1042PRECAST CONCRETE PRODUCTS

Art. 1042.01 Precast Concrete Products 922

1042.01Description. This item shall consist of the manufacture and shipping

of precast concrete products.

CONSTRUCTION REQUIREMENTS

1042.02General. Precast concrete products shall be according to the Bureau

of Materials Policy Memorandum "Quality Control/Quality Assurance Program for Precast Concrete Products".

The reinforcement bars used in precast concrete products shall be according to Article 1006.10(a).

Precast concrete structural members, precast concrete piles, precast concrete headwall for pipe drain, precast concrete right-of-way markers, precast concrete drainage markers, precast concrete permanent survey markers, precast concrete section markers, and precast temporary concrete barrier shall be wet cast only.

When a precast product has attained the specified strength, the earliest the product may be loaded, shipped, and used is on the fifth calendar day. The first calendar day shall be the date casting was completed.

Construction requirements for reinforcement bars shall be according to Section 508.

1042.03Precast Concrete Structural Members (Section 504). Bridge slabs,

pile caps, and other structural members shall be according to the following.

minimum compressive strength of 4500 psi (31,000 kPa) at 28 days.

duplicate prints of shop drawings to the Engineer for review and preliminary approval. Discrepancies in the contract plans or existing conditions discovered during preparation of the shop drawings shall be reported to the Engineer for resolution prior to submitting the shop drawings for review and approval. These drawings shall be on full size sheets, 22 x 34 in. (550 x 850 mm) or reduced size sheets, 11 x 17 in. (275 x 425 mm). Each full or reduced size sheet shall provide adequate space for review and approval stamps at the lower right hand corner. Both lettering and details shall ensure legibility for review and reproduction after microfilming. All drawings shall be completely titled according to the contract plans including structure number, state contract number, route, section, and county, and shall pertain to only one structure. If the submitted shop drawings have significant discrepancies, revised sets shall be submitted until details comply with the contract requirements. After all review comments have been addressed and preliminary approval is given, the Contractor shall furnish six or more full or reduced size prints of the drawings as directed by the Engineer, and these shall be distributed and become a part of the contract. Changes to previously approved shop drawings shall be subject to the

Precast Concrete Products Art. 1042.03 923 approval of the Engineer, and the Engineer shall be supplied with a record of all such changes.

After the Engineer’s preliminary approval and prior to distribution, prints of shop drawings for structures that carry railroad traffic shall also be submitted for the approval of the Railroad Engineer. Upon request, the Contractor shall also furnish full size reproducibles, 22 x 34 in. (550 x 850 mm), including margins. The margin at the left end shall be 1 1/2 in. (40 mm) and the others 1/2 in. (13 mm) wide. These reproducibles shall become the property of, and shall be delivered to, the Railroad upon completion of the contract.

All modifications based on department-permitted alternatives, such as altered reinforcement geometry, or size and spacing, shall be summarized and the list included with the initial review submittal.

shall be within ±1/4 in. (±6 mm) of the specified cover. Welded wire reinforcement shall be accurately bent and tied in place.

Miscellaneous accessories to be cast into the concrete or for forming holes or recesses shall be carefully located and rigidly held in place by bolts, clamps, or other effective means. If paper tubes are used for vertical dowel holes, or other vertical holes which require grouting, they shall be removed before transportation to the construction site.

the exposed face and top of curb section shall be finished according to Article 503.15(a).

of the concrete will be caused.

has attained a compressive strength of not less than 2000 psi (14,000 kPa).

for additional tests may be taken if approved by the Engineer.

more than 1/8 in. (3 mm) for the full depth of the member when tested with a straightedge in a vertical direction, nor more than 1/4 in. (6 mm) in the full length of the member when tested with a straightedge in a horizontal direction; nor shall the surface of the member deviate more than 1/8 in. (3 mm) from a straight line 10 ft (3 m) long connecting two points on the member's surface.

Art. 1042.03 Precast Concrete Products 924

cause crushing, spalling or undue marring of the concrete. The ends of precast members shall not be permitted to extend a distance exceeding the depth of the member on any vehicle, bolster, or other point of bearing during hauling or stockpiling.

