960POST-TENSIONING COMPONENTS

960-1Description

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 .

960-1.1Material 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).

960-2Component 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.

960-2.1Anchorage Assembly:

1092 FY 2023-24 Return to Table of Contents

when tested in an unbonded state, without exceeding anticipated anchor set.

Bridge Design Specifications and AASHTO LRFD Bridge Construction Specifications.

drawings.

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 .

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.

borescope inspection directly behind wedge plate using a straight 3/8 inch diameter drill bit.

shall be galvanized in accordance with Section 962. Other anchorage assembly components, including wedges, wedge plates, and local zone reinforcement need not be galvanized.

anchorage. 960-2.1.1 Trumpets:

metal galvanized per ASTM A123, high -density polyethylene or polypropylene.

thickness at transition location shall be the thickness of the corrugated du ct or greater .

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:

alignment with bearing plate. 1093 FY 2023-24 Return to Table of Contents

separate wedge plate and anchorage plate.

960-2.2Filler Containment Assembly:

960-2.2.1 Duct and Pipe:

pipe in accordance with this Section.

Fabricate all duct splices to prevent kinks during all phases of construction.

polymer.

960-2.2.1.1 Corrugated Plastic Duct:

polypropylene material except where steel pipe is required.

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:

smooth high -density polyethylene duct.

established by either ASTM D3035 or ASTM F714, as appropriate for manufacturing process used.

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:

diameter of 1/2 inches larger than bar outside diameter, measured across deformations.

internal diameter of 1/2 inches larger than largest dimension of the largest enclo sed element. 1094 FY 2023-24 Return to Table of Contents

sectional area 2 -1/2 times PT steel cross -sectional area. 960-2.2.1.5 Connections, Fittings, and Tolerance:

couplers, connection to anchorages), shall produce smooth interior alignment with no lips or kinks.

to join or repair duct, to make connections, or for any other purpose.

connected to each other and the outside diameters vary more than plus or minus 0.08 inch.

minimum pressure rating of 150 psi.

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.

high-density polyethylene or polypropylene material to make connections between corrugated plastic duc t and steel pipe.

made from high -density polyethylene or polypropylene material to make connections between corrugated plastic duct and anchorages with integral trumpets.

elastomer sleeves and stainless steel band clamps to make connections between sections of smooth plastic duct.

connections between smooth plastic duct and steel pipe.

clamps to make connections between sections of steel pipe that are external to the concrete.

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.

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:

systems at joints between match cast precast segments.

of segmental duct couplers.

polypropylene material.

1095 FY 2023-24 Return to Table of Contents

bulkhead at segment joints and provide for duct alignment.

of 6 degree deviation from perpendicular.

deviation of duct without tendon strands touching duct or coupler on either side of segment joint.

PT that is to be removed from structure, are not required to be coupled across segment joints. 960-2.2.1.7 “O” -Rings:

0.25 inches and compression seals with thicknesses less than or equal to 0.25 inches for use with

segmental duct couplers, anchorage 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 H2O,

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

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 diameter or thickness > 0.25 in)

Mechanical Properties

Shore hardness, ASTM D2240 30-60 1096FY 2023-24Return to Table of Contents

Tensile strength, ASTM D412 600 psi min.

Compression Set Method B 22 hours @ 257° F, ASTM D395 60%

or compression seal to its final compressed position shall not be greater than 25 psi times the

area encircled by “O”-ring or seal.

flow within its own cross sectional area by using a hollow or voided design.

960-2.2.1.8 Heat Shrink Sleeves:

recovery and be sized specifically for the duct size being coupled.

backing for grouted applications and sleeves with a high-density polyethylene or polypropylene

backing for flexible filler applications.

polyethylene or polypropylene materials.

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 162 o F 256ºF

Lap Shear at 73 o F 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

73 o F 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 @

73 o F, 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

specified in the manufacturer’s instructions.

requirements for grouted applications for applications using flexible filler. 1097FY 2023-24Return to Table of Contents

requirements for flexible filler applications for applications using grout.

