jack/gauge
calibration.
each jack and gauge unit used on the project prior to start of work and every six months
thereafter or as requested by the Engineer. 673FY 2023-24Return to Table of Contents
may be accomplished with use of a master gauge. Supply master gauge to the Engineer in a
protective waterproof container capable of protecting calibration of gauge during shipment to a
laboratory. Provide a quick-attach hydraulic manifold to enable quick and easy installation of
master gauge to verify permanent readings. Master gauge will remain in the possession of the
Engineer for duration of project and will be returned to the Contractor after final acceptance of
project by the Engineer.
hydraulic lines, requires recalibration using a load cell.
subsequent calibrations or use of master gauge required by the Engineer.
462-7.3.2 Stressing Tendons:
Contract Documents or as otherwise approved by the Engineer in writing.
strands or wires, or for curved tendons with two or more strands or wires.
to use a monostrand jack.
462-7.3.2.1 Jacking Maximum Stress:
Maximum temporary stress (i.e., jacking stress) in PT steel must
not exceed 80% and 75% of Guaranteed Ultimate Tensile Strength (GUTS) for PT strands and
bars, respectively. The maximum temporary jacking stress must not exceed 50% of GUTS for PT
bars that will be reused.
462-7.3.2.2 Initial and Permanent Stresses:
term retention of permanent stresses or forces of no less than those shown in the Contract
Documents.
stress after anchor set must not exceed 70% of GUTS at anchorages and 74% of GUTS at all
other locations between anchorages.
remaining in PT steel after all losses, including long term creep and shrinkage of concrete, elastic
shortening of concrete, relaxation of steel, losses in PT steel from sequence of stressing, friction,
and unintended wobble of ducts, anchor set, friction in anchorages, and all other losses particular
to the specific PT system.
462-7.3.2.3 Stressing Sequence:
as noted in the Contract Documents.
other end or simultaneously at both ends.
462-7.3.2.4 Elongation:
of tendon can be measured at all times.
674FY 2023-24Return to Table of Contents
within 7% of theoretical elongation or entire operation must be halted, checked, and source of
error determined and remedied to satisfaction of the Engineer before proceeding.
required force falls outside acceptable tolerances, additional tests may be required, at the
Engineer’s discretion and without additional compensation to the Contractor, for Tendon
Modulus of Elasticity and/or In Place Wobble and Friction Test, or Lift-Off Test.
462-7.3.2.5 Friction:
anchor set in the shop drawings; submit calculations and show a typical tendon force diagram on
shop drawings based upon expected actual coefficients and values for the PT system to be used.
reduced, subject to written approval of the Engineer.
462-7.3.2.6 Tendon Wire Failure:
slipping during stressing may be accepted provided these conditions are met:
of original total design PT force;
required by the Contract Documents for that mating joint for that stage of construction for
precast or cast-in-place segmental construction. This 98% minimum PT force requirement
applies to segmental construction, or any similar construction, that has members post-tensioned
together across a common joint face at any stage of construction; and,
reduction in cross-sectional area of PT steel due to wire failure.
alternative means of restoring PT force lost due to wire failure, any of the above conditions may
be waived at discretion of and with approval of the Engineer in writing.
462-7.3.2.7 Cutting of PT Steel:
3/4 inches to 1-1/2 inches away from the anchorage.
462-7.3.2.8 Post-Tensioning Operations Record:
bars;
675FY 2023-24Return to Table of Contents
stressing by number);
Inspector);
records within five days of completed tendon installation.
462-7.3.3 System Protection:
462-7.3.3.1 Tendon:
within four hours after tendon stressing.
acceptance of tendon will be delayed more than four hours after stressing, immediately provide
temporary weatherproofing of tendons at open ends of anchorages. If tendons and anchorages are
temporarily weatherproofed, install anchorage caps within 1 day of tendon being accepted.
remove tendon, flush duct with potable water per 462-7.2.4, and replace with new tendon.
462-7.3.3.2 Anchorage:
Plans, Index 462-002:
blockouts.
access or vent holes.
of Section 960.
at anchorages as indicated in the Contract Documents and as shown on Standard Plans,
Index 462-002 within seven days of completing filler injection operations (see 462-7.4 for filler
injection operations). For anchorages which require acrylic aliphatic polyurethane top coating,
apply the acrylic aliphatic polyurethane top coating after the elastomeric coating has fully cured.
See Standard Plans Index 462-002 and the Contract Documents for details on anchorages which
require acrylic aliphatic polyurethane top coating. Construct anchorage pour-backs using
reinforced concrete, magnesium ammonium phosphate concrete, or a Type Q epoxy grout
meeting the requirements of Section 926.
treatments, coatings, and oils by grit blasting or water blasting. Flush surface with water and
blow dry. Surfaces must be clean, sound, and without any standing water. Test substrate at all
pour-back locations using ACI 503 and develop a minimum of 175 psi tension (e.g., pull-off
value). Testing frequency may be reduced, as determined by the Engineer, after the Contractor 676FY 2023-24Return to Table of Contents
has demonstrated an ability to prepare substrate surfaces for bonding as indicated by the result of
the ACI 503 test.
phosphate concrete in accordance with the manufacturer’s current standard technical guidelines.