Precast members shall be handled with a suitable hoisting device or crane provided with a spreader sling of sufficient capacity to handle the members. The spreader shall be of sufficient length to prevent horizontal forces in the member due to lifting, and shall be equipped with leads and hooks at each end. For the purpose of engaging the threaded inserts provided in the member, the manufacturer shall provide a sufficient number of eye bolts of proper size. If lifting holes are utilized for handling, the maximum diameter of the holes shall be 2 in. (50 mm).

Before lifting the member, all lifting inserts in each end shall be fully engaged with the spreader lead hooks. In the event that raising by alternate lifting and blocking of opposite ends is performed, the lifted end shall not be rotated unless a proper pivoting device for the opposite end has been provided.

1042.04Precast Concrete Piles and Extensions (Section 512). Precast

concrete piles and extensions shall be according to Articles 1042.03(a)(b)(c)(d)(e) and the following.

After removal of the side forms, the entire pile shall be supported and shall not be handled until the specified strength is obtained.

The maximum allowable deviation of the longitudinal axis from a straight line drawn from the center of the tip to the center of the butt shall not exceed 1/4 in. per 25 ft (6 mm per 7.6 m) of length of the pile.

1042.05Precast Concrete Box Culverts (Section 540). Precast concrete box

culverts shall be according to Articles 1042.03(c)(d)(e) and the following additional requirements.

minimum compressive strength per ASTM C 1577.

the requirements of ASTM C 1577 for the design cover specified but limited to maximum design covers shown in the tables.

1042.06Precast Concrete Pipe (Sections 542, 550, 551, 552, and 601)

Precast concrete pipe shall be according to Articles 1042.03(c)(d)(e). Class PC concrete shall not apply. The concrete mix design specifications and material proportions shall be determined by the Contractor. Before the work begins, the concrete mix design specifications, material proportions, and aggregate gradations shall be approved by the Engineer.

Precast Concrete Products Art. 1042.10 925 The pipe strength shall be per AASHTO, except drain tile shall have a minimum crushing strength of 1400 lb/ft (20.5 kN/m). Pipe shall be according to the following additional requirements.

elbows, and tees shall be according to AASHTO M 170 (M 170M) Classes I to V, Tables 1 to 5, except that the use of elliptical reinforcement in circular pipe will not be permitted. The mortar used in the fabrication of elbows and tees shall be a packaged, dry, rapid hardening mortar or nonshrink grout according to Sections 1018 and 1024, respectively.

shall be according to AASHTO M 207 (M 207M).

shall be according to AASHTO M 206 (M 206M).

AASHTO M 86 (M 86M).

(M 178M).

1042.07Precast Reinforced Concrete Flared End Sections (Section 542)

Precast reinforced concrete flared end sections shall be according to Articles 1042.03(c)(d)(e). Class PC concrete shall not apply. The concrete mix design specifications and material proportions shall be determined by the Contractor. Before the work begins, the concrete mix design specifications, material proportions, and aggregate gradations shall be approved by the Engineer.

The end section strength shall be per AASHTO, and the following additional requirements.

(M 170M) for Class III, Wall B reinforced concrete pipe.

(M 207M) for Class HE-II reinforced concrete pipe.

1042.08Precast Concrete Inlet Boxes for Pipe Culverts and Medians

(Section 542). Precast inlet Boxes Types 24A, 24B, 24C, 24D, 24E, 24F, 24G, 36A, 48A, and Flush Inlet Box for Medians shall be according to Articles 1042.03(a)(c)(d)(e).

1042.09Precast Concrete Headwall for Pipe Drain (Section 601). Concrete

headwall for pipe drain shall be Class PC concrete according to Section 1020 with a minimum compressive strength of 4000 psi (28,000 kPa) at 28 days, and shall be according to Articles 1042.03(c)(d)(e).

1042.10Precast Concrete Catch Basins, Manholes, Inlets, Drainage

Structures, and Valve Vaults (Sections 602 and 603). Precast concrete catch basins, manholes, inlets, drainage structures, and valve vaults shall be according to

Art. 1042.10 Precast Concrete Products 926 Articles 1042.03(c)(d)(e). Class PC concrete shall not apply. The concrete mix design specifications and material proportions shall be determined by the Contractor. Before the work begins, the concrete mix design specifications, material proportions, and aggregate gradations shall be approved by the Engineer.

