METAL MATERIALS AND FABRICATION DETAILS FOR METAL ITEMS
960-1 Description.
This Section covers all post -tensioning (PT) systems and components remaining in a completed structure, including temporary erection PT left in -place and permanent PT for design capacity. The submittal for approval of PT systems must use materials and components meeting the requirements of this Section and Section 462. Submit PT system shop drawings to the Engineer f or review and acceptance in accordance with Section 5. The PT system shop drawings must include component drawings, system drawings, and test reports. The acceptance of a PT system for use on the project is based on the exact major components, as defined i n 960-2, that were used in system testing and that are shown on the approved PT system shop drawings .
960-1.1 Material References: Meet the requirements of this Section and the following:
Epoxy Compounds* ................................ ............Section 926 Bar (post-tensioning) ................................ ..........Section 933 Duct Filler for Post Tensioned Structures* .........Section 938 Reinforcing Steel (mild) ................................ .....Section 415 Parallel Wire (post -tensioning) ........................... Section 933 Strand (post -tensioning) ................................ ......Section 933 *Use products listed on the Department’s Approved Product List (APL).
960-2 Component Standards.
All PT system components must be materials compatible with the filler material and installation process used to encapsulate the tendons. The component materials must not chemically degrade during the service life of the structure. The service life of the structure is 75 - years unless specified otherwise in the Contract Documents . The following are major components and must be marked with the manufacturer’s name, trademark, model number, and size corresponding to catalog designation: an chorages, bearing plates, trumpets, caps, duct couplers, connections, “O” -rings, heat shrink tubing, duct, and local zone reinforcement. Any of these items that cannot be marked must be contained in packaging or appropriately tagged with the necessary info rmation. The following are examples of common off -the-shelf accessories and need not be stamped: bolts, washers, inlets, outlets, drains, ports, valves, plugs, nipples, hose adapters, and grease. Substitution, modification, or deletion of any major component of the PT system, excluding local zone reinforcement, after system testing and approval by the Engineer is not permitted. Provide only PT systems utilizing tendons completely encapsulated in grout or flexible filler filled anchorages and ducts. Do no t use systems transferring prestress force by bonding prestress steel strand directly to concrete. Embedded anchorages for bars are permitted. Strand or strand-tendon couplers are not permitted.
960-2.1 Anchorage Assembly:
1.Construct anchorages from f errous metal. FY 2023-24 Return to Table of Contents
2.Anchorages shall develop at least 95% of PT steel actual ultimate strength when tested in an unbonded state, without exceeding anticipated anchor set.
3.Average concrete bearing stress shall be in compliance with AASHTO LRFD Bridge Design Specifications and AASHTO LRFD Bridge Construction Specifications.
4.Test anchorages with typical local zone reinforcement shown in system drawings.
5.Test anchorages in accordance with AASHTO LRFD Bridge Construction Specifications, or the European Assessment Document Post -Tensioning Kits for Prestressing of Structures (EAD 160004 -00-0301, September 2016 Edition) with the exception that the design concrete strength used in the testing will be 6,500 psi. For anchorages that will be used for tendons with flexible filler, test anchorages in accordance with EAD 160004 -00-0301 Section C.3 Resistance to Fatigue .
6.Anchorages with grout or flexible filler outlets shall be suitable for inspection from either top or front of anch orage. Anchorages may be fabricated to facilitate both inspection locations or may be two separate anchorages of the same type, each providing singular inspection entry locations.
7.Geometry of grout and flexible filler outlets must facilitate access f or borescope inspection directly behind wedge plate using a straight 3/8 inch diameter drill bit.
8.Ferrous metal components of an anchorage that are to be embedded in concrete shall be galvanized in accordance with Section 962. Other anchorage assembly components, including wedges, wedge plates, and local zone reinforcement need not be galvanized.
9.All anchorages shall have a permanent vented anchorage cap bolted to the anchorage.
960-2.1 1 Trumpets:
1.Trumpets associated with anchorages shall be constructed from ferrous metal galvanized per ASTM A123, high -density polyethylene or polypropylene.
2.For connections between the trumpet and corrugated duct, the trumpet thickness at transition location shall be the thickness of the corrugated du ct or greater .
3.For connections between the trumpet and smooth plastic duct, the trumpet thickness at the transition location shall be the minimum thickness provided in Table
960-1 or greater.