Construct all pour-backs in leak proof forms creating neat lines. Epoxy grout may require
pumping for proper installation. Construct forms to maintain a liquid head to ensure intimate
contact with concrete surface. Use vents as needed to provide for escape of air to ensure
complete filling of forms.
shown on Standard Plans, Index 462-002 with an elastomeric coating system meeting the
requirements of Section 975 and having a thickness of 30 mils to 45 mils. Apply the acrylic
aliphatic polyurethane top coating to a dry film thickness of 5 to 6 mils. Ensure concrete,
anchorage caps, or other substrates are structurally sound, clean, and dry. Concrete must be a
minimum of 28 days old. Remove all laitance, grease, curing compounds, surface treatments,
coatings, and oils by grit blasting or water blasting using a minimum 3,000 psi nozzle pressure.
Blow surface with compressed air to remove dust or water. Apply the elastomeric coating within
90 days of filler injection. Apply the acrylic aliphatic polyurethane top coat and the
manufacturer’s approved primer over the elastomeric coating before applying Class 5 coating, if
required.
4 foot concrete test block with a similar surface texture to surfaces to be coated. Coat a vertical
face with chosen elastomeric coating system. Determine number of coats required to achieve the
specified thickness without runs and drips. Mix and apply elastomeric coating as per
manufacturer’s current standard technical specifications. Spray application is preferred; roller
application is permitted. Have coating manufacturer representative on site to supervise and
comment on application of elastomeric coating onto test block. Apply coating using approved
and experienced personnel with a minimum of three years experience applying similar
polyurethane systems. Submit credentials of these persons to the Engineer for review and
consideration for approval.
462-7.4Filler Injection Operations:
462-7.4.1 Grouting Operations: Conduct all grouting operations in the presence
of the Engineer.
462-7.4.1.1 Grout Injection Operations Plan:
six weeks in advance of any scheduled grouting operation.
required before any grouting of permanent structure takes place.
supervisor in conformance with this Specification;
including all required certifications;
demand and working conditions, as well as, standby equipment and spare parts;
677FY 2023-24Return to Table of Contents
maintaining less than 40% relative humidity of air within the duct;
manufacturer’s recommendations;
tendon;
Engineer before grouting operations begin. Discuss Grouting Operations Plan, required testing,
corrective procedures, and any other relevant issues at the meeting.
successful grout injection by injecting full-scale mockups that are constructed with all associated
PT system components using the mockup tendon profiles shown in the Plans and the proposed
Grouting Operations Plan. Utilize smooth duct and associated couplers and fittings meeting the
requirements of Section 960 for all mockups. Utilize smooth duct for the mockups which has an
inside diameter required for a given mockup tendon size. If the mockup is also being used to
perform PT system acceptance testing, use the duct type appropriate for the PT system location.
Place the mockup tendons specified in the Plans inside the ducts to simulate the in-place PT
tendons. Stress mockup tendons to the minimum values shown in the Plans by using jacks or
other methods approved by the Engineer. Perform pressure tests on the mockups in accordance
with 462-8.2.1 prior to grout injection. For the grout injection operations, utilize the same grout
material and types and sizes of grout injection equipment that will be used on the project
including but not limited to mixers, pumps, hoses, valves and pressure gauges. Inject grout into
the mockups using the proposed Grouting Operations Plan. Allow the grout to harden a
minimum of 24 hours after injection before inspecting the mockup. Inspect the mockup in
accordance with the requirements of 462-8.3.2.1 and then carefully cut open the duct at all high
points and other locations as directed by the Engineer to check for voids. Prepare a report
documenting the findings and submit it to the Engineer. If voids are found, determine the cause
and revise the proposed Grouting Operations Plan accordingly. If directed by the Engineer,
construct additional mockups and repeat the grout injection operation using the revised Grouting
Operations Plan as many times as are required until the results are acceptable.
462-7.4.1.2 Inlets and Outlets:
dirt and are air-tight.
462-7.4.1.3 Supplies:
Provide an adequate supply of water and compressed air for
clearing and testing ducts, as well as, mixing and pumping grout before grouting operations start.
462-7.4.1.4 Equipment:
water, a high-speed shear colloidal mixer, a storage hopper (e.g., holding reservoir) and pump
with all necessary connecting hoses, valves, and pressure gauge. 678FY 2023-24Return to Table of Contents
PT ducts can be filled and vented in not more than 30 minutes without interruption.
perform required functions.
and experienced operators available to meet the timeframe requirements of 462-8.3.2.1-6.
462-7.4.1.4.1 Mixer and Storage Hopper:
for blending and a holding tank. Blending tank must be equipped with a high speed shear
colloidal mixer capable of continuous mechanical mixing producing a homogeneous and stable
grout free of lumps and un-dispersed cement. Holding tank must be kept agitated and at least
10% full at all times during pumping operations to prevent air from being drawn into duct.
mixer by use of a flow meter or calibrated water reservoir with measuring accuracy equal to 1%
of total water volume.
462-7.4.1.4.2 Pumps:
circulating and agitating grout when actual grouting is not in progress,
pressure in duct.
145 psi.
foreign substances from contaminating grout and prevent loss of grout or water.
grouting rate.
300 psi at the pump and at the duct inlet.
pressure rating).
462-7.4.1.4.3 Vacuum Grouting: Provide vacuum grouting
equipment meeting these minimum requirements:
feet per minute and equipped with a flow-meter, graduated hopper, or other acceptable means
approved by the Engineer capable of measuring the amount of grout being injected.
mixers, or other mixing methods recommended and approved by the grout manufacturer, in
writing, for the specific project covered by this Section for voids less than 5.5 gallons in volume.