Catch Basin Types A, B, C, and D; Manhole Type A; Inlet Types A and B; Drainage Structure Types 1, 2, 3, 4, 5, and 6; Valve Vault Type A; and reinforced concrete flat slab top (Highway Standard 602601) shall be according to AASHTO M 199 (M 199M), except as shown on the plans. Additionally, catch basins, inlets, and drainage structures shall have a minimum concrete compressive strength of 4500 psi (31,000 kPa) at 28 days and manholes, valve vaults, and reinforced concrete flat slab tops shall have a minimum concrete compressive strength of 5000 psi (34,500 kPa) ) at 28 days.

1042.11Reserved

1042.12Precast Concrete Shoulder Inlet (Section 610). Shoulder Inlet with

Curb shall be according to Articles 1042.03(a)(c)(d)(e).

1042.13Precast Concrete Right-of-Way Markers, Drainage Markers,

Permanent Survey Markers, and Section Markers (Sections 666 and 667). Right- of-way markers, drainage markers, permanent survey markers, and section markers shall be Class PC concrete according to Section 1020 with a minimum compressive strength of 3500 psi (24,000 kPa) at 14 days, and shall be according to Articles 1042.03(c)(d)(e).

1042.14Precast Temporary Concrete Barrier (Section 704). Temporary

concrete barrier shall be Class PC concrete according to Section 1020 with a minimum compressive strength of 4000 psi (27,500 kPa) at 28 days, and shall be according to Articles 1042.03(c)(d)(e).

1042.15Precast Concrete Block, Brick, Masonry Units, and Pavers

Class PC concrete shall not apply. The concrete mix design specifications and material proportions shall be determined by the Contractor. Before the work begins, the concrete mix design specifications, material proportions, and aggregate gradations shall be approved by the Engineer.

The block, brick, masonry unit, and paver strength shall be per ASTM, and the following additional requirements.

according to ASTM D 6684. Freeze/thaw durability shall be determined according to ASTM C 67 or ASTM C 1262. The freeze thaw criteria shall be as follows.

less loss in dry weight (mass) of any individual unit when subjected to 50 cycles of freezing and thawing.

Precast Concrete Products Art. 1042.18 927

conclusion of 100 cycles shall not exceed 1.0 percent of its initial weight (mass).

the conclusion of 150 cycles shall not exceed 1.5 percent of its initial weight (mass).

according to ASTM C 55.

units shall be according to ASTM C 139. Hollow load-bearing concrete masonry units shall be according to ASTM C 90.

except proof of resistance to freezing and thawing shall be according to ASTM C 1645 (saline test solution).

1042.16Handling Hole Plugs. Plugs for handling holes in precast concrete

products shall be as follows.

shape and shall have a minimum compressive strength of 3000 psi (20,700 kPa) at 28 days.

with a flat round top and a stem with three different size ribs. The plug shall fit snuggly and cover the handling hole.

The plug shall be according to the following.

Mechanical Properties Test Method Value (min.) Flexural Modulus ASTM D 790 3300 psi (22,750 kPa) Tensile Strength (Break) ASTM D 638 1600 psi (11,030 kPa) Tensile Strength (Yield) ASTM D 638 1200 psi (8270 kPa)

Thermal Properties Test Method Value (min.) Brittle Temperature ASTM D 746 -49 °F (-45 °C) Vicat Softening Point ASTM D 1525 194 °F (90 °C)

1042.17Precast Concrete Handholes. Precast concrete handholes shall be

according to Articles 1042.03(a)(c)(d)(e).

1042.18Precast Modules for Retaining Walls. Precast modules shall be

defined as units with a wall surface area of greater than 2 sq ft (0.19 sq m) per standard module or unit. Precast modular walls shall conform to the supplier's standards as previously prequalified by the Department, AASHTO LRFD Bridge Design Specifications for prefabricated modular walls, and the following.

Art. 1042.18 Precast Concrete Products 928

or AASHTO M 111.

1020 with a minimum compressive strength of 3500 psi (24 MPa) at 7 days. The modules may be reinforced or unreinforced and shall be according to Article 1042.03, and the following requirements.

1006.10(b)(1)b., or 1006.10(b)(2)b

0.2 in. in 5 ft (5 mm in 1.5 m).

(1.5 m) shall not be more than 0.1 in. (2.5 mm).