960-2.2.2 Attachments:

960-2.2.2.1 Anchorage Caps:

nylon, polyester, or Acrylonitrile Butadiene Styrene (ABS).

be fastened directly to the anchorage bearing plate. Fastening the anchorage cap to the wedge

plate is not permitted.

gaskets placed against the bearing plate.

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.

form a vertical axis oriented 90 degrees from horizontal.

150 psi.

be submitted when stainless steel anchorage caps are used.

960-2.2.2.2 Inlets, Outlets, Drains, Ports, Valves, and Plugs:

threaded plugs made of nylon, high-density polyethylene or polypropylene materials, or stainless

steel.

provide permanent inlets, outlets and drains made from steel. Provide temporary inlets, outlets,

drains and valves made from brass or steel.

mechanical shut-off valves or plugs. Mechanical shut-off valves must be 1/4 turn ball valves.

minimum pressure rating of 150 psi.

3/4 inches for strand and 3/8 inches for single bar tendons and four-strand ducts.

Locate drains, and inlets and outlets serving as drains, at the bottom of the duct cross section.

permanent structure, on the PT system shop drawings.

960-2.3Steel Reinforcing:

960-2.3.1 Mild:

1098FY 2023-24Return to Table of Contents

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

960-2.3.2.2 Bar:

Bridge Design Specifications and AASHTO LRFD Bridge Construction Specifications.

Construction Specifications or the European Assessment Document Post-Tensioning Kits for

Prestressing 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.

960-2.4PT System Materials:

subcomponents.

960-2.4.1 Nylon: Use one of the following cell classes according to

ASTM D5989:

stabilizer added.

960-2.4.2 Stainless Steel: Conform to the following:

960-2.4.3 Polypropylene: Conform to all of the following:

cell class range of PP0340B44541 to PP0340B67884.

according to ASTM D3895 of not less than 20 minutes.

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:

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.

according to ASTM D3895 of 40 minutes. 1099FY 2023-24Return to Table of Contents

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:

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 reinforcement in the

test specimen.

compatible with concrete, the PT system components to which the sleeves will be attached, and

the filler material and filler material installation process. Identify the applicable ASTM

specifications that the sleeve material complies with.

960-3System Approval Requirements

960-3.1Independent 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 Laboratory: 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 certified 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 documented 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 witnessed by the Engineer.

960-3.2Testing 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. 1100FY 2023-24Return 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

defined a group of PT strand/bar assemblies of various sizes using common anchorage devices and design.

tendon from anchorage 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:

injection attachments.

system for three hours. 1101FY 2023-24Return to Table of Contents

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:

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.

system for three hours.

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:

and connection type required to install a tendon from anchorage cap to anchorage cap using

between 15 and 50 feet of duct Do not cast any component into concrete.

with no more than a 10% loss of vacuum.

960-3.3Standard Tendon Sizes: Develop and test PT systems for the sizes and types

shown in the Contract Documents.

960-3.4System 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.

960-3.5Component Samples: Furnish all required material samples to laboratories for

testing and to the Department as requested, at no cost to the Department.

960-3.6Calculations, 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 components. 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:

1102FY 2023-24Return to Table of Contents

For each PT system, submit 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 PT systems.

Include a cover letter with the package signed by an officer of the PT system supplier

exceed all material and component/system requirements of this Section, as demonstrated by the

submittal.

tests were performed to applicable ASTM and fib Specifications.

1103FY 2023-24Return to Table of Contents STRUCTURAL STEEL AND MISCELLANEOUS METAL ITEMS (OTHER THAN ALUMINUM)

962-1General

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 gantries, iron castings, steel gratings, fencing, field splices filler metals, and bridge components (including steel castings, steel forgings, 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.

962-2Structural Steel

962-2.1Structural 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 accordance 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.

1104 FY 2023-24 Return to Table of Contents