However, mix a minimum of one full bag of grout regardless of the size void to be grouted. 679FY 2023-24Return to Table of Contents
greater in volume.
462-7.4.1.4.4 Standby Equipment: Provide a standby colloidal
grout mixer and pump during grouting operations.
462-7.4.1.5 Grouting:
manufacturer’s recommendations.
accuracy of grouting equipment volume-measuring components each day of use before
performing any grouting operations. Testing in a warehouse or similar condition is acceptable.
Use either water or grout for testing using standard testing devices with volumes of 0.5 gallon
and 6.5 gallon and an accuracy of equal to or less than four ounces. Perform one test with each
device. Results must verify accuracy of grouting equipment void volume-measuring component
within 5% of test device volume and must verify accuracy of grouting equipment grout volume
component within 10% of test device volume for the 0.5 gallon test device. When testing the
6.5 gallon device, ensure an accuracy of 3% (test device volume) and 6% (grout volume).
approved Grouting Operations Plan.
462-7.4.1.5.1 Temperature:
temperature is 90°F for normal grouting procedures and 85°F when performing repair operations
with vacuum grouting.
temperature below maximum limit.
temperature is below 40°F or is expected to fall below 40°F within one day subsequent to
grouting.
forecasted within two days subsequent to grouting.
462-7.4.1.5.2 Mixing and Pumping:
complete.
462-7.4.1.5.3 Production Test:
by grout manufacturer during grouting operations. Target fluidity rate is established by
manufacturer’s representative based on ambient weather conditions.
discharged from anchorage cap outlet immediately after uncontaminated uniform consistency
discharge begins for each tendon greater than 50 feet in length. For tendons 50 feet or less,
perform a fluidity test on a per batch basis. For fluidity tests done on a per batch basis, perform 680FY 2023-24Return to Table of Contents
test after new batch has been transferred from mixing tank to holding tank and thoroughly mixed
with remains of the previous batch to produce a new homogenous mixture. During mixing
process, continually re-circulate grout from hose into holding tank. Ensure measured grout efflux
time is not less than efflux time measured at injection end of grout hose.
Density method contained in Section 938. Density at discharge outlet must not be less than grout
density at inlet. Continuously discharge grout until density requirements are met. Discard grout
used for testing fluidity.
without modifying water-cement ratio.
hourly to verify conformance to this Section.
perform a wick induced bleed test on this sample in accordance with Section 938 at beginning of
each day’s grouting operation. Begin grouting operations after sample is obtained.
found to not have been achieved in the wick induced bleed test at any time during required test
time period, complete grouting of any partially grouted tendons currently being grouted but do
not begin grouting any new or additional tendons. Immediately inform the Engineer when
grouting operations have ceased due to non-compliance of the wick induced bleed test.
testing shows grout meets specified requirements.
462-7.4.1.5.4 Grout Injection Operations:
any water that may be present within the duct. If water is present:
duct and retain for further testing as directed by the Engineer; blow the duct with oil free dry
compressed air meeting the ASTM D4285 with the end vent port open.
proceed with grouting injection operations.
Grouting Operations Plan.
of 10 psi to 50 psi measured at grout inlet.
within the system. Do not exceed a pumping pressure of 75 psi at the grout inlet for flat ducts.
of ducts and complete encasement of steel.
any residual water or entrapped air has been removed prior to closing outlet.
anchorage and anchorage cap outlets until all free water and air are discharged and consistency
of grout is equivalent to that of grout being pumped into inlet. Close anchorage outlet and 681FY 2023-24Return to Table of Contents
discharge a minimum of two gallons of grout from anchorage cap into a clean receptacle. Close
anchorage cap outlet.
pumping pressure while grouting the duct, seal inlet valve, and wait two minutes to determine if
any leaks exist after all outlets have been bled and sealed. If leaks are present repair all identified
leaks using methods pre-approved by the Engineer and repeat steps until no leaks are present.
Bleed pressure to 5 psi and wait a minimum of ten minutes for any entrapped air to flow to high
points if no leaks are present. Increase pumping pressure not to exceed actual realized pumping
pressure of duct and discharge grout at each high point outlet to eliminate any entrapped air or
water after specified ten minute period has expired. Complete process by locking a pressure of
30 psi into tendon duct.
close inlet and pump grout at next outlet which has just been closed or is ready to be closed as
long as a one-way flow is maintained. Do not pump grout into a succeeding outlet from which
grout has not yet flowed. Fit outlet/inlet to be used for pumping with a positive shut-off valve as
shown in the approved system drawings and pressure gauge if this procedure is used.
cannot be achieved by the steps stated and in compliance with the approved Grouting Operations
Plan. After waiting 48 hours, vacuum grout duct in accordance with this Section.
