518Pre-Stressed Concrete Members

518.1 Description

This Work consists of manufactu ring and erecting pre-stressed c oncrete Bridge piles, girders, or other pre-stressed concrete Bridge members.

518.1.1 Pre-Tensioning

Pre-tensioning is tensioning in w hich the pre-stressing reinfor cement is stressed before the Contractor places the concrete. After the concrete attains the required strength, the Contractor releases the pre-stressing force from the external a nchorages and transfers that force, by bond, into the concrete. 518.2 MATERIALS

518.2.1 Portland Cement Concrete

The Contractor shall provide an approved State Materials Bureau c o n c r e t e m i x i n accordance with the requirements for Special Concrete, as defin ed in Section 509, “Portland Cement Concrete Mix Designs,” and specified compressive strengt h in accordance with the Contract.

518.2.1 1 Fly Ash

The Contractor shall provide PCC that contains fly ash in accor dance with Section 509, “Portland Cement Concre te Mix Designs.”

518.2.1 2 Coarse Aggregate

The Contractor shall provide coarse aggregate that consists of Material no larger than one-third (1/3) the size of the smallest clear space into which the Contractor shall place this concrete.

518.2.1 3 Design and Acceptability Requirements

For pre-stressed concrete members, the Contractor shall provide the concrete mix design in accordance with Table 509.2.8.1:1, “Concrete Classes for Lab oratory Design of Concrete Mixtures.” The Contractor shall obtain the State Materials Bureau's approv al of the concrete mix designs before casting. Once t he State Materials Bureau approv es a concrete mix design, the Contractor may only make subsequent changes in the mix proporti ons in accordance with Section 509.2.8, “PCC Mixture Design and Approval.” The Contractor shall enter the actual batch weights used in eac h batch of concrete and the measured moisture contents for each of the aggregates conta ined within each batch into the Field Report Form provided to the Contractor/Supplier at th e same time the approved mix was provided. Insure that all test results for compressive str ength and fresh concrete properties, including slump, air content and unit weight, are a lso entered into the Field Report.

518.2.1 4 Testing Requirements for Release Strength

The Contractor shall use the Maturity Method as required in Sec tion 510.3.5.2, “Portland Cement Concrete” or make additional field cured cylinders for i n-place strength tests (to Section 518: Pre-Stressed Concrete Members Page 400 determine application of pre-str essing forces). The Contractor shall make at least four (4) field cured cylinders from concrete placed on each casting bed. The test results shall confirm the compliance with the release strength requirement shown in the Plans.

518.2.1 5 Acceptance Requirements

Compressive strength test shall confirm compliance with Section 510, “Portland Cement Concrete.” A test is defined as the average of two (2) or more cylinders from the same sample broken at the same age. The Contractor shall make and cure at least two (2) cylinders per girder or pile from concrete pla ced in each member and in accor dance with AASHTO T 23. The Contractor shall break at least two (2) cylinders per gird er or pile as selected by the Department’s Inspector. The Contractor shall ensure the compressive strength is in acco rdance with the required 28-Day compressive strength. The Department will not Accept gi rders or piles with test results less than 90% of the 28-Day requ ired strength. Girders or pile s greater than 90% and less than 100% of the 28-Day required strength will be evaluated by the State Bridge Engineer for possible Acceptance. Girders or piles will not be sh ipped until the required ultimat e compressive strength is confirmed by Maturity Method or compressive strength tests.

518.2.2 Steel Products

518.2.2 1 Reinforcing Steel

The Contractor shall provide st eel reinforcement in accordance with Section 540, “Steel Reinforcement.” Reinforcing bars that project from the tops of girder and those within four (4) ft of girder ends shall be uncoated deformed low-carbon, chromium, steel bar s conforming to ASTM A1035 or uncoated deformed stainless steel bars conforming to A STM A955.

518.2.2 2 Pre-Stressing Reinforcement

Pre-stressing reinforcement consists of high strength steel wir e, high strength seven (7) wire steel strands, or uncoated high strength steel bars, in ac cordance with the Contract or as approved by the State Bridge Engineer. The Contractor shall provide pre-stressing reinforcement that i s uncoated, clean, and free of dirt, loose rust, oil, grease , or other Deleterious Material when placed in the member.

518.2.2 2.1 High-Strength Wire

The Contractor shall provide high-strength steel wire in accor dance with AASHTO M 204.

518.2.2 2.2 High-Strength Multiple-Wire Steel Strand

The Contractor shall provide high-strength multiple-wire steel strands in accordance with AASHTO M 203M, Supplement S1 (low -relaxation), unless otherwise specified.