Table 960-1 Trumpet Thickness at the Transition Location System Size Minimum Trumpet Thickness at the Transition Location 4-Strand 0.08 inch 7-Strand 0.08 inch 12-Strand 0.10 inch 19-Strand 0.12 inch 27-Strand 0.14 inch 31-Strand 0.16 inch
960-2.1 2 Wedges and Wedge Plates:
1.Wedge plate shall be ferrous metal.
2.Wedge plates must have centering lugs or shoulders to facilitate alignment with bearing plate. FY 2023-24 Return to Table of Contents
3.For longitudinal tendons greater than four strands, design system with separate wedge plate and anchorage plate.
960-2.2 Filler Containment Assembly:
960-2.2 1 Duct and Pipe:
1.Use plastic duct, steel pipe, or a combination of plastic duct and steel pipe in accordance with this Section.
2.Ducts shall be manufactured by a seamless fabrication method. Fabricate all duct splices to prevent kinks during all phases of construction.
3.Do not alter the natural duct color that results from UV protected polymer.
4.Corrugated ferrous m etal ducts are prohibited.
960-2.2 1.1 Corrugated Plastic Duct:
1.PT systems with duct injected with grout shall use corrugated polypropylene material except where steel pipe is required.
2.Furnish ducts with minimum wall thickness as follows: Table 960-2 Corrugated Plastic Duct Minimum Wall Thicknesses Duct Shape Duct Diameter* Duct Minimum Wall Thickness Flat Any Size 0.08 inch Round 0.9 inch 0.08 inch Round 2.375 inch 0.08 inch Round 3.0 inch 0.10 inch Round 3.35 inch 0.10 inch Round 4.0 inch 0.12 inch Round 4.5 inch 0.14 inch Round 5.125 inch 0.16 inch Round 5.71 inch 0.16 inch *The diameter is the nominal inner diameter of the duct.
960-2.2 1.2 Smooth Plastic Duct:
1.PT systems with duct injected with flexible filler shall use smooth high -density polyethylene duct.
2.Duct shall have a maximum dimension ratio (DR) of 17 as established by either ASTM D3035 or ASTM F714, as appropriate for manufacturing process used.
3.Duct shall have a minimum p ressure rating of 125 psi.
960-2.2 1.3 Steel Pipe: Steel pipes shall be ASTM A53, Type E, Grade B,
Schedule 40 and galvanized in accordance with Section 962.
960-2.2 1.4 Minimum Internal Diameter:
1.For prestressing bars, duct shall have a minimum internal diameter of 1/2 inches larger than bar outside diameter, measured across deformations.
2.For prestressing bars with couplers, duct shall have a minimum internal diameter of 1/2 inches larger than largest dimension of the largest enclo sed element. FY 2023-24 Return to Table of Contents
3.For multi -strand tendons, ducts must have a minimum cross - sectional area 2 -1/2 times PT steel cross -sectional area.
960-2.2 1.5 Connections, Fittings, and Tolerance:
1.Devices or methods for all duct connections (e.g., splices, joints, couplers, connection to anchorages), shall produce smooth interior alignment with no lips or kinks.
2.Use of tape, caulking, epoxy, or other sealants is not permitted to join or repair duct, to make connections, or for any other purpose.
3.Use a reducer when adjacent sections of duct are directly connected to each other and the outside diameters vary more than plus or minus 0.08 inch.
4.Provide all connections that are external to the concrete with a minimum pressure rating of 150 psi.
5.Use heat shrink sleeves and circular sleeve couplers made from high-density polyethylene or polypropylene material, or duct couplers made from high -density polyethylene or polypropylene material with O -rings or seals to make connections between sections of corrugated plastic duct or between corrugated plastic duct and trumpets.
6.Use heat shrink sleeves and circular sleeve couplers made from high-density polyethylene or polypropylene material to make connections between corrugated plastic duc t and steel pipe.
7.Use heat shrink sleeves with or without circular sleeve couplers made from high -density polyethylene or polypropylene material to make connections between corrugated plastic duct and anchorages with integral trumpets.
8.Use heat welding techniques, electrofusion duct couplers, or elastomer sleeves and stainless steel band clamps to make connections between sections of smooth plastic duct.
9.Use elastomer sleeves and stainless steel band clamps to make connections between smooth plastic duct and steel pipe.
