602DoublewalTM Precast Wall

602.1General Description

This work includes the materials, manufacture, construction, measurement, and payment for Doublewal™ precast walls. The scope of work of the wall erection includes: • Grading for wall construction • Compacting the wall foundation (including areas underlying the footings and the precast modules) • Dewatering (general and local) to execute the work properly • Constructing footings • Erecting precast concrete modules and caps • Placing and compacting soils within the Doublewal™ modules • Excavating and replacing unsuitable materials • Constructing berms Ensure that the architectural treatment of the modules is according to the plan details. 602.1.01 Definitions Doublewal™—Doublewal™ is a trademark. 602.1.02 Related References

GDT 35 AASHTO T 22 ASTM D 573 ASTM D 1752 Type II 945 945 945 945 945

602.1.03 Submittals

Submit Shop Drawings with each job to the Department for review and approval. The Shop Drawings shall be approved by the Department before beginning to fabricate the wall elements. Indicate on the Shop Drawings: • General notes for constructing the wall • Dimensions for the modules • Fabrication tolerances • Material requirements • Reinforcing steel • Module size markings that will agree with the wall designations on the construction plans • Project construction number, Prime Contractor, and wall designation in the title block in the lower right corner of the sheet • Summary of quantities that indicate the cubic yards (meters) of concrete and pounds (kilograms) of reinforcing steel in each module and unit of parapet and footing

602.2Materials

Ensure that reinforcing steel conforms to Section 853.

For precast modules and caps, use Class AAA concrete according to Section 500. For footings, traffic barriers, and precast parapets use Class A cast-in-place concrete according to Section 500.

Follow these joint treatment requirements:

on the inside of the back of the wall. Use fabric that meets the requirements of Subsection 881.2.05. In floodplains, use only woven fabric 3 ft. (1 m) above and entirely below the 100-year flood elevations.

See Figure 1 (Figure 1 metric).

recommended by the Doublewal™ Corporation.

Vertical joints 12 in. (300 mm) Horizontal joints 12 in. (300 mm) Laps in fabric 44 in. (1.1 m) 946 946 946 946 946

Use modular backfill materials within the rectangular cells of the Doublewal™ precast wall that meet the following requirements: • Are free from organic or otherwise harmful material • Conform to the following gradation limits: Sieve Size Percent Passing 4 in. (100 mm) 100 2 in. (50 mm) 80 to 100 No. 10 (2.00 mm) 20 to 90 No. 200 (75 µm) 0 to 12

Ensure that underdrain pipe meets the requirements of Subsection 573.2, Materials. Ensure that filter fabric meets the requirements of Section 881.2.05. Ensure that stone conforms to Subsection 806.2.01. 947 947 947 947 947

FIGURE 1 Front face of wall * ** *** *** ** * Front face of wall * 3/8 in thick x 5 in wide x L long rubber bearing pad 3/8 in thick x 5 in wide x L long rubber bearing pad to be used where module width transitions 3/8 in thick x 5 in wide x L long rubber bearing pad ** *** For length of bearing pad see shop drawings. Thickness may vary ± 1/8 in to account for leveling adjustments. NOTE: Front face and rear face of modules shall be reinforced sufficiently to prevent cracking which might result from unequal distribution of bearing pressures. The reinforcing for the modules shall be as shown on the plans. 948 948 948 948 948

FIGURE 1 (METRIC) Fron t face of wall * ** * ** *** ** * Front face of wall * 10 mm thick x 127 mm wid e x L long rubber bea ring pad 10 mm thick x 127 mm wid e x L long rubber bea ring pad to be used where module wid th transitions 10m m thick x 127 mm wide x L long rubber bea ring pad ** * ** For length of bearing padse e shop dra wings. Thickne ss may vary ± 3 mm to acco unt for le veling ad justments. NOT E: Front face and rear face of modu les shall be reinforced sufficiently to prevent cracking which might result f rom unequal distribution of bea ring pressures. The reinforcing for th e modules shall be as sh own on the p lans. 949 949 949 949 949

Joint filler acceptance furnished for the work is based on Subsection 106.05, Materials Certification.

Use resilient, weather-resistant elastomer bearing pads. Use fiber reinforcement with rayon, nylon, and fiberglass or combinations of these fibers. The physical properties of the material are as follows: • Dimensions. Ensure that dimensions are as detailed on the Plans. Various thicknesses may be required for leveling purposes. • Compression Modulus. Ensure 1,200 psi (8 MPa) compression at less than 50 percent of the ultimate compressive strain. Determine compression on a 0.5 in. (13 mm) specimen. • Shear Modulus. Ensure 500 psi (3.5 MPa) in direct shear while compressed and 1,200 psi (8 MPa) at 50 percent ultimate shear strain uncompressed. Determine shear on a 0.5 in. (13 mm) specimen. • Tensile Strength. Ensure at least 400 psi (3 MPa) tested in transverse and longitudinal directions. • Property Retention. Ensure heat aging at ASTM D 573 at 158 °F (70 °C) for 72 hours. Ensure change in tensile strength does not exceed 25 percent. Ensure change in elongation does not exceed 25 percent. Ensure no creep failure when stressed to the above maximum requirements for long periods. Have the above properties certified according to Subsection 106.05, Materials Certification. 602.2.01 Delivery, Storage, and Handling Safely handle, store, and ship modules and prevent damage to the module.