462-7.4.1.5.5 Vertical Grouting:
the total anticipated grout volume used on a particular tendon, at upper end of tendon to store
bleed water and grout; maintain grout level above level of prestressing plate and anchorage for
all vertical tendons. Design and size this device to maintain level grout at an elevation that
ensures potential bleed will not drop below the highest point of upper anchorage device. Design
reservoir to allow all bleed water, if any, to rise into reservoir.
this Section. Immediately add grout if level of grout begins to drop, potentially allowing bleed
water into the upper anchorage device and tendon duct. Remove reservoir after grout has
hardened. Visually inspect for voids using a borescope or probe in presence of the Engineer. Fill
all voids found in duct using volumetric measuring vacuum grouting process in accordance with
this Section.
water have been purged prior to using a higher elevation outlet for pumping. Pump grout at
increasingly higher outlets which have been or are ready to be closed, as long as one-way grout
flow is maintained for vertical tendons within allowable grouting pressures.
462-7.4.1.5.6 Grouting Operations Report:
within five days of each grouting operation for review by the Engineer.
compared to actual quantity of grout used to fill duct. Notify the Engineer immediately of
shortages or overages.
minimum, but not necessarily be limited to:
682FY 2023-24Return to Table of Contents
grouting;
within the duct;
inlet;
operations and inspection.
462-7.4.2 Flexible Filler Operations:
tendons with vertical or predominately vertical profiles as shown on Standard Plans, Index 462-
001.
profiles shown on Standard Plans, Index 462-001.
462-7.4.2.1 Microcrystalline Wax: Conduct all wax injection operations,
repairs, and inspections in the presence of the Filler Injection Foreman, Filler Injection QC
Inspector and the Engineer.
462-7.4.2.1.1 Wax Injection Operations Plan:
with the PT system vendor and the PT wax manufacturer.
Engineer for approval at least six weeks in advance of any scheduled injection operation.
by the Engineer is required before any injection of permanent structure can begin.
address and provide the following:
and crew supervisor in conformance with this Specification;
in wax injection including all required certifications;
in relation to demand and working conditions, as well as, standby equipment and spare parts;
injection;
due to wax injection temperature; 683FY 2023-24Return to Table of Contents
moisture in the duct, blowing oil-free dry compressed air, and measuring humidity of air within
the duct;
continuously maintaining less than 40% humidity of air within the duct;
ducts and anchorage assembly;
locking pressure;
tests and repair procedures;
accordance with the manufacturer’s recommendations;
and/or slope of tendon;
accounting for grade and/or slope of tendon;
and outlets, including minimum wax discharge quantities;
injection, filling voids created by inspection procedures, and sealing duct after PT system
inspection;
protect concrete surfaces from wax spills, leaks, etc. during wax injection, post injection
inspection and post injection repair;
crew, and the Engineer before wax injection operations begin. Discuss Wax Injection Operations
Plan, required testing, corrective procedures, and any other relevant issues at the meeting.
Engineer’s satisfaction successful wax injection by injecting full-scale mockups that are
constructed with all associated PT system components using the mockup tendon profiles shown
in the Plans and the proposed Wax Injection Operations Plan. Utilize smooth duct and associated
couplers and fittings meeting the requirements of Section 960 for all mockups. Utilize smooth
duct for the mockups which has an inside diameter required for a given mockup tendon size. If
the mockup is also being used to perform PT system acceptance testing, use the duct type
appropriate for the PT system location. Place the mockup tendons specified in the Plans inside
the ducts to simulate the in-place PT tendons. Stress mockup tendons to the minimum values
shown in the Plans by using jacks or other methods approved by the Engineer. Perform pressure 684FY 2023-24Return to Table of Contents
tests on the mockups in accordance with 462-8.2.1 prior to wax injection. If vacuum assisted wax
injection is required to be used, perform vacuum tests on the mockups in accordance with 462-
8.2.1 prior to wax injection. For the wax injection operations, utilize the same wax material and
types and sizes of wax injection equipment that will be used on the project including but not
limited to heaters, pumps, hoses, valves and pressure gauges. Inject wax into the mockups using
the proposed Wax Injection Operations Plan. Allow the wax to cool a minimum of 24 hours after
injection before inspecting the mockup. Inspect the mockup in accordance with the requirements
of 462-8.3.2.2.1 and then carefully cut open the duct at all high points and other locations as
directed by the Engineer to check for voids. Prepare a report documenting the findings and
submit it to the Engineer. If voids are found, determine the cause and revise the proposed Wax
Injection Operations Plan accordingly. If directed by the Engineer, construct additional mockups
and repeat the wax injection operation using the revised Wax Injection Operations Plan as many
times as are required until the results are acceptable.
462-7.4.2.1.2 Inlets and Outlets:
free of dirt and are air-tight.
properly.
compatible with heated wax injection for discharging excess wax. Kinks and clogs in the vent
hoses are not permitted during pumping operations.
462-7.4.2.1.3 Supplies:
clearing and testing ducts before wax injection operations start.
outlet locations.
and buckets of cold water.
462-7.4.2.1.4 Equipment:
wax, wax melting unit(s), wax mixer for maintaining uniform temperature, a storage holding
reservoir, pump, and volumetric flow rate and displacement volumetric meters with all necessary
connecting hoses, valves, pressure gauges, timer, and temperature gauge.
ensure PT ducts can be filled and vented in not more than time specified by the wax
manufacturer and this Specification.
output to perform required functions.
have the required equipment and personnel as stated in the approved Wax Injection Operations
plan available to meet the timeframe requirements of 462-8.3.2.2.1-6.
equipmentable to measure and have sufficient capacity to ensure a minimum of 90% vacuum in
the PT system prior to filler injection. Provide a continuously running vacuum pump or vacuum
reservoir capable of maintaining vacuum during the wax injection process. 685FY 2023-24Return to Table of Contents
maintained in accordance with equipment manufacturer’s instructions and is calibrated and in
good working condition.
blockages.
project site during injection operations.