Concrete surfaces exposed to view in the completed wall shall be finished according to Article 503.15(a).

1042.19Precast Panels for Mechanically Stabilized Earth Retaining Walls

The precast panels shall conform to the supplier's standards as previously prequalified by the Department, AASHTO LRFD Bridge Design Specifications for mechanically stabilized earth walls, and the following.

1020 with a minimum compressive strength of 4000 psi (27.5 MPa) at 28 days and shall be according to Article 1042.03, and the following requirements.

overlapping joints between panels designed to conceal joints and bearing pads.

(b)(1)b., or 1006.10(b)(2)b

0.2 in. in 5 ft (5 mm in 1.5 m).

Precast Concrete Products Art. 1042.21 929

(1.5 m) shall not be more than 0.1 in. (2.5 mm).

panels with a tolerance not to exceed 1 in. (25 mm) from the locations specified on the approved shop drawings. Panel embed devices shall not be in contact with the panel reinforcement steel.

Concrete surfaces exposed to view in the completed wall shall be finished according to Article 503.15(a). The back face of the panel shall be roughly screeded to eliminate open pockets of aggregate and surface distortions in excess of 1/4 in. (6 mm).

1042.20Precast Concrete Lagging. Lagging shall be according to 1042.03

and the following. Lagging exposed to view in a completed wall shall be finished according to Article 503.15. The back face of the lagging shall be roughly screeded to eliminate open pockets of aggregate and surface distortions in excess of 1/4 in. (6 mm). Reinforcement for precast concrete lagging exposed to view in the finished wall application shall be epoxy coated. Lifting inserts shall have a total minimum design capacity based on a yield strength of four times the dead load calculated for the width of lagging used. Threaded inserts or other accessories, cast into the precast concrete lagging, shall be galvanized according to AASHTO M 111 or M 232.

1042.21Precast Segmental Concrete Block. Segmental concrete block for

retaining walls shall be defined as units with a wall surface area of less than or equal to 2 sq ft (0.19 sq m) per standard block or unit and shall be dry-cast or wet-cast according to the following.

be according to ASTM C 1372, except as follows.

Articles 1010.01 and 1010.05.

exception of gradation. The proposed aggregate gradation shall be approved by the Engineer.

use shall be Class PC concrete according to Section 1020 with a minimum compressive strength of 3000 psi (21 MPa) at 28 days.

Art. 1043.02 Adjusting Rings 930

SECTION 1043. ADJUSTING RINGS

1043.01Reserved

1043.02High Density Polyethylene (HDPE) Plastic Adjusting Rings. HDPE

plastic adjusting rings shall be manufactured from Class B HDPE plastic, as identified in ASTM D 1248, using the injection molding process. They shall be designed and tested to meet or exceed an HS25 wheel load according to the AASHTO Standard Specifications for Highway Bridges and shall be stabilized against the effects of ultraviolet light.

Recycled material may be used. If recycled material is used, only polyethylene and less than two percent polypropylene will be allowed in the reclaim process. All feed stock shall be tested by the manufacturer on a procurement/production batch basis to verify the following property values.

Physical Property Test Standard Value Melt Flow Index

ASTM D 1238 0.01 to 1.06 oz/10 min (0.30 to 30.0 g/10 min) Specific Gravity

ASTM D 792 0.84 to 0.98 Tensile Strength, Yield ASTM D 638 2000 psi (13,800 kPa) minimum

HDPE plastic adjusting rings shall have no void areas, cracks, or tears, and have no effects due to exposure to ultraviolet light. Ripples or sags shall be limited to less than ten percent of the surface. The actual diameter or length shall not vary more than 0.125 in. (3 mm) from the specified diameter or length. Variations in height are limited to  0.063 in. (1.6 mm) for parts up to 2 in. (50 mm) or  0.125 in. (3 mm) for parts from 2 in. (50 mm) to 3 in. (75 mm). Variations shall not exceed 0.25 in. (6 mm) from flat (dish, bow or convoluting edge) or 0.125 in. (3 mm) for bulges or dips in the surface.

1043.03Recycled Rubber Adjusting Rings. Recycled rubber products shall

consist of no less than 80 percent by weight recycled rubber. The riser shall meet or exceed the following when maintained at 73 ± 3 °F (23 ± 2 °C) for at least 24 hours prior to and during testing.