10.Use welding or elastomer sleeves and stainless steel band clamps to make connections between sections of steel pipe that are external to the concrete.
11.Use welding, elastomer sleeves and stainless steel band clamps or heat shrink sleeves and circular sleeve couplers made from high -density polyethylene or polypropylene material to make connections between steel pipe and trumpets that are internal to the concrete.
12.Use elastomer sleeves with a minimum wall thickness of 3/8 inches and reinforced with a minimum of four ply polyester reinforcement. Use a 3/8 inch wide stainless steel power seated band and clamps on each end of the elastomer sleeves to secure the sleeves to plastic ducts or steel pi pes. Seat the bands with a 120 pound force prior to clamping them in place.
960-2.2 1.6 Segmental Duct Couplers:
1.Include segmental duct couplers for permanent internal PT systems at joints between match cast precast segments.
2.Use “O” - rings or compression seals between adjoining sections of segmental duct couplers.
3.Plastic duct couplers shall be high -density polyethylene or polypropylene material.
4.Metallic components shall be stainless steel per 960 -2.4.3. FY 2023-24 Return to Table of Contents
5.Segmental duc t couplers shall mount perpendicular to the bulkhead at segment joints and provide for duct alignment.
6.Segmental duct couplers shall be able to receive duct at an angle of 6 degree deviation from perpendicular.
7.Segmental duct couplers must be able to accommodate angular deviation of duct without tendon strands touching duct or coupler on either side of segment joint.
8.Ducts for prestressing, used exclusively for temporary erection PT that is to be removed from structure, are not required to be coupled across segment joints.
960-2.2 1.7 “O” -Rings:
1.“O”-rings with cross section diameters less than or equal to 0.25 inches and compression seals with thicknesses less than or equal to 0.25 inches for use with segmental duct couplers, a nchorage caps and other similar components shall conform to the requirements of Table 960-3. Table 960-3 "O"-Ring and Compression Seal Material Properties (cross section diameter or thickness ≤ 0.25 in) Mechanical Properties Shore hardness, ASTM D2240 50-75 Ultimate elongation %, ASTM D412 250% min. Tensile strength, ASTM D412 1400 psi min. Accelerated Testing Thermal Deterioration 70 hours @ 257° F, ASTM D573 Change in tensile strength ± 30% Change of elongation -50% Change of hardness ± 15 points Compression Set Method B 22 hours @ 257° F, ASTM D395 50% Volume change due to absorption of H 2O, Method D, for 70 hours @ 212°F, ASTM D 471 + 10% Environmental Resistance Ozone Resistance Exposure Method B, ASTM D1171 or Method B - Procedure B4, ASTM D1149 Pass Low Temp. Non -brittle after 3 Min. @ -40°F, ASTM D2137 Pass
2.“O”-rings with cross section diameters greater than 0.25 inches and compression seals with thicknesses greater than 0.25 inches for use with segmental duct couplers, anchorage caps and other similar components, shall conform to the requirements in Table 960-3 with the additions and modifications in Table 960-4. Table 960-4 “O”-Rings and Compression Seal Material Properties (cross section diame ter or thickness > 0.25 in) Mechanical Properties Shore hardness, ASTM D2240 30-60 FY 2023-24 Return to Table of Contents Tensile strength, ASTM D412 600 psi min. Compression Set Method B 22 hours @ 257° F, ASTM D395 60%
3.Compression Force - Maximum force to compress an “O” -ring or compression seal to its final compressed position shall not be greater than 25 psi times the area encircled by “O” -ring or seal.
4.Voided Area - Compression seals must accommodate material flow within its ow n cross sectional area by using a hollow or voided design.
960-2.2 1.8 Heat Shrink Sleeves:
1.Heat shrink sleeves shall have unidirectional circumferential recovery and be sized specifically for the duct size being coupled.
2.Use sleeves with a crosslinked polymer, typically polyolefin backing for grouted applications and sleeves with a high -density poly ethylene or polypropylene backing for flexible filler applications.
3.Use adhesive with the same bond value to steel and high-density polyethylene or polypropylene materials.
