714.01Description
This work shall consist of the construction of a cast-in-place or precast reinforced concrete box structure and such parts of similar structures composed of concrete in accordance with these specifications and 105.03.
The Contractor may be allowed to substitute a three-sided structure in accordance with 723 which shall be subject to a revision of the waterway permits, and shall be as approved by the Engineer. 10
MATERIALS
714.02Materials
Materials shall be in a ccordance with the following:
Chemical Anchor System ............................................ 901.05 Coarse Aggregates, Class A or Higher, Size No. 91 ... 904.03 Epoxy Coated Rein forcing Bars .................................. 910.01 20 Geotextile .................................................................... 918.02(b) Hydrated Lime ............................................................. 913.04(a) Joint Membrane for Pr ecast Reinforced Concrete Box and Three-Sided Structure Sections .............. 907.07 Masonry Ceme nt ......................................................... 901.01(c) Mortar Sand ................................................................. 904.02(e) Natural Sand ................................................................ 904.02(a) Non-Epoxy PCC Sealer ............................................... 909.10 Pipe Joint Sealant ........................................................ 907.11 30 Portland Ceme nt .......................................................... 901.01(b) Precast Reinforced Concrete Headwalls, Wingwalls, Footings, and Sp andrel Walls ............................... 907.06 714.02
Precast Reinforced Concrete Structure Sections ......... 907.05 Reinforci ng Bars .......................................................... 910.01 Structure Backfill ........................................................ 904.05 WWR, Smooth and Deformed..................................... 910.01
Cast-in-place concrete for a reinforced co ncrete box structure, or splices between 40 an existing culvert structure and a precast reinforced concrete box structure section extension shall be class A or higher in acco rdance with 707.04(c). It shall have a 28- day minimum concrete compre ssive strength of 5,000 psi. Cast-in-place concrete for headwalls or wingwalls shall be class A or higher in accordance with 707.04(c). It shall have a 28-day minimum concrete compressive strength of 4,000 psi.
When the Contractor elects to provide a cast-in-place structure, acceptance of the structure will be based on tests for relative yield, air content, slump, water/cementitious ratio, and compressive strength. Relative yield and air content shall be in accordance with 702.05. The slump and concrete temperature shall be in 50 accordance with 707.04(c). The amount of time from the introduction of mixing water to the cement and aggregates to the completion of the discharge of the concrete shall not exceed 90 minutes. The water/cementitious ratio shall be in accordance with
707.04(d). The 28-day compressive strength shall be equal to or greater than the
specified concrete compressive strength an d shall otherwise be in accordance with
(c)3. The Contractor shall provide the necessary 6 in. diameter by 12 in
cylinder molds for the Department’s use.
For plastic concrete sampling, acceptance testing procedures and casting cylinders will be in accordance with 505.01. Except for footings, concrete flexural strength or 60 results from beam breaks will not be accepted in lieu of concrete compression cylinder test results.
Cast-in-place concrete used to seal existi ng culverts shall be class A. Cast-in-place concrete for footings shall be class B.
Unless otherwise specified herein, reinforcement may consist of either reinforcing bars or WWR. If specified to be coated, WW R shall be coated with either galvanized coating or epoxy coating. Reinforcing bars shall be coated with epoxy coating. For WWR, material with minimum yield strength of 65 ksi shall be used. 70
CONSTRUCTION REQUIREMENTS
714.03General Requirements
Unless otherwise specified, the applicable requirements of 702 and 703 shall apply to the construction of box structures, structure extensions, and concrete parts of similar structures. Excavation and disposal shall be in accordance with the applicable requirements of 206. Areas designated for waterproofing shall be waterproofed in accordance with 702.23. All underground dr ains encountered during excavation for 714.03
the structure shall be perpetuated as dictated by field conditions. Drainage openings 80 through masonry shall be in accordance with 702.16. Handling of box structures shall be in accordance with 907.05. Handling of wingwalls shall be in accordance with
907.06
When riprap is specified, geotextile shall first be placed on the in-situ soil in accordance with 616.11. Riprap shall then be placed in accordance with 616.