462-7.4.2.1.4.1 Storage Reservoir and Mixing:
heating system capable of producing a melted wax free of lumps within the temperature limits
specified by the manufacturer.
full at all times during pumping operations to prevent clogs and air from being drawn into duct
injection a quantity of heated wax required to inject the PT system. The quantity of heated wax
required to inject the PT system is calculated as 25% more than the total quantity to fill the duct
and anchorages, to discharge wax at outlets, to fill pumping equipment and hoses, and to
maintain the minimum amount of wax in the holding tanks during pumping operations.
of heated wax, either by mixing or other methods.
462-7.4.2.1.4.2 Pumps:
following:
system for heating pump components when wax injection is not in progress;
ducts;
without loss of pressure in duct.
of at least 75 psi;
velocity range of 40-70 ft/min.
air, or other foreign substances from contaminating wax and prevent loss of wax.
wax injection rate.
more than 300 psi at pump and duct inlets.
output (diameter, pressure rating and temperature). 686FY 2023-24Return to Table of Contents
462-7.4.2.1.4.3 Vacuum Wax Injection:
voids in incomplete wax filling operations, provide vacuum wax injection equipment meeting
these minimum requirements:
volume;
of ten cubic feet of air per minute and equipped with a flow-meter, graduated reservoir, or other
acceptable means approved by the Engineer capable of measuring the amount of wax being
injected.
heating methods recommended and approved by the wax manufacturer, in writing, for the
specific project covered by this Section.
wax injection equipment meeting these minimum requirements:
of ten cubic feet of air per minute (free air) with the capability of removing 90% of standard
atmospheric pressure within the PT system and equipped with a vacuum pressure gauge;
connections required for attachment to the PT system.
462-7.4.2.1.4.4 Heaters: Use a heater and temperature
monitoring system capable of liquefying the entire mass of PT wax to be used for a given
injection operation within the temperature limits specified by the PT wax manufacturer. The
heater systems must apply a uniform heat to the PT wax and avoid locally high temperatures that
may damage the PT wax or container. Use a heater and temperature monitoring system which
complies with the recommendations of the PT wax manufacturer.
462-7.4.2.1.5 Wax Injection:
with the wax manufacturer’s published product data sheet and within the limits of this Section.
procedures set forth in approved Wax Injection Operations Plan.
462-7.4.2.1.5.1 Temperature:
injection between 212°F and 240°F.
ambient temperature is below minimum temperatures specified by the wax manufacturer.
462-7.4.2.1.5.2 Production Test:
established limits during operations.
shows wax meets specified requirements.
462-7.4.2.1.5.3 Wax Injection Operations:
drainage of any water that may be present within the duct. If water is present: 687FY 2023-24Return to Table of Contents
from the duct and retain for further testing as directed by the Engineer;
Engineer to proceed with blowing of compressed air.
drains and ports except the inlet and outlet ports at the anchorage caps. Blow oil-free dry
compressed air meeting ASTM D4285 through one of the anchorage cap ports until the humidity
measured at the inlet and outlet ends are less than 40% and continuing blowing for an additional
30 minutes. Stop blowing, wait a minimum of 15 minutes, and take humidity measurements at
the inlet and outlet ends of blowing. Further blowing is not required if both humidity readings
are less than 40%. If the humidity readings are 40% or greater, then repeat the process of
blowing and waiting for 15 minutes until the humidity measurements at the inlet and outlet end
of blowing are less than 40%. Take humidity measurements of air within the duct at the inlet end
and outlet end of blowing using separate humidity meters. Use humidity meters approved by the
Engineer.
tendon are free of water, moisture and debris at the anchorages and low points of the tendon
profile.
etc.
Injection Operations Plan.
filling of ducts and anchorage assembly with wax.
prior to and throughout injection operations. Establish a non-turbulent, laminar system
circulation by continuously recirculating the wax between the pump and the storage container
prior to injecting the wax into the duct. Pump components must be at wax injection temperature
prior to wax injection into duct. Do not allow wax to free fall during recirculation or injection
operations. Maintain a positive head of liquid wax above all withdrawal and recirculation ports
and do not allow air intrusion into the pumping system. Do not pour liquid wax into an open
pump or hopper.
accordance with the approved Wax Injection Operations Plan at a flow rate through duct at a
velocity between 40 and 70 feet per minute and pressure limited to 75 psi at the duct inlet and
145 psi at the pump.
is used, provide a minimum of 90% vacuum in the duct prior to injection. Connect both the
anchorage outlet and the cap outlet to the vacuum system. After the vacuum is established, lock
off the air supply to the duct and monitor the vacuum for 1 minute. If the loss of vacuum after
1 minute exceeds 10%, repair leaks as directed by the Engineer and retest the duct. If the results
are acceptable, reestablish and maintain a minimum 90% vacuum using the outlets at the higher
end anchorage shown on Standard Plans, Index 462-001 while injecting wax using the inlet at the
lower end anchorage shown on the same Standard. Close all outlets, inlets, and ports other than
at injection and vacuum locations during injection procedure. Pump wax into inlet and
continuously vacuum air at the outlet. After the duct is fully injected with wax and the wax 688FY 2023-24Return to Table of Contents
reaches the vacuum end, close the outlet valve, turn off the vacuum pump and continue the
injection pump. Bleed all outlets starting at the anchorage cap at the injection end and proceed to
bleed every valve thereafter from injection end to vacuum end, ending with the anchorage cap at
the vacuum end. When bleeding each valve, collect a minimum of two gallons of continuously
flowing wax free from air before closing the valve. After all outlet valves are closed, close inlet
valve with locking pressure between 30 psi and 45 psi. Do not reuse discharged wax.
is not used, inject wax under pressure at locations shown on Standard Plans, Index 462-001.