4.Heat shrink sleeves shall have an adhesive layer that meets the requirements of the following table: Table 960-5 Heat Shrink Sleeve Adhesive Layer Minimum Requirements Property Test Method Minimum Requirements Grouted Applications Flexible Filler (Internal and External Applications) Softening Point ASTM E28 162oF 256ºF Lap Shear at 73oF ISO 21809 -3 87 psi 44 psi Tensile Strength ASTM D638 2,900 psi 3,190 psi Hardness ASTM D2240 46 Shore D 55 Shore D Elongation ASTM D638 600% 600% Volume Resistivity ASTM D257 3.9 x 10^16 ohm-inch 3.9 x 10^16 ohm-inch Adhesion Strength at 73oF ISO 21809-3 5-20 lbf/inch 28 lbf/inch Impact Resistance ISO 21809 -3 Pass 15 J Indentation Resistance ISO 21809 -3 Pass 0.026 inch Cathodic Disbondment @ 73oF, 28 days ISO 21809-3 0.5 inch*radian < 0.4 inch Backing Thickness - 0.025 inch 0.035 inch Adhesive Thickness - 0.035 inch 0.055 inch Operating Temperature - 122°F 212°F
5.Install heat shrink sleeves using procedures and methods specified in the manufacturer’s instructions.
6.Do not use heat shrink sleeves with properties meeting the requirements for grouted applications for applications using flexible filler. FY 2023-24 Return to Table of Contents
7.Do not use heat shrink sleeves with properties meeting the requirements for flexible filler applications for applications using grout.
960-2.2 2 Attachments:
960-2.2 2.1 Anchorage Caps:
1.Provide permanent anchorage caps made of stainless steel, nylon, polyester, or Acrylonitrile Butadiene Styrene (ABS).
2.The anch orage cap must encapsulate the entire wedge plate and be fastened directly to the anchorage bearing plate. Fastening the anchorage cap to the wedge plate is not permitted.
3.Seal Anchorage cap with “O” -ring seals or precision fitted flat gaskets place d against the bearing plate.
4.Provide holes of 3/8 inch minimum diameter at the top and bottom of the cap. The holes must be suitable for filler venting , draining water, and inspection of the content inside the anchorage cap from the top , bottom or front of the anchorage cap as appropriate (e.g. anchorage caps not accessible from the front after filler injection must have a vent at the top of the cap). Anchorage caps may be fabricated with top/bottom holes on both the front face and outside perimeter the cap to facilitate venting, draining , and inspection.
5.Install the anchorage cap such that the top and bottom holes form a vertical axis oriented 90 degrees from horizontal.
6.Anchorage caps shall have a minimum pressure rating of 150 psi.
7.Stainless steel bolts shall be used to attach cap to anchorage.
8.Certified test reports documenting steel chemical analysis shall be submitted when stainless steel anchorage caps are used.
960-2.2 2.2 Inlets, Outlets, Drains, Port s, Valves, and Plugs:
1.Provide permanent inlets, outlets, drains, ports, valves, and threaded plugs made of nylon, high -density polyethylene or polypropylene materials, or stainless steel.
2.For unbonded post -tensioning systems using flexible fi ller, provide permanent inlets, outlets and drains made from steel. Provide temporary inlets, outlets, drains and valves made from brass or steel.
3.All inlets, outlets, drains and ports shall have pressure rated mechanical shut -off valves or plugs. M echanical shut -off valves must be 1/4 turn ball valves.
4.Inlets, outlets, drains, ports, valves, and plugs shall have a minimum pressure rating of 150 psi.
5.Inlets, outlets and ports shall have a minimum inside diameter of 3/4 inches for strand and 3/8 inches for single bar tendons and four -strand ducts.
6.Drains shall have a minimum inside diameter of 3/8 inches. Locate drains, and inlets and outlets serving as drains, at the bottom of the duct cross section.
7.Specifically designate temporary items, not part of the permanent structure, on the PT system shop drawings.
960-2.3 Steel Reinforcing:
960-2.3 1 Mild:
1.Reinforcing steel shall conform to Section 415 and Section 462. FY 2023-24 Return to Table of Contents
2.Test typical local zone reinforcement for compli ance with AASHTO LRFD Bridge Design Specifications and AASHTO LRFD Bridge Construction Specifications, as applicable. Include reinforcement details in the PT system shop drawings submitted for approval.
960-2.3 2 Prestressing:
960-2.3 2.1 Strand: Prestressing strands shall be in accordance with
Section 933.
960-2.3 2.2 Bar:
1.Prestressing bars shall be in accordance with Section 933.
2.Bar couplers shall be in compliance with AASHTO LRFD Bridge Design Specifications and AASHTO LRFD Bridge Construction Specifications.