The box structure, headwalls, wingwalls, and footings shall be designed and constructed in accordance with the dimensions shown on the contract plans. Construction joints shall not be used within the cross-section of precast box structures. 90
714.04Design Requirements
Where reinforcing bars are used, reinforcing bar splicing and spacing shall be in accordance with the AASHTO LRFD Bridge Design Specifications, except as modified herein.
A box structure may be designed in accordance with ASTM C1577 if the box section is listed therein. A box structure section not listed therein shall be designed in accordance with the AASHTO LRFD Bridge Design Specifications with the following 100 exceptions.
The box structure shall be designed in accordance with the soil parameters shown in the contract documents.
Minimum structural reinforcement area shall be at least 0.002 of the gross concrete area, A g, or 0.125 sq in./ft, whichever is greater. The allowable variation in diameter of reinforcement shall be in accordance with the tolerances prescribed in the AASHTO specification for that type of reinforcement.
If coated reinforcement is specified, reinforcement, including support devices, in that structure shall be coated. In lieu of coating, the support devices may be manufactured of a non-corrosive material.
Headwalls, wingwalls, and footings may be precast or cast-in-place. Headwalls and wingwalls shall be designed based on a minimum equivalent fluid pressure of 40 lb/cu ft. If flowable backfill is to be us ed, the Contractor shall consider the effects of hydrostatic pressure on the wingwalls. Weep holes shall be provided in all wingwalls. Horizontal pressures shall be increased for sloping backfill surfaces and 120 live-load surcharge. Headwall connections and wingwall footings shall be checked for sliding and for overturning.
Wingwalls and wingwall footings shall be designed in accordance with the soil parameters shown in the contract documents. 714.04
For headwalls with guardrail mounted on top, the anchorage of the headwall to the box structure section, or a moment slab with bridge railing shall be designed for the bridge railing test level shown on the plans.
Reinforcement in headwalls shall consist of reinforcing bars and shall be epoxy coated. Tension splices in circumferential reinforcement shall be made by lapping. Where reinforcing bars are used in wi ngwalls, the maximum spacing for wingwall reinforcing bars shall be 18 in. for horizontal bars and 12 in. for vertical bars.
Concrete cover for headwall and wingwall reinforcement shall be a minimum of 2 in. Concrete cover for footing reinforcement shall be 3 in. for the top and sides, and 4 in. for the bottom.
Working drawings shall be submitted in accordance with 105.02 for:
greater than 12 ft span,
Design calculations shall be submitted with the working drawings. Design 150 calculations will not be required for box structures of a size shown in Table 1 of ASTM C1577. Detailed plans for falsework and centering will not be required. Working drawings shall include notes indicating design assumptions, applicable design codes, and material requirements, all details, dimensions, and quantities necessary to construct the structure, headwalls, wingwalls, or footings and shall include, but not be limited to, the following information.
details, locations and details of lifting devices or inserts, locations and details of pre- or post-installed anchorages, concrete clear cover, size and spacing of reinforcing bars or WWR, and reinforcing bar bending diagrams.
reinforcing bar sizes, reinforcing bar bending diagrams, lengths, spacings, and anchorage details. Headwall elevation and section views shall be provided.
dimensions, elevations, reinforcement sizes, bending diagrams, 714.04
lengths, spacings, and anchorage details. Wingwall plan, elevation, and section views shall be provided.
reinforcing bar sizes, reinforcing bar bending diagrams, lengths, and spacings indicated. Footing plan and section views 180 shall be provided. The actual soil bearing pressure shall be shown on the footing detail sheets.
wingwalls.
structure.
be submitted with the working drawings where the structure span length measured along the roadway centerline is greater than 20 ft, except where the height of cover is greater than 8 ft and exceeds the perpendicular span length. The structure shall have a load rating greater than 1.0 for the loading described herein or as shown on plans. The load rating methodology shall be in accordance with the AASHTO Manual of Bridge Evaluation using the LRFR methodology.
