534.17Finishing Concrete Products shall be finished to meet t he ordinary finish

534.17 Finishing Concrete Products shall be finished to meet t he ordinary finish

requirements of Standard Specification Section 502. Units, or portions of units, that will be exposed to view in their final location shall receive a rubbed finish, per Section 502. The Contractor may use alternative methods of achieving an acceptab le finish on exposed units if approved by the Fabrication Engineer. Marking: The date of manufact ure, the production lot number, and the type of unit shall be clearly and indelibly scribed on a rear, unexposed por tion of each unit.

534.18 Repairing Defects Defects requiring repair will be cons idered either non-

structural or structural. Non-Structural Defects: Exposed surfaces shall be of uniform a ppearance; only minor repairs to remove and blend fins, patch minor spalls and to rep air small, entrapped air pockets, shall be permitted. Repair honeycombing, ragged or ir regular edges and other non- structural or cosmetic defects using a patching material from t he Department Qualified Products List (QPL). The repai r, including preparation of the repair area, mixing and application and curing of the patching material, shall be in ac cordance with the manufacturer's product data sheet. Corners not exposed in the final product may be ground smooth with no further repair n ecessary, if the depth of the de fect does not exceed one-half inch. Remove form ties and other hardware to a depth of not le ss than one inch from the face of the concrete and patch the holes using a patching mater ial from the Department QPL. Structural Defects: Repair stru ctural defects only with the ap proval of the Fabrication Engineer. Submit a nonconformance report (NCR) to the Fabricat ion Engineer with a proposed repair procedure. Do not perform structural repairs w ithout an NCR that has been reviewed by the Fabrication Engineer. Structural defects inclu de, but are not be limited to, exposed reinforcing steel, cracks in bearing areas, through cra cks and cracks 0.013 inch in width that extend more than 12 inches in length in any directio n. Give the QAI adequate notice prior to beginning any structural repairs.

534.19 Handling, Storage and Transportation Handle, store and transport units in a

manner as to eliminate the danger of chipping, cracks, fracture , and excessive bending stresses. Any units found damaged upon delivery, or damaged af ter delivery, shall be subject to rejection. 5-164 Do not place precast units in an upright position until a compr essive strength of at least 4,000 psi is attained. Precast units may be handled and moved, but not transported, until the 28 day design strength has been attained. Support stored precast units above the ground on dunnage in a m anner to prevent twisting or distortion. Protect the units from discoloration a nd damage. Set precast units on one-half inch thick neoprene pads during s hipment to prevent damage to the unit legs. The Contractor shall repair any damage to precast units resulting from shipping or handling; this shall be accomplished by saw cu tting a minimum of one-half inch deep around the perimeter of the damaged area, removing an y loose concrete out to the saw cut perimeter and installing a polymer-modified cementitiou s patching material, from the Department’s QPL, per the manufacturer’s product data sheet .

534.20 Installation of Precast Units When footings are require d, install the precast units

on concrete footings that have reached a minimum compressive st rength of 3,000 psi. Construct the completed footing surface to the lines and grades shown on the Plans. When checked with a 10 foot straightedge, the surface shall not vary more than one-quarter inch in 10 feet. The footing keyway shall be filled with a Department- approved non-shrink flowable cementitious grout with a minimum design compressive s trength of 5,000 psi at 28 days, unless otherwise specified in the Contract. Three sided frame and box culvert joints shall be sealed with a Department-approved flexible joint sealant in accordance with ASTM C990. Joints sha ll be closed tight. Culvert units shall be equipped with joint closure mechanisms to draw u nits together and close joints to the required opening. Completely fill the exterior face of joints between precast uni ts with a material from the Department QPL and cover with a minimum 12 inch wide joint wrap . Additionally, for box culverts and three sided frames, cover the entire top surface w ith waterproofing membrane; waterproofing membrane shall extend one foot from the top down the sides of the units. The surfaces shall be free of dirt and deleterious materials before applying the filler material and joint wrap. Install the external wrap in one continuous piece over each unit joint, taking care to keep the joint wrap in place during backfilling. Seal the back of joints between the end unit and attached eleme nts with a non-woven geotextile. Install and tighten the bolts fastening the connect ion plate(s) between the elements that are designed to be fastened together as designate d by the manufacturer. Fill holes that were cast in the units for handling with either Portland cement mortar or with precast plugs secured with Portland cement mortar or other approved adhesive. Place and compact the bedding material as shown on the Plans pr ior to lifting and setting the culvert units. Backfilling of the structure shall be done in accordance with the manufacturer’s instructions and the Contract Documents. Unifor mly distribute backfill material in layers of not more than 8 inches in depth, loose me asure, and thoroughly 5-165 compact each layer using approved compactors before successive layers are placed. Compact the Granular Borrow bedding and backfill in accordance with Section 203.12, Construction of Earth Embankment with Moisture and Density Cont rol, except that the minimum required compaction shall be 92 percent of maximum dens ity, as determined by AASHTO T-180, Method C or D. Place and compact the backfill wi thout disturbance or displacement of the structure, keeping the fill at approximatel y the same elevation on both sides of the structure. Whenever a compaction test fails, the Contractor shall not place additional backfill over the ar ea until the lift is re-compacte d and a passing test achieved. Use hand-operated compactors within five feet of the precast st ructure as well as over the top until it is covered with at least 12 inches of backfill . Take appropriate precautions to protect the top of the culvert from damage during backfilling a nd/or paving operations. Any damage to the top of the precast structure shall be repaired, o r units replaced, at no cost to the Department.