3.Test bar couplers in accordance with AASHTO LRFD Bridge Construction Specifications or the European Assessment Document Post -Tensioning Kits for Prestressi ng of Structures (EAD 160004 -00-0301, September 2016 Edition) . For bar couplers that will be used for tendons with flexible filler, test bar couplers in accordance with the EAD 160004-00-0301 Section C.3 Resistance to Fatigue .
4.Use only spherical nut s to anchor bars at bearing plates.
960-2.4 PT System Materials:
1.Use material specifications in this Section for all PT system components and subcomponents.
2.Use only virgin material for all non -ferrous components.
3.Test only samples taken f rom finished product as applicable.
960-2.4 1 Nylon: Use one of the following cell classes according to
ASTM D5989:
1.S-PA0141 – weather resistant.
2.S-PA0231 – heat stabilized.
3.S-PA0401 – ultimate strength not less than 10,000 psi with UV stabilizer added.
960-2.4 2 Stainless Steel: Conform to the following:
1.ASTM A240 Type 316 - for metallic components other than bolts.
2.ASTM F593 Type 316 - for bolts.
960-2.4 3 Polypropylene: Conform to all of the followin g:
1.Non-colored, unfilled polypropylene according to ASTM D4101 with a cell class range of PP0340B44541 to PP0340B67884.
2.Contains antioxidants with a minimum Oxidative -Induction Time (OIT) according to ASTM D3895 of not less than 20 minutes.
3.Contains a non -yellowing light stabilizer.
4.Remolded finished material has a minimum failure time of 100 hours when tested for stress crack resistance using ASTM F2136 at an applied stress of 600 psi.
960-2.4 4 High -density Polyethylene: Conform to all of the following:
1.Smooth pipe is to meet the requirements of ASTM D3350 with a minimum cell class of 445574C. All other HDPE components are to meet the requirements of ASTM D3350 with the values of the first four digits of the cell class meeting a minimum of 4455, be composed of a resin listed in the Plastic Pipe Institute’s Technical Report 4 for Hydrostatic design basis and have a code letter designation of “C” per ASTM D3350 .
2.Contains antioxidants with a minimum Oxidative -Induction Time (OIT) according to ASTM D3895 of 40 minutes. FY 2023-24 Return to Table of Contents
3.Remolded finished material has a minimum failure time of 24 hours when tested for stress crack resistance using ASTM F2136 at an applied stress of 600 psi.
960-2.4 5 Elastomer Sleeves: Conform to all of the following:
1.Meet requirements of ASTM D1171 using Ozone Chamber Exposure Method B (no cracks permitted under 2X magnification) or ASTM D1149 Method B - Procedure B4 (no cracks permitted under 2X magnification). Do not include polyester reinf orcement in the test specimen.
2.Manufactured using an elastomeric polymeric material that is compatible with concrete, the PT system components to which the sleeves will be attached, and the filler material and filler material installation process. Id entify the applicable ASTM specifications that the sleeve material complies with.
960-3 System Approval Requirements .
960-3.1 Independent Testing: Use independent laboratories meeting the credentials
described in this Section to perform all testing , other than field testing, and to submit certified test reports for materials and components. Certification may be performed by a qualified independent laboratory outside of the United States, only if the facility is pre -approved by the State Materials Office. Conform all testing procedures used for materials or components to applicable American Society of Testing and Materials (ASTM) and International Federation of Structural Concrete (fib) Specifications or as modified in this Section.
960-3.1 1 Material La boratory: Test plastic components in a certified
independent laboratory accredited through the laboratory accreditation program of the Geosynthetic Accreditation Institute (GAI), the American Association for Laboratory Accreditation (A2LA) or qualified by an ISO 17025 accreditation agency using personnel with documented experience running the required test methods.
960-3.1 2 Component and System Laboratory: Test individual components and
the PT system as a whole witnessed by and/or performed in a certifie d independent laboratory audited by the AASHTO Materials Reference Laboratory (AMRL), or with an AASHTO R18 Accreditation as set forth by the AASHTO Highway Subcommittee on Materials or qualified by an ISO 17025 accreditation agency using personnel with do cumented experience running the required test methods.
960-3.1 3 System Testing: In lieu of performing PT system tests witnessed by
and/or performed in a certified independent laboratory, the PT system tests may be performed at the project site and witne ssed by the Engineer.