Allow wax to flow from duct and anchorage discharge points until a steady flow of wax free
from air is continuously discharged. Collect a minimum of two gallons of continuously flowing
wax free from air at discharge point before closing outlet valve. Do not reuse discharged wax.
After all outlets are closed, close the inlet valve at locking pressure between 30 and 45 psi.
system.
in accordance with the approved PT system drawings. Remove all excess wax from exposed
surfaces.
462-7.4.2.1.5.4 Wax Injection Operations Report:
wax injection Contractor within five days of each wax injection operation for review by the
Engineer.
compared to actual quantity of wax used to fill duct. Notify the Engineer immediately of
shortages or overages.
include at a minimum, but not necessarily be limited to:
to wax injection;
applicable;
compressed air through duct; h. Verification that water or moisture is not
present within the duct prior to wax injection;
at the inlet;
system;
of wax injection;
completely fill the duct;
689FY 2023-24Return to Table of Contents
points;
inlet opening and closing;
and any deviations from the Wax Injection Operations Plan;
injection operations and inspection;
vacuum in duct prior to injection;
the job site for review by the Engineer. Submit all daily reports to the Engineer on a weekly basis
or as directed by the Engineer.
462-7.4.2.1.6 Manufacturer’s Installation Technician:
Provide for a PT system vendor installation technician, certified by the vendor as having
sufficient knowledge and expertise to oversee the wax injection personnel. The vendor’s
technician shall be under the direct employ of the vendor and shall be present for all wax
injection activities for a minimum of the first two days of wax injection for each of the
Contractor’s wax injection crews. The vendor’s technician shall submit written certification to
the Engineer that the Contractor’s installation process is in conformance with the approved Wax
Injection Operations Plan.
462-7.5Repair: Perform no remedial or repair work without the Engineer’s approval in
writing.
462-7.5.1 Lifting and Access Holes:
meeting requirements of Section 930 or Type Q epoxy grout meeting requirements of
Section 926. Immediately before casting concrete (i.e., within 24 hours), mechanically clean and
roughen the mating concrete surfaces to remove any laitance and expose small aggregate. Use
grit blasting or water blasting using a minimum 10,000 psi nozzle pressure. Flush surface with
water and blow dry. Form, mix, place, and cure material in strict compliance with manufacturer’s
recommendations.
an area extending six inches outside perimeter of repair with a high molecular weight
methacrylate (HMWM) meeting the requirements of Section 413. Prepare surface to be coated
and apply HMWM in accordance with Section 413. Friction (skid) tests per Section 413 are not
required.
462-7.5.2 Inlets, Outlets, Drains and Ports:
required in the Contract Documents.
Documents using a Type Q epoxy compound, Type E epoxy compound, or Type F-1 epoxy
compound meeting requirements of Section 926.
manufacturer’s recommendations. 690FY 2023-24Return to Table of Contents
462-7.5.3 Duct:
duct repair:
procedure has been completed.
Install heat-shrink wrap in accordance with manufacturer’s
instructions.
procedure has been completed using elastomer sleeves and stainless steel band clamps.
462-8Acceptance and Testing
462-8.1Contractor Material Testing:
and double-tee bridges, but are required on all other PT applications.
Wobble and Friction Test in price of PT system.
462-8.1.1 Tendon Modulus of Elasticity Test:
Perform a tendon modulus of elasticity test in accordance with the
following procedure if required in the Contract Documents or ordered by the Engineer.
tendons to determine modulus of elasticity for purpose of accurately determining tendon
elongations while stressing.
tendon duct at least two inches clear of tendon all around for purpose of this test.
assembly with a load cell at dead end.
detention from 80% of GUTS to zero in ten decrements.
each increment and decrement.
measured to an accuracy of plus or minus 1/32 inches.
E = PL/Adl
where,
P = force in tendon
L = distance between pulling wedges and dead end wedges
or exact length in the center 30 feet of tendon
A = cross sectional area of tendon
dl = tendon elongation within length, L, for load, P
approval if bench test varies from modulus of elasticity used for shop or working drawings by
more than 1%. 691FY 2023-24Return to Table of Contents
required when observed tendon elongations in erected structure fall outside acceptable tolerances
or to otherwise settle disputes to the satisfaction of the Engineer.
not to exceed two per source, will be required if source of prestressing steel changes during
project.
submitted to the Engineer for approval in writing.