714.05Erection Requirements 200
The soils in the bottom of the excavati on shall be compacted in accordance with
203.23
An 8 in. layer of coarse aggregate No. 8 in accordance with 301 shall be placed under the full width of the footing. All cast- in-place footings shall be given a smooth float finish. The footing concrete shall r each a compressive strength of 2,000 psi or flexural strength in accordance with 702.24(c) before placement of the wingwalls. The surface shall not vary more than 1/4 in. in 10 ft if tested with a 10 ft straightedge.
Structure backfill shall be placed a nd compacted in accordance with 211. 210 Structure backfill shall be placed and compacted on each side of the structure to the fill line shown on the plans. During the backfill operation, the difference in elevations of the fill on each side of the structure shall not exceed 24 in.
Unless otherwise specified by the manufacturer on the working drawings, once the level of structure backfill reaches the top of the structure, two lifts shall be spread and hand compacted over the structure without traversing the structure with heavy
714.05
728
equipment. Compaction with heavy equipment will not be allowed until a minimum
of two lifts have been placed, hand compacted, and accepted.
220
The operation of equipment over a structure shall be in accordance with the
structure manufacturer’s recommendations.
714.06Precast Concrete Headwalls, Wingwalls, and Footings
The headwall shall be a single precast piece which spans from sidewall to sidewall
of a span. The vertical headwall reinforcement shall be attached to the top of the
structure by either drilling holes or precasting holes. A chemical anchoring material,
if used, shall be from the QPL of Chemical Anchor Systems.230
Each wingwall that is not precast as one unit with the footing shall be set on
masonite or steel shims. A minimum gap of 1/2 in. shall be provided between the
footing and the bottom of each wingwall. Once the wingwalls are placed, the space
underneath the wingwall section to the top of the keyway sides shall be filled with
prepackaged grout in accordance with ASTM C1107, or conventional or self-
consolidating fine grout in accordance with ASTM C476, except as modified herein.
If conventional fine grout is used, it shall be troweled into the keyway and mounded
on one side of the wingwall. The mound of conventional fine grout shall be vibrated240
until it passes through to the other side of the wingwall. After completing this process
on one side, if the conventional fine grout has not passed through to the other side, the
process shall be repeated on the other side. Conventional or self-consolidating fine
grout shall be from a prepackaged source or composed of one of the following
mixtures.
sand or mortar sand.
sand or mortar sand.
hydrated lime with No. 23 natural sand or mortar sand.
The maximum water/cement ratio shall be 0.446 for both conventional and self-
consolidating fine grout. An air-entraining agent from the QPL of PCC Admixtures
and Admixture Systems may be used. A Type F or Type G chemical admixture from
the QPL of PCC Admixtures and Admixture Systems shall be used in self-
consolidating fine grout to achieve the slump flow and visual stability index260
requirements. Filling procedure B of ASTM C1611 will be used for measuring slump
flow. Appendix X1 of ASTM C1611 will be used for determining the visual stability
index value.
714.06
729
Acceptance of conventional fine grout will be based on an air content of 12%
±4%. Acceptance of self-consolidating fine grout will be based on tests for air content,
slump flow, and visual stability index. Air content shall be 12% ±4%. Slump flow
shall be 27 in. ±3 in. Visual stability index value shall not exceed 1.
A Type C certification in accordance with 916 shall be provided for the270
prepackaged grout.
Wingwalls shall be connected to the outside box structure sections with bolted
steel plates.
714.07Rejection
Structure sections, headwalls, wingwalls, or footings will be rejected due to the
following conditions:
single end crack which does not exceed one-half the thickness of the
section or wall,
not in accordance with this specification,
satisfactory joint.290
714.08Repairs
Structure sections, headwalls, wingwalls, and footings shall be repaired, if
necessary, due to imperfections in manufacture, or damage caused by handling or
construction. Repairs will be acceptable if it is determined that the repairs are sound,
properly finished and cured, and if the repaired structure section, headwall, wingwall,
or footing is in accordance with the requirements herein.