602.3Construction Requirements

602.3.01 Personnel The Contractor shall have Doublewal™, or its licensee, provide an Erection Supervisor who is thoroughly familiar with the Doublewal™ erection technique to assist the Contractor in erecting the Doublewal™ and verify that the Doublewal™ is erected properly. 602.3.02 Equipment General Provisions 101 through 150. 602.3.03 Preparation Make arrangements to obtain precast concrete modules and caps, joint materials, and the expertise to construct the Doublewal™ precast wall. 602.3.04 Fabrication

Have the reinforcing steel for precast modules and other components shop fabricated according to the requirements of the Doublewal™ Corporation.

Perform casting according to the requirements of the Doublewal™ Corporation.

attached to the steel form.

Cure the units as specified in Subsection 865.2.01.B.10 and long enough for the concrete to develop the specified compressive strength. 950 950 950 950 950

Keep the forms in place until they can be removed without damaging the unit.

Cast concrete surfaces for the front face against steel forms or architectural form liners if noted on the Plans. Ensure that the units are manufactured within the following tolerances:

measuring with a 8 ft. (2.4 m) straightedge.

1) Smooth Finish. Correct variations greater than 0.1 in. (2.5 mm) when tested with a 5 ft. (1.5 m) straightedge before moving the panel from the casting yard. 2) Other Finish Types. Ensure that other finish types conform to approved samples displayed by the manufacturer.

Perform compression tests to determine the minimum strength requirements on cylinders.

day’s production.

(40 m³) of concrete placed, whichever amount of concrete is less. Cure according to GDT 35.D.B.6.

If the cylinder tests are questionable, take cores from modules at the manufacturer’s option and expense and use them to determine the 28-day strength.

Determine the acceptability of the precast units at the casting yard by performing compression tests and visually inspecting them during and after casting. Ensure the units conform with the specifications and drawings. The precast units are acceptable, regardless of curing age, when compression test results show that the strength will conform to 28-day specifications and all other requirements. Instruct the manufacturer to furnish the facilities and assistance to perform sampling and testing rapidly and satisfactorily.

Mark each unit according to the requirements of the Office of Materials.

Before shipment, concrete technical service personnel from the OMR and/or the plant’s certified personnel shall examine the surfaces of precast units for approval. The Engineer will inspect the surfaces at the job site. Patch honeycombing and other defects in the wall surfaces to the Engineer’s satisfaction. 951 951 951 951 951

Units will be rejected if they do not meet the requirements in Subsection 602.3.04.B.4, Concrete Finish and Tolerances, Subsection 602.3.04.B.5, Compressive Strength, and any of the above paragraphs. Units that are cracked or damaged, or do not meet tolerance requirements in this specification will not be allowed on the job site. 602.3.05 Construction

Excavate and compact the foundation bed for the Doublewal™ precast wall as required in this specification. Obtain the Engineer’s approval before beginning the erection.

Cast the footings in place to the dimensions and details shown on the project plans. Construct the footings with or without forms. Strictly follow the top of footing elevations shown on the plans. Before erecting the wall, compact the foundation area to at least 95 percent of maximum laboratory dry density specified in Subsection 208.3.05.B.2.c.

Install the precast concrete module units according to the manufacturer’s recommendations as shown on the

approved shop drawings.

equal to the width of the lower course unit.

this specification.

another (measured on the top of the module’s front face and back face), by more than 1/8 in. (3 mm). Measure

with a 10 ft. (3 m) straightedge and level.

beam bearing pads. Do not allow the total thickness of the rubber bearing pads to exceed 0.75 in. (20 mm).

successive course.

joint treatment in the horizontal joints of both faces as in Subsection 602.2.C, Joint Treatment.

concrete structures.

• Vertical tolerances (plumbness) and horizontal alignment tolerances shall not exceed 3/8 in. (10 mm)

when measured along a 8 ft. (2.4 m) straightedge.

• Overall wall vertical tolerance (plumbness from top to bottom) shall not exceed 0.5 in. per 8 ft. (5 mm/m)

of wall height, except for battered wall designs. In this case, the variation of the battered plane from the

theoretical shall not exceed 0.5 in. per 8 ft. (5 mm/m) of wall.

• The footing surface shall not vary from level more than 1/8 in. per 10 ft. (1 mm/m).

by the manufacturer.