960-3.2 Testing Requirements:
960-3.2 1 Component and System Tests: Corrugated duct, smooth duct and all
associated components that are used for both internal and external PT systems, e.g. couplers, anchorages, inlets, outlets, drains, ports, valves, plugs, etc., shall meet the requirements of fib Technical Report Bulletin 75 titled, Polymer -Duct Systems for Internal Bonded Post -Tensioning, Performance Level 2 (PL2), with modifications as shown in Table 960-6. FY 2023-24 Return to Table of Contents Table 960-6 Required Component and System Tests Reference to fib Bulletin 75 Required Tests for each PT System Type(1) Procedures Appendix Test Description Internal PT System with Grout Internal PT System with Flexible Filler External PT System with Flexible Filler Component Assessment A.1 Dimensional requirement Yes No No A.2 Stiffness of duct Yes(2) No No A.3 Longitudinal load resistance Yes Yes Yes A.4 Lateral load resistance Yes No No A.5 Flexibility of duct system Yes Yes No A.6 Leak tightness of duct system Yes Yes No A.7 Concrete pressure on duct Yes(3) No No A.8 Wear resistance of duct Yes No No A.9 Wear resistance of duct under sustained load Yes No No A.10 Bond behavior of duct Yes No No A.11 Precast segmental duct coupler system Yes(4) Yes(4) No A.12 Fracture resistance of duct No No No System Assessment B.1 Leak tightness of anchorage -duct assembly Yes(5) Yes(5) Yes(5) B.2 EIT performance of duct system No No No B.3 EIT performance of anchorage - duct assembly No No No B.4 Full scale duct system assembly Yes(5)(6) Yes(5)(6) Yes(5)(6) B.5 Leak tightness of assembled duct system Yes(5)(6) Yes(5)(6) No
1.Yes = Test is required; No = Test is not required.
2.Do not preload strand into duct prior to testing.
3.Identify duct as meeting Performance Class I or II criteria.
4.Use an epoxy compound meeting the requirements of Section 926, Type AB.
5.Perform tests on the largest assembly and the smallest assembly for each family of PT systems. A family of PT syst ems is defined a group of PT strand/bar assemblies of various sizes using common anchorage devices and design.
6.For each test, use a PT system assembly consisting of at least one of each component and connection type required to install a tendon from a nchorage cap to anchorage cap. For bar tendon systems, use between 15 and 50 feet of duct with a straight profile.
960-3.2 2 Filler Containment Assembly Pressure Test: In addition to the other
testing specified in this Section, test all filler containment assemblies, i.e., anchorages, anchorage caps, inlets, outlets, drains, ports, valves, plugs, etc., for all system sizes as follows:
1.Assemble the anchorage and anchorage cap with all required filler injection attachments.
2.Seal the op ening in the anchorage where the duct/trumpet connects.
3.Condition the assembly by maintaining a pressure of 150 psi in the system for three hours. FY 2023-24 Return to Table of Contents
4.After conditioning, lock off the air supply to the assembly.
5.After lock off, the assembly m ust sustain 150 psi internal pressure for five minutes with no more than 15 psi, or 10%, reduction in pressure. This test may be combined with the External Duct Systems Pressure Test for external PT systems.
960-3.2 3 External PT Systems Pressure Test : In addition to the other testing
specified in this Section, test all sizes of external PT systems as follows:
1.Prepare a system assembly consisting of at least one of each component and connection type required to install a tendon from anchorage cap to anchorage cap using between 15 and 50 feet of duct with a straight profile.
2.Condition the assembly by maintaining a pressure of 100 psi in the system for three hours.
3.After conditioning, lock off the air supply to the assembly.
4.After lock off, the assembly must sustain 100 psi internal pressure for five minutes with no more than 10 psi reduction in pressure.
960-3.2 4 Vacuum Test for Internal and External PT Systems with Flexible
Filler: In addition to the other testing specified in this Section, test all sizes of internal PT systems with flexible filler and all external PT as follows:
1.Prepare a system assembly consisting of at least one of each component and connection type required to install a tendon from anchora ge cap to anchorage cap using between 15 and 50 feet of duct Do not cast any component into concrete .
2.Condition the assembly by maintaining a 90% vacuum in it for 1 hour.
3.After conditioning, lock off the air supply to the assembly.