714.09Extension of Existing Structure
All applicable requirements of this specification shall apply to the extension of an300
existing box structure, slab-top structure, or arch structure. Such portions of the
existing structure designated for removal shall be removed. All portions of the existing
structure which are to remain in place and are damaged shall be repaired or replaced
as directed. Those portions left in place which are wholly or partially filled with debris
shall be cleaned out. Material removed shall be disposed of in accordance with the
applicable requirements of 202.02.
Before removing concrete from an existing structure with wingwalls, the
Contractor shall saw around the perimeter of the removal area on the interior and
714.09
730
exterior of the existing structure a depth of 1 in. All existing reinforcement in the top310
slab, bottom slab, and sidewalls exposed after concrete removal shall be cleaned and
straightened in preparation for lapping with reinforcement from adjacent new work.
Where existing reinforcement has deteriorated or been damaged during the removal
operation, holes shall be drilled into the face of the existing structure to provide
embedment for replacement reinforcing bars. The holes shall be of the diameter and
depth required by the manufacturer of the chemical anchor system. The holes shall be
cleaned prior to placing the chemical anchor system and the reinforcing bars.
No concrete shall be removed from an existing structure that has a headwall but
no wingwalls. Reinforcing bars used to tie the existing structure to the new structure320
section shall be installed by drilling holes into the face of the existing structure to
provide embedment for reinforcing bars. The diameter and depth of the holes shall be
according to the recommendations of the manufacturer of the chemical anchor system.
The holes shall be cleaned prior to placing the chemical anchor system and the
reinforcing bars.
An existing structure shall be extended by one of the following methods.
A cast-in-place concrete splice shall be constructed as a transition between the330
existing structure and the precast structure extension. The splice reinforcement in the
precast structure extension section that will abut the existing structure shall be exposed
18 in. on the tongue end of the precast structure extension section. It shall be lapped
18 in. with either exposed existing structure reinforcement, in the case of an existing
structure with wingwalls, or newly installed reinforcing bars in the existing structure,
in the case of an existing structure with a headwall only as shown on the plans. Existing
exposed structure reinforcement from an existing structure with wingwalls shall be cut
off 1 in. from the face of the new precast extension.
If the existing tongue or groove joint end is acceptable and matches the mating340
joint on the new precast reinforced concrete box structure extension, the new extension
may be installed using the mating joint of the existing box structure. No cutting of the
box structure or splicing of reinforcement is then required. The joint between the new
precast box structure extension and the existing structure shall be sealed as directed
below.
The reinforcement for the structure extension shall be lapped with the exposed
reinforcement of the existing structure as shown on the plans.
350
714.10Precast Reinforced-Concrete Box Structure Section Joints
Joints between precast reinforced concrete box structure sections shall be sealed
with pipe joint sealant as shown on the plans. The sealant shall be applied once the
714.10
731
concrete surface temperature is above 40°F or above the minimum application
temperature recommended by the pipe joint sealant manufacturer. The concrete
surfaces shall be clean and dry prior to application of the pipe joint sealant. Heat may
be applied to the concrete surfaces until they are in accordance with the temperature
and dryness requirements.360
After sealing with pipe joint sealant and assembling the box sections, the outside
surfaces of the top slab and both walls of every joint between structure sections shall
be covered with a joint membrane in accordance with 907.07 that is centered on the
joint. The exterior concrete box surface shall be clean and dry before the joint
membrane is applied. The outside surfaces of the top slab and both walls of every joint
shall be completely covered for the entire length of each joint. Where joining two
sections of joint membrane material, or where two ends meet, a 3 in. overlap shall be
provided. The overlapping strip shall be firmly pressed onto the end of the underlying370
strip to seal the joint. Joints between structure sections and wingwalls, between
wingwalls and spandrel walls, and between structure sections and headwalls or
spandrel walls shall also be covered with joint membrane. The manufacturer’s
application instructions shall apply in addition to the above requirements.
The joint membrane shall be maintained in its installed location centered on the
joint and shall not be damaged or dislodged during the backfilling operation.
714.11Method of Measurement
Precast reinforced concrete box structures or structure extensions, precast coated380
reinforced concrete box structures or structure extensions, precast headwalls, precast
wingwalls, cast-in-place reinforced concrete box structures or structure extensions,
cast-in-place coated reinforced concrete box structures or structure extensions, cast-
in-place headwalls, and cast-in-place wingwalls will not be measured. The accepted
quantities for payment will be the quantities shown on the plans.