534.21 Method of Measurement Precast Structural Concrete Arche s, including three-

sided frames, and Precast Concrete Box Culverts will be measure d as one lump sum, complete, in place and accepted.

534.22 Basis of Payment The accepted Precast Structural Concre te Arches, including

three-sided frames, or Precast Concrete Box Culverts will be pa id for at the respective Contract lump sum price. The lump sum price shall include asso ciated wingwalls, headwalls, toe walls, cut-off walls and appurtenances, and shal l be full compensation for all labor, equipment, materials, professional services, and inciden tals necessary for designing, manufacturing, furnishing and installing the precast concrete e lements and accessories. Falsework, reinforcing steel, wel ded steel wire fabric, joint w rap, geotextile, repair material, grout, cast-in-place concrete fill or grout fill for anchorage of precast wings and/or other appurtenances will not be measured and paid for separately, but will be incidental to the lump sum pay item. Cast-in-place concrete, reinforcing steel i n cast-in-place elements and waterproofing membrane will be measured and paid for separately , under the provided Contract Pay Items. Pay adjustments for quality level will not be made for precast concrete. Excavation for precast structural concrete structures, includin g excavation below culverts for bedding and backfilling, will be measured and paid for as provide in Section 206, Structural Excavation. When the minimum cover material extends above the subgrade line , the removal of the cover material necessary to complete the work will not be paid for directly, but shall be considered incidental to the precast structural concrete lump s um pay item. Payment will be made under: P a y I t e m P a y U n i t

534.70 Precast Structural Concrete Arch L u m p S u m

534.71 Precast Concrete Box Culvert Lump Sum

5-166 SECTION 535 - PRECAST, PRESTRESSED CONCRETE SUPERSTRUCTURE

535.01 Description This work shall consist of casting and erec ting precast/prestressed

concrete products and related material. Materials, work, inspe ction and documentation not specifically addressed by this Specification shall be done in a ccordance with the applicable sections of the Precast/Prestressed Concrete Institute (PCI) , Manual for Quality Control for Plants and Production of Structural Precast Concrete Products (MNL 116), including Commentary. ALL REQUIREMENTS IN THIS SPECIFICATION ARE THE RESPONSIBILITY O F THE CONTRACTOR, UNLESS NOTED OTHERWISE.

535.02 Materials Materials for precast/prestressed concrete pro ducts shall meet the

requirements of the following Subsections of the Standard Speci fications: Portland Cement and Portland Pozzolan Cement 701.01 W a t e r 701.02 Air-Entraining Admixtures 701.03 Water Reducing Admixtures 701.04 High Range, Water Reducing, Admixture (HRWR) 701.0401 Set-Retarding Admixtures 701.05 F l y A s h 701.10 C a l c i u m N i t r i t e S o l u t i o n 701.11 S i l i c a F u m e 701.12 Ground Granulated Blast Furnace Slag 701.13 F i n e A g g r e g a t e f o r C o n c r e t e 703.01 C o a r s e A g g r e g a t e f o r C o n c r e t e ( C l a s s A , A A o r L a t e x ) 703.02 Reinforcing Steel 709.01 W e l d e d S t e e l W i r e F a b r i c 709.02 S t e e l S t r a n d 709.03 Portland cement shall conform to AASHTO M85 (ASTM C150), Type I , Type II, or Type III or AASHTO M 240. Supply the Department with copies of Certified Mill Test Reports for the cement. Provide a Materials Certification from the manufacturer of the prestressing strand. The certification shall include a representative load elongation cu rve for each coil. The manufacturer shall identify each coil of strand. Do not remove the identification from the coil. Partial coils may be used with the approval of the Fabri cation Engineer. Failure to maintain traceability of a coil will be cause for rejection. P rovide Certified Mill Test Reports for the reinforcing st eel, welded wire fabric and fusio n bonded epoxy coating.