462-8.1.2 In-Place Wobble and Friction Test:
the same function for tendons in excess of 100 feet long.
draped external tendons, or continuous profiled tendons passing through one or more spans.
tested.
slabs or precast voided slabs.
with a load cell or a second certified jack at dead end.
force (if a load cell is used).
and dead end (i.e., back of load cell) and any friction within anchorages, wedge plates, and jack
as a result of slight deviations of strands or wires through these assemblies.
intermediate wedge seating and slip of the jack’s wedges for long tendons requiring multiple jack
pulls with intermediate temporary anchoring.
anticipated elongations, investigate reason and make detailed calculations confirming final
tendon forces are in agreement with requirements of the approved Contract Documents.
more than plus or minus 10% in reconciling theoretical and actual elongations.
compensate for elongation discrepancies if necessary.
the project.
irreconcilable differences between forces and elongations or other difficulties during the course
of routine stressing operations.
approval in writing.
462-8.1.3 Required Reports: 692FY 2023-24Return to Table of Contents
Engineer at least 30 days before installing tendon.
Engineer within two weeks after successful installation of tested tendon.
462-8.1.4 Test Results Application:
drawings using results of “Tendon Modulus of Elasticity Test” and “In-Place Wobble and
Friction Test,” as appropriate, and correct calculations as necessary.
in writing.
462-8.2Contractor Field Tests:
462-8.2.1 Prior to Concrete Placement:
462-8.2.1.1 All Tendons Except as Noted:
those used for internal longitudinal tendons in precast box-girder segments in the casting cell
(e.g., cantilever tendons).
used in a single structural component (e.g. segment, beam, etc.).
placement by sealing them at their anchorages or construction joint termini and then applying
compressed air in accordance with this Section to determine if assembly connections are pressure
tight.
off outside air source. Record pressure loss for one minute. If pressure loss exceeds 0.75 psi, or
10%, find and repair leaks in duct assembly using repair methods approved by the Engineer and
retest.
462-8.2.1.2 Tendons for Which Vacuum Assisted Filler Injection Will
Be Used:
those used for internal longitudinal tendons in box-girder segments.
assemblies used in a single structural component (e.g. segment, beam, etc.).
placement by sealing them at their anchorages or construction joint termini and then applying a
vacuum in accordance with this Section to determine if assembly connections are pressure tight.
outside air source. Record vacuum loss for five minutes. If vacuum loss exceeds 10%, find and
repair leaks in duct assembly using repair methods approved by the Engineer and retest.
462-8.2.2 Post Concrete Placement:
caps, inlets and outlets and test the duct with compressed air in accordance with this Section to
determine if duct connections require repair.
outside air source. Record pressure loss for one minute. A pressure loss less than 25 psi, or 50%,
is acceptable for ducts with a length of equal to or less than 150 feet and a pressure loss less than
15 psi is acceptable for ducts longer than 150 feet. 693FY 2023-24Return to Table of Contents
methods approved by the Engineer and retest.
462-8.3Contractor Inspections:
462-8.3.1 Post Concrete Placement/Prior to Filler Injection Operations:
described, prove PT ducts are free and clear of any obstructions or damage and are able to accept
intended PT tendons by passing a torpedo through ducts.
1/4 inches smaller all around than clear, nominal inside dimensions of duct. Make no deductions
to torpedo section dimensions for tolerances allowed in manufacture or fixing of ducts. For
straight ducts, use a torpedo at least two feet long. For curved ducts, determine length so that
when both ends touch outermost wall of duct, torpedo is 1/4 inches clear of innermost wall. The
Engineer will reject member if torpedo will not travel completely through duct and workable
repair cannot be made to clear duct. Torpedo must pass through duct easily when pushed through
by hand, without resorting to excessive effort or mechanical assistance.
segmental box-girders may be preplaced prior to concrete casting. Prove PT ducts are free and
clear of any obstructions or damage by moving the group of strands back and forth in duct for a
minimum distance of one foot in each direction. Move strands easily, by hand, without resorting
to excessive effort or mechanical assistance.
462-8.3.2 Post Filler Injection Operations:
462-8.3.2.1 Post Grouting Operations:
within 96 hours after grouting of that tendon.
has cured for a minimum of 24 hours.
and outlets and drains located at anchorages and points along the tendon.
inlets or outlets located at anchorages for inspection. Drill through hardened grout to penetrate
full-length of grout port access piping to top of trumpet or duct. If drilling of inlets or outlets is
not feasible with conventional equipment, propose an alternative method of tendon inspection for
approval by the Engineer in writing. Use drilling equipment that will automatically shut-off
when steel is encountered. Do not drill into anchorage cap unless anchorage caps are determined
to have voids by sounding.
presence of the Engineer.
within 4 days from grouting.
produced by drilling for inspection purposes as specified within four hours of completion of
inspections if no additional voids are detected in tendon ducts or anchorages.
face of concrete and seal the surface as specified within 4 hours of inlet/outlet removal. Use an
injection tube to extend to bottom of holes for backfilling with epoxy grout. 694FY 2023-24Return to Table of Contents
grouting operations were prematurely terminated prior to completely filling duct. Probing is not
allowed. Determine location and extent of all voided areas. Fill voids using volumetric
measuring vacuum grouting equipment in accordance with this Section.
462-8.3.2.2 Post Flexible Filler Injection Operations:
462-8.3.2.2.1 Microcrystalline Wax:
tendon within 96 hours after injecting that tendon with wax.
until wax has cooled for a minimum of 24 hours.
inlets/outlets located at anchorages and high points along the tendon.
along tendon as well as all ports located at anchorages. Repair wax leaks according to the Wax
Injection Operations Plan.
perform the following inspection operations for each tendon:
ensure the system is free from voids,
inspect to ensure the system is free from voids,
1/2 inch or if the strands are exposed and uncoated, address the void using this section and
methods described in the approved Wax Injection Operations Plan;
replace all inspection port caps and seal in accordance with the approved Wax Injection
Operations Plan.