Geotextile and riprap will be measured in accordance with 616.12. Structure
backfill will be measured in accordance with 211.09. Flowable backfill will be
measured in accordance with 213.08. Field drilled holes will be measured in
accordance with 702.27.390
Plain or coated reinforcement or WWR used in precast reinforced concrete box
structures or structure extensions, precast headwalls, precast wingwalls, cast-in-place
reinforced concrete box structures or structure extensions, cast-in-place headwalls, or
cast-in-place wingwalls will not be measured for payment.
If the Contractor elects to provide a three-sided structure in lieu of the box
structure shown on the plans, it will be measured in accordance with 723.17.
Additional geotextile and riprap placed within the limits of the three-sided box
structure will not be measured for payment.400
714.11
732
Additional excavation required for a culvert when the culvert is placed at an
elevation more than 1 ft below the elevation shown on the plans will be measured to
include the entire width needed to comply with OSHA or IOSHA requirements.
714.12Basis of Payment
The accepted quantities of precast reinforced concrete box structures or structure
extensions, precast coated reinforced concrete box structures or structure extensions,
cast-in-place reinforced concrete box structures or structure extensions, and cast-in-
place coated reinforced concrete box structures or structure extensions of the size410
specified will be paid for at the contract unit price per linear foot.
Geotextile or riprap will be paid for in accordance with 616.13. Structure backfill
will be paid for in accordance with 211.10. Flowable backfill will be paid for in
accordance with 213.09. Field drilled holes will be paid for in accordance with 702.28.
If the Contractor elects to provide a three-sided structure in lieu of the box
structure shown on the plans, the Department will not incur additional cost for
allowing the Contractor to substitute a three-sided structure for the box structure
shown on the plans.420
Payment will be made under:
Pay Item Pay Unit Symbol
Structure Extension, Coated Reinforced Concrete,
Box Sections, ____ ft x ____ ft .......................................... LFT
span rise
Structure Extension, Reinforced Concrete,
Box Sections, ____ ft x ____ ft .......................................... LFT430
span rise
Structure, Coated Reinforced Concrete,
Box Sections, ____ ft x ____ ft .......................................... LFT
span rise
Structure, Reinforced Concrete,
Box Sections, ____ ft x ____ ft .......................................... LFT
span rise
The cost of excavation except as provided in 206.11(a), expansion joint material,
perpetuation of existing drains shown on the plans, removal of portions of existing440
structures, cleaning out old channels or structures, chemical anchor system, precast
reinforced concrete structure joints, pipe joint sealant, joint membrane, and necessary
incidentals shall be included in the cost of the structure or structure extension.
The cost of precast concrete headwalls, precast concrete wingwalls, cast-in-place
headwalls, or cast-in-place wingwalls shall be included in the cost of the structure or
structure extension.
714.12
733
The cost of plain or coated reinforcement or WWR used in precast reinforced
concrete box structures or structure extensions, precast headwalls, precast wingwalls,450
cast-in-place reinforced concrete box structures or structure extensions, cast-in-place
headwalls, or cast-in-place wingwalls shall be included in the cost of the structure or
structure extension.
The cost of concrete used in a cast-in-place splice shall be included in the cost of
the structure extension.
The cost of designing a box structure, box structure extension, headwalls, and
wingwalls shall be included in the cost of the structure or structure extension.
460
The costs of coring, testing, excavation, repairs, plugging core and handling holes,
mortar, grout, sealer, cylinder molds, and necessary incidentals shall be included in
the cost of the structure. The cost of wingwall footing and the aggregate base shall be
included in the cost of the structure or structure extension.
No additional payment will be made for carrying an underground drain through a
structure or structure extension. However, no deduction will be made for the volume
of concrete occupied by the drain pipe in a cast-in-place structure or structure
extension.
470
No additional payment will be made for the repair or replacement of existing
concrete damaged by Contractor operations.
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