Precast Concrete Structures Art. 504.02 UNIT PRICE ADJUSTMENTS Percent Type of Construction Adjustment in Unit Price For concrete in substructures, culverts (having a waterway opening of more than 10 sq ft (1 sq m)), pump houses, and retaining walls (except concrete pilings, footings, and seal coats): When protected by: Protection Method II 115 % Protection Method I 110 % For concrete in superstructure (approach slab): When protected by Method I or II 107 % For concrete in superstructures: When protected by: Protection Method II 123 % Protection Method I 115 % For concrete in footings: When protected by Method I or II 107 % For concrete in slope walls: When protected by Method I 107 % SECTION 504. PRECAST CONCRETE STRUCTURES
504.01 Description. This work shall consist of the construction of structures
or portions thereof, with precast concrete or precast, prestressed concrete structural members.
504.02 Materials. Materials shall be according to the following.
Item Article/Section
a.Portland Cement Concrete ..................................................................... 1020
b.Reinforcement Bars ........................................................................... 1006.10
c.Prestressing Steel .............................................................................. 1006.10
d.Welded Wire Reinforcement .............................................................. 1006.10
e.Transverse Tie Rods and Dowel Rods .............................................. 1006.06
f.Nonshrink Grout ................................................................................. 1024.02
g.Epoxy Bonding Compound ................................................................ 1025.01
h.Precast Concrete Products ..................................................................... 1042
i.Preformed Bearing Pads ........................................................................ 1082
j.Metal Hardware Cast into Concrete .................................................... 1006.13
k.Packaged, Dry, Combined Materials for Mortar ...................................... 1017
l.Bond Breaker (Note 1) Note 1. The bond breaker shall be one of the following three options: Two coats of Type I, II, or III membrane curing compound, meeting the requirements of Article 1022.01, applied with a roller. Art. 504.03 Precast Concrete Structures Two coats of protective coat, meeting the requirement of
Article 1023 — 01, applied with a roller.
A single layer of “#30 roofing felt” bonded to the concrete with a roofing adhesive.
504.03 Equipment. Equipment shall be according to the following.
Item Article/Section
a.Hand Vibrator ................................................................................ 1103.17(a)
b.Vibrating Screed ....................................................................... 1103.17(g)(1) CONSTRUCTION REQUIREMENTS
504.04 General. This work shall be according to Section 503, and the
following.
504.05 Precast Concrete Members. Tie bolts, anchor dowels, bearing pads,
inserts, nonshrink grout, and other items required for the erection of the units shall be furnished with the member. Erection of precast bridge slabs shall commence at the centerline and proceed, one slab at a time, working out to the curb. As each slab is placed, the transverse tie bars shall be inserted and secured. Any shifting of the beams must be done while they are held free of the supports by the hoisting device or crane. The use of a steel pinch bar will not be permitted. The abutting edges of each unit shall be carefully cleaned of any concrete or extraneous matter in order that the slabs can be bolted tightly together. Care shall be exercised to keep the bearing seat areas free of foreign material when placing the slabs. After the units have been placed and fastened together and the end anchor dowels are placed, the longitudinal keyways between the units shall be filled with nonshrink grout according to Article 504.06(e). Pile caps shall be carefully lowered into their proper position over the piles and to the specified elevation. After the units have been placed, the recess holes shall be filled with nonshrink grout according to Article 504.06(e).
504.06 Precast, Prestressed Concrete Members. Deck beams, I-beams,
Bulb T-beams, and other prestressed concrete structural members shall be fabricated according to the Department’s “Manual for Fabrication of Precast Prestressed Concrete Products” in effect on the date of invitation for bids.
a.Damage Inspection. The completed members shall not be placed until they are inspected for damage at the jobsite by the Engineer. The members shall be inspected for damage again after placing and before decking begins.
b.Deck Beam Erection Tolerances. The tolerance for the total width of the deck shall be the theoretical width plus 1/2 in. (13 mm) per joint. The maximum distance between beams, measured below the keyway, shall be Precast Concrete Structures Art. 504.06 3/4 in. (19 mm). The deviation from the specified width for the transverse joints shall be - 1/4 in. (6 mm) to + 1/2 in. (13 mm) at expansion joints, and 0 to + 1/2 in. (13 mm) at fixed joints. The beams individually may comply with the dimensional tolerances and still not place satisfactorily in the structure. Acceptance of the beams, therefore, will be conditioned upon satisfactory placement.