518.2.2 2.3 Uncoated High-Strength Steel Bars

The Contractor shall provide uncoated high-strength steel bars in accordance with AASHTO M 275. If the Department allows bars with a greater min imum ultimate strength, the Contractor shall produce and test them in accordance with AASHT O M 275.

518.2.2 2.4 Identification of Pre-Stressing Reinforcement

The Contractor shall assign pre-stressing reinforcement and an chorage assemblies with a lot number and tag for identification purposes. The Departme nt will reject high-strength Materials lacking identification.

518.2.2 2.5 Sampling of Pre-Stressing Reinforcement

The Contractor shall provide samples for further testing if re quested by the Department’s Inspector. The Contractor shall provide certification with the samples th at states the samples were taken from and are representative of the lot numbers provided. The Contractor shall provide load elongation curves and mechan ical properties representative of the strands or bars to the Department’s Inspe ctor. The Contractor shall sample and test in accordance with AASHTO 203/M 203. If the Department requests, the Contractor shall provide the following : 1. Enough wire to make up one (1) parallel lay strand at least eight (8) ft long, consisting of the same number of wires required for the strand in which they are to be assembled. Cut wires requiring heading for anchoring to len gth and headed on both ends; 2. At least eight (8) ft of wire strand of each diameter, measu red between near ends of fittings. Provide the sample with fittings attached; 3. One completely fabricated pre-stressing tendon ten (10) ft l ong for each size tendon, including anchorage assemblies; 4. At least eight (8) ft of high-tensile strength bars of each diameter, measured between threads at ends of bars if furnished with threaded ends and nuts, or between anchorage devices; and 5. At least two (2) anchorage assemblies, complete with distrib ution plates of each size or type, unless such anchorage assemblies are attached to the s amples of pre- stressing reinforcement. The Contractor shall provide Mate rial samples for testing six ( 6) weeks in advance of the anticipated time for use, to allow testing.

518.2.2 2.6 Protection of Pre-Stressing Steel

The Contractor shall protect pre-stressing steel against physic al damage, rust or other results of corrosion, from manufacture to grouting. The Depart ment will reject pre-stressing steel that is physical damaged. The Contractor shall package pr e-stressing steel in containers or other shipping forms to protect the steel against phys ical damage and corrosion during shipping and storage. The Contractor shall place a corrosion inhibitor that prevents rust or other results of corrosion in the package or form, or apply directly to the steel if the Stat e Bridge Engineer allows. The Section 518: Pre-Stressed Concrete Members Page 402 Contractor shall ensure the corro sion inhibitor has no damaging effect on the steel or concrete, or bond strengt h of steel to concrete. The Contractor shall immediately replace or restore damaged pac kaging or forms. If using a corrosion-inhibiting carri er-type packaging Material, t he Contractor shall provide the Material in accordance with Military Specification MIL-P3420. The Contractor shall clearly mark the shipping package or form with the following: 1. A statement that the package contains high-strength pre-stre ssing steel; 2. The care in handling; 3. The type, kind, and amount of corrosion inhibitor used, incl uding the date placed or applied; 4. Safety orders; and 5. Instructions for use. If directed by the State Bridge Engineer or the Department’s P recast Inspector, the Contractor shall submit the following for the corrosion inhibit or: 1. A sample, a list of chemical s and their proportions, and ins truction for use; 2. Evidence that the pre-stressing steel will be protected from rust and other results of corrosion; and 3. A Certificate of Compliance. After the Contractor installs the pre-stressing, the Department will not allow the Contractor to weld or have ground welding Equipment on the form s or on the steel in the member.

518.2.2 3 Structural Steel

The Contractor shall provide Structural Steel items in accordan ce with Section 541, “Steel Structures.” The Contractor shall straighten steel shoe plates prior to cast ing them in girders.

518.2.2 4 Debonding and Camber Control Sleeves

Sleeves shall have such strength, durability, chemical resista nce, and other properties so that the sleeves will provide complete debonding between strand s and concrete as called for on the drawings. Debonding and cam ber control sleeves product information shall be submitted for approval by the State Bridge Engineer. 518.2.3 Mortar The Contractor shall provide non-shrink mortar used to grout ke yways in precast box girders in accordance with Section 521, “Non-Shrink Mortar” wit h the additional requirement that the non-shrink mortar shall be a commercial pre-blended pr oduct from the Department’s Approved Product List.

518.3 Construction Requirements

518.3.1 Precast Concrete Institute Certified Plant

All prestressed concrete structu ral members shall be manufactur ed in a plant