Wax Injection Operations Plan within 4 days from filler injection.
voids that are produced for inspection purposes as described in the approved Wax Injection
Operations Plan within four hours of completion of inspections if no additional voids are
detected in tendon ducts or anchorages.
wax injection operation was prematurely terminated prior to completely filling duct. Determine
location and extent of all voided areas. Fill voids using gravity feed or injection, do not use
vacuum repair injection unless proven by a mockup and approved by the Engineer.
462-9Method of Measurement
pounds, of permanent PT steel tendons installed in the completed structure and accepted.
anchorage (measured from front face of bearing plate) with no allowance made for waste or
extension past bearing faces.
Item 462-2, Post Tensioning Tendons.
695FY 2023-24Return to Table of Contents
Table 462-2 PT
Strand and Bar Weight per Unit Length
Prestressing System Weight per Unit Length, Lb/Ft
1/2 inch diameter 7-wire strand 0.52
0.6 inch diameter 7-wire strand 0.74
5/8 inch high strength deformed bar 0.98
3/4 inch high strength deformed bar 1.49
1 inch high strength deformed bar 3.01
1-1/4 inch high strength deformed bar 4.39
1-3/8 inch high strength deformed bar 5.56
1-3/4 inch high strength deformed bar 9.10
2-1/2 inch high strength deformed bar 18.20
3 inch high strength deformed bar 24.09
Note: Weight per unit length of high strength deformed bars is based on values given in ASTM A722.
462-10Basis of Payment
462-10.1General:
completed and accepted.
filler injection of all temporary and permanent, internal and external ducts. Payment also
includes anchorage assemblies and associated supplemental reinforcing steel required by
supplier, PT system hardware not embedded in concrete, ducts, grout and grouting operations,
flexible filler and filler injection operations, all testing, including construction of and filler
injection into mockups, Tendon Modulus of Elasticity Test and In-Place Wobble and Friction
Test, protection of PT anchorages, inlets, outlets, drains, and all labor, materials, tools,
equipment, and incidentals necessary for completing the work in accordance with the Contract
Documents. This payment also includes lubricants in tendon ducts for friction control and
flushing lubricants or contaminants from ducts.
embedded within precast components or cast-in-place concrete will be deemed to be included in
cost of precast component or cast-in-place concrete in which it is embedded.
Contract Documents or actual quantities used and accepted, whichever is less, if the Contractor
constructs structure with an accepted alternate not detailed in the Contract Documents.
individual precast concrete segments or units will be measured and paid for under this item and
will not be considered incidental to cost of those precast concrete segments or units.
injection, inspection, repair, protection, and written approval by the Engineer.
may occur prior to erection of segments into final position when ducts have been injected and
anchorage protection system applied and the segmental unit otherwise approved in writing for
placement by the Engineer.
462-10.2Pay Items:
696FY 2023-24Return to Table of Contents
Payment will be made under:
Item No. 462- 2- Post-Tensioning Tendons - per pound. 697FY 2023-24Return to Table of Contents TIMBER STRUCTURES
470-1Description
Furnish and erect treated timber into various structures.
470-2Materials
Meet the following requirements: Timber ................................ ................................ .Section 952 Preservative ................................ ......................... Section 955 Use timber as specified in the Plans.
470-3Timber Handling
Handle treated timber with rope slings, without sudden dropping, breaking of outer fibers, bruising, or penetration of the surface with tools. Do not use cant dogs, hooks, or pike poles.
470-4Cutting and Framing
Before treatment, cut and frame all timbers which are shown by the Plans to be furnished in special lengths or framed to detailed dimensions. Limit the cutting of treated timber to minor fitting which might be necessary and that is authorized by the Engineer. For all places where the surface is broken, by cutting or otherwise, thoroughly coat with the preservatives and by the methods specified in AWPA M4.
470-5Bolt Holes
The Contractor may drill holes in the field. For timbers originally treated with pentachlorophenol, creosote, creosote solutions, or waterborne preservatives, field treat all cuts, abrasions, bolt holes, and recesses that occur after treatment with two liberal applications of a compatible preservative in accordance with the requirements specified in AWPA Standard M4, Standard for the Care of Pressure -Treated Wood Products.
470-6Pile Caps
Ensure that pile caps have full even bearing on all piles in the bent, and secure them to each pile by a 3/4 inch diameter drift bolt extending at least 9 inches into the pile. Where so shown in the Plans, cover the tops and ends of pile caps with 10 ounce, minimum weight, copper sheet meeting the requirements of ASTM B370.
470-7Floors
Attach the planks to each joist or nai ling strip with at least two 8 inch nails for 3 inch planks, or two 10 inch nails for 4 inch planks. Use nails that are at least 1/4 inch in diameter. For treated timber floors where a bituminous wearing surface is to be applied, lay the planks with the best side up and with adjacent edges in contact. Grade the planks as to thickness before laying, and lay the planks so that no two adjacent planks vary in thickness more than 1/8 inch. Cut the floor to straight lines along the side of the roadway and walkway . 698 FY 2023-24 Return to Table of Contents
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