4.After lock off, the assembly must sustain a 90% vacuum for 5 minutes with no more than a 10% loss of vacuum.
960-3.3 Standard Tendon Sizes: Develop and test PT systems for the sizes and types
shown in the Contract Documents.
960-3.4 System Modifications: Contact the Engineer for direction before changing any
materials or components of a PT system that has been approved by the Engineer for use on the project. Repeat all appropriate material, component, and entire system tests if the manufacturer and/or model of any major component, as defined in 960 -2, is modified or replaced, excluding local zone reinforcement.
960-3.5 Component Samples: Furnish all required material samples to laboratories for
testing and to the Department as requested, at no cost to the Depar tment.
960-3.6 Calculations, Shop Drawings, Test Reports, and Certification: Show fully
detailed shop drawings of all component configurations, connections, anchorages, inlets, outlets, drains, high point inspection port details, anchorage inspection details, permanent anchorage caps, application limits of the PT system, and installation procedures of comp onents. On the first page of each PT system shop drawing set, provide a list of all system components in tabular format that includes the following information, at a minimum: part/item number, description, material, manufacturer and model. The manufacturer need not be identified for common off -the- shelf accessories as defined in 960 -2. Submit details of typical local zone reinforcement in the PT system shop drawings signed and sealed by a Specialty Engineer. Indicate that all major PT system components , as defined in 960 -2, are stamped with the following:
1.Manufacturer’s name
2.Trademark model number FY 2023-24 Return to Table of Contents
3.Size corresponding to catalog description on PT system drawings. For each PT system, s ubmit a package that includes calculations, shop drawings, test reports, proof of current laboratory accreditations, and all material and component certifications required throughout this Section. Proof of current laboratory accreditation must specifically indicate applicable accreditation categories related to P T systems . Include a cover letter with the package signed by an officer of the PT system supplier (vendor) certifying that :
1.The submitted PT system, as a whole and all of its individual components, meet or exceed all material and component/system req uirements of this Section, as demonstrated by the submittal.
2.All testing required by this Section was performed as defined in 960 -3.1 and that all tests were performed to applicable ASTM and fib Specifications.
3.The PT system meets the requirements of Section 462. FY 2023-24 Return to Table of Contents SECTION 962 STRUCTURAL STEEL AND MISCELLANEOUS METAL ITEMS (OTHER THAN ALUMINUM)
962-1 General.
This Section covers the material and fabrication requirements for structural steel and miscellaneous metal components . All steel must be melted and manufactured in the United States and meet Section 6-5.2. All overhead cantilevers, monotubes, trusses and gantrie s, iron castings, steel gratings, fencing, field splices filler metals, and bridge components (including steel castings, steel forg ings, and bearing material) s upplied under this Specification shall be from producers currently on the Department’s Production Facility Listing. Producers seeking inclusion on the Department’s Production Facility Listing must meet the requirements of Secti on 105. Provide certifications that meet the applicable section and 962 -12.
962-2 Structural Steel.
962-2.1 Structural Steel Materials: Provide structural steel for bolted or welded
construction that meets the requirements of Table 962-1.1 and 962 -1.2 when impact testing is specified. Grade HPS 70W shall not be substituted for Grade HPS 50W. Weathering steel shall not be substituted for non -weathering steel without Engineer approval. Do not apply heat treatment unless approved by the Engineer. When galvanizing is specified, provide galvanizing in accordan ce with 962-11.1. Table 962 -1 Structural Steel Materials Product ASTM Grade/Style Reportable Properties Supplementary Requirements Plate A709 36 Composition, Yield Strength, Tensile Strength, Elongation, Killed None 50 50S Carbon Equivalency 50CR Heat-treating temperatures 50W Composition, Yield Strength, Tensile Strength, Elongation, Killed, Fine Grain Corrosion Resistance Index HPS 50W Corrosion Resistance Index, Heat Treatment Temperatures HPS 70W
962-2.2Impact Requirements : Structural steel subject to tensile stress for main load -
carrying members shall meet the impact requirements listed in Table 962-2. Mill test reports shall identify average impact test values. Provide certifications that meet this section and 962 -12. For non-fracture and fracture critical tension components , provide structural steel in accordance with ASTM A709. FY 2023-24 Return to Table of Contents
Source: Florida Standard Specifications for Road and Bridge Construction, 2024 Edition. Pages 1100–1111 of 1,299.