Perform patching only when the repaired area will conform to the balance of the work in appearance, strength,

and durability. Repair to the Engineer’s satisfaction. 952952952952952

TM Precast Wall

Backfill each successive course of modular units.

modular backfill material in two lifts or layers.

laboratory dry density.

allow the modular backfill material and the top of the last erected course to differ in elevation by more than

6 ft. (1.8 m).

modular backfill material cost.

limits of the bridge, contains fines to fill the voids in the aggregate. Compact the aggregate material to at least

95 percent of the maximum laboratory dry density.

Cast the appropriate storm drainage into wall modules at the elevation and locations indicated on drainage

profiles. Construct the catch basin and place the storm drain in coordination with construction of the Doublewal™

precast wall.

Furnish, install, operate, and maintain dewatering systems as necessary to:

• Keep the site dry and workable

• Grade and compact the wall foundation

• Erect and backfill the wall

Ensure that these systems include equipment and materials and are continued as long as necessary. Include

dewatering costs in the price bid for modular backfill material.

602.3.06 Quality Acceptance

General Provisions 101 through 150.

602.3.07 Contractor Warranty and Maintenance

General Provisions 101 through 150.

602.4Measurement

When a Doublewal™ precast wall is built to plan dimensions, the plan quantities will be the pay quantities. When the

Engineer changes the Plan dimensions during construction or when original Plans are in error, the revised plan

quantities will be the pay quantities.

Excavation, including removing unstable material and shoring to construct a Doublewal™ precast wall will not be

measured and paid for separately. 953953953953953

TM Precast Wall

The area of modules, complete in place and accepted, are designated for payment by the surface area per square

foot (meter) of the front face of each module width. The front face of the wall is the face exposed to view.

The modular backfill material used in the modules is designated for payment by the cubic yard (meter), complete

in place.

Modular backfill material that extends beyond the width and height of modules is incidental. The cost will be

included in the price bid for Contract Items.

Increases in foundation excavation from undercut ordered by the Engineer that requires modular backfill material

to provide stability will be measured and paid for at the Contract Unit Price per cubic yard (meter) of modular

backfill material.

Backfilling undercut areas with materials of grades at or lower than common excavation soils will not be measured

or paid for separately.

The concrete footings will be measured for payment by the cubic yard (meter). This measurement includes steps

and reinforcing steel indicated on the plans.

The following Units, complete in place and accepted, will be designated on the Plans and measured and paid for

at the Contract Unit Price bid per yard (meter) for each type Unit.

• Precast parapet A

• Precast parapet B

• Cast-in-place coping

• Cast-in-place traffic barrier A

• Cast-in-place traffic barrier B

• Precast traffic barrier B

This measurement also includes cast-in-place concrete and reinforcing steel to install the precast units as shown

on the plans.

Use precast parapet B and cast-in-place traffic barrier B, or use precast traffic barrier B, whenever noise walls,

light standards, or other appurtenances are mounted on top of the traffic barrier or parapet. Use precast parapet A

and cast-in-place traffic barrier A or use precast traffic barrier B when no appurtenance is used on top of the

parapet or traffic barrier.

602.4.01 Limits

General Provisions 101 through 150. 954954954954954

TM Precast Wall

602.5Payment

When the wall is built to Plan dimensions, the plan quantities will be the pay quantities. When plan dimensions are

revised as directed by the Engineer, the wall will be paid for using the revised plan quantities. Payment is full

compensation for fabricating, transporting, and erecting materials according to the plans and specifications.

No separate measurement or payment will be made for tools, supervision, labor, coatings, joint materials (including but

not limited to cork, rubber pads, and filter fabric), site preparation, or other incidentals to perform the work.

The following items, when shown on the Plans, will be paid for according to the applicable sections of the

project specifications:

• Concrete side barrier

• Sound barriers

• Light standards

• V gutters

• Guard rail

• Fencing

• Handrail

Sleeves for chain link fencing and anchor bolts for light standards and noise barriers, when installed on the wall shall

be included in the price bid for wall items.

Modifications to accommodate drainage systems are incidental and shall be included in the price bid for wall items.

Payment will be made under:

Item No. 602 Modules—(width) Per square foot (meter)

Item No. 602 Modular backfill material Per cubic yard (meter)

Item No. 602 Concrete footing Per cubic yard (meter)

Item No. 602 Precast parapet A Per linear foot (meter)

Item No. 602 Precast parapet B Per linear foot (meter)

Item No. 602 Cast-in-place traffic barrier A Per linear foot (meter)

Item No. 602 Cast-in-place traffic barrier B Per linear foot (meter)

Item No. 602 Cast-in-place coping Per linear foot (meter)

Item No. 602 Precast traffic barrier B Per linear foot (meter)

602.5.01 Adjustments

General Provisions 101 through 150.. 955 955 955 955 955