c.Handling, Storing, and Transporting. The members shall be maintained in upright position at all times and shall be supported as described herein. During lifting, members shall be supported only by the inserts provided for that purpose. During transportation, wood blocks or other suitable material shall be placed under the tie down chains to prevent chipping of the concrete. If temporary storage is required at the jobsite the members shall be supported on timber, at least 4 in. (100 mm) wide, and shall be maintained in level position so that no twisting of the member will occur. For both transportation and temporary storage, the ends of I-beams shall not extend a distance of more than the depth of the beam and, in no case, more than 3.5 ft (1.1 m) beyond the bolsters or other supports. The ends of Bulb T-beams shall not extend more than 6 ft (1.8 m) beyond the supports. The ends of deck beams shall not extend a distance of more than 1 1/2 times their depth, and in no case more than 3 ft (0.9 m), beyond the supports. No stacking of deck beams will be allowed at the jobsite.
d.Erection. Before starting work, the Contractor shall submit an erection plan to the Engineer for approval detailing the proposed methods of erection and the amount, location(s), and type(s) of equipment to be used. Beams shall be placed on clean bridge seats and tops of bearing devices. Any shifting of beams shall be done while they are held free of the supports. 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. 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. Erection of deck beams shall begin at the expansion end. During the initial placement of the beams, every effort shall be made by the Contractor to achieve optimum match between beams. The Contractor may be required to shift or interchange interior beams, or pairs of beams on skewed bridges, to achieve a better fit when directed by the Engineer. As the beams are placed in their final position, and prior to securing transverse ties and drilling and grouting dowels, the beams shall be brought to firm even bearing on the Art. 504.06 Precast Concrete Structures seats through the use of the bearing pads and fabric shims furnished with the beams, and/or grinding of the concrete seats as required. After deck beams are properly placed and firm even bearing ensured, the beams, either in pairs for skewed structures or all beams for right angle structures, shall be secured in lateral position by placing and tightening of the transverse tie assemblies. Dowels at the fixed ends of the deck beams shall be installed, nonshrink grout placed, and cured according to Articles 1020.13(a)(3) or 1020.13(a)(5) for a minimum of 24 hours. Before dowel bars are installed, the hole depths and diameters will be verified. If the bearing area is specified to be grouted it shall be done at the time of dowel placement. In stage construction with deck beams, the first stage shall be constructed as a complete deck including grouting according to Article 504.06(e) and the placement of the wearing surface if one is specified. The transverse ties for the first stage of construction shall not be released during construction of the next stage. Threaded sleeves shall be used to secure the deck beams to the previous stage and at no time shall the transverse tie nuts for the previous stage be loosened or removed. The next stage of construction shall proceed as specified above, except the keyway along the stage construction line shall be aligned with clamping devices. This keyway shall be the last keyway to be grouted. The Contractor shall furnish all material for the clamping devices, including sufficient 1/16 in. (2 mm) and 1/8 in. (3 mm) steel shims to adjust for differential elevations between the two deck beams. The 2 in. (50 mm) holes for the clamping devices shall be cast at the locations shown on the plans. Care shall be taken to drill the holes perpendicular to the beams. The clamping devices shall be installed and pulled up tight so that a full, firm bearing is obtained between the clamping plates and the deck beam concrete.
e.Grouting. After the erection is completed, the longitudinal keyways between beams shall be filled with nonshrink grout. The Contractor shall also place nonshrink grout between the ends of the deck beams at fixed piers and for the transverse tie assembly pockets. During the curing period, no vehicular traffic, including the Contractor's equipment, will be permitted on the beams. Grouting of the keyway at the staged construction line shall be done after the shear key clamping devices are fully secured. The clamping devices shall not be loosened or removed until the nonshrink grout has fully cured. After the clamping devices are removed the drilled holes and unfilled area of adjacent key shall be flushed out with water and then completely filled with grout. The temperature of the grout at time of placement shall be a minimum of 50 °F (10 °C) and a maximum of 90 °F (32 °C). Surfaces to which the grout is applied shall be wetted a minimum of one hour before placement of grout. The surface shall be maintained in a Precast Concrete Structures Art. 504.06 dampened condition during that period. Prior to placement of grout, all excess water shall be removed and all openings between beam edges at the base of the longitudinal keyways shall be caulked or sealed with a suitable compressible material to prevent leakage. Keyways shall be clean and free of all oil, grease, laitance and other foreign substances. During placement, the grout shall be worked into the area with a pencil vibrator. The surface shall be troweled to a smooth finish. The nonshrink grout shall be immediately cured according to Articles 1020.13(a)(3) or 1020.13(a)(5) for a minimum of seven days, and field testing will not be required. However the cure time may be reduced provided the Contractor molds specimens, covers them, and performs cube tests according to ASTM C 1107. The tests shall verify the 6000 psi (41.37 MPa) grout strength has been obtained, but in no case shall the cure time be less than three days. For Contractor cube tests, each sample shall consist of three specimens and a minimum of two samples will be required for each day of grouting. Additional samples may be requested by the Engineer. Specimens shall be cured underneath the curing material with the beams for a minimum of 48 hours before transport to the laboratory for testing. The laboratory shall be inspected for Hydraulic Cement – Physical Tests by the Cement and Concrete Reference Laboratory (CCRL). The nonshrink grout for the longitudinal keyways and between the ends of deck beams at fixed piers will be inspected by the Engineer for cracks. When deck beams are used as the final driving surface, any cracks 0.007 in. (0.2 mm) or wider shall be sealed according to Section 590. If cracks propagate along the keyway from the ends of beams, it could indicate one or more beams are not firmly seated. Prior to sealing, the Contractor shall check for beam wobble and shim any beams not firmly seated.
f.Construction Inserts. All inserts, including those necessary for the fabrication and construction of the structure or portions thereof shall be cast into the member according to Article 3.5.2 of the Manual for Fabrication of Precast Prestressed Concrete Products.
g.Bond Breaker for Bulb T-Beams. After the bulb T-beams have been erected at the job site and just prior to installation of the bridge deck reinforcement, portions of the top surface of the beams identified on the plans shall have bond breaker applied. The concrete surface shall be clean and dry for a minimum of 2 hours, prior to application of the bond breaking material. The temperature of the concrete and air shall be 40°F (4°C) or higher at the time of application. For systems requiring multiple coats, the second coat may follow immediately after the first coat. The material shall not be exposed to rain, snow, or foot traffic for a minimum period of 4 hours after application. Art. 504.07 Steel Structures
504.07 Method of Measurement. This work will be measured for payment as
follows.
a.Contract Quantities. The requirements for the use of Contract Quantities shall conform to Article 202.07(a).
b.Measured Quantities. Precast concrete bridge slabs and precast, prestressed concrete deck beams will be measured by the square foot (square meter) of horizontal surface area of the individual slabs or beams, as shown on the plans. In determining the total number of square feet (square meters) to be paid for, the overall horizontal surface area of all the slabs or beams specified will be used. Precast, prestressed concrete I-beams, Bulb T-beams, or IL-beams will be measured by the foot (meter). In determining the total length of beams to be paid for, the specified overall length of the individual beams will be used. Precast concrete pile caps will be measured for payment in place as each precast concrete cap.
504.08 Basis of Payment. This work will be paid for at the contract unit price
per square foot (square meter) for PRECAST CONCRETE BRIDGE SLAB and PRECAST, PRESTRESSED CONCRETE DECK BEAMS, of the depth specified, or per foot (meter) for FURNISHING AND ERECTING PRECAST PRESTRESSED CONCRETE BEAMS, of the type and depth specified. Precast concrete pile caps will be paid for at the contract unit price per each for PRECAST CONCRETE CAPS. SECTION 505. STEEL STRUCTURES
505.01 Description. This work shall consist of furnishing, erecting, and
painting steel structures or portions thereof.
505.02 Materials. Materials shall be according to the following.
Item Article/Section
a.Structural Steel .................................................................................. 1006.04
b.Turned and Ribbed Bolts ................................................................... 1006.07
c.High-Strength Steel Bolts, Nuts and Washers ............................... 1006.08(a)
d.Anchor Bolts and Rods ....................................................................... 1006.09
e.Steel Forgings .................................................................................... 1006.12
f.Gray Iron Castings ............................................................................. 1006.14
g.Malleable Castings ............................................................................ 1006.16
h.Paint Materials and Mixed Paints ........................................ 1008.01, 1008.02
i.Stud Shear Connectors ..................................................................... 1006.32 Materials for structures that will carry railroad traffic shall satisfy AREMA Specifications.
Referenced in this section
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Source: Illinois Standard Specifications for Road and Bridge Construction, 2022 Edition. Pages 346–351 of 1,217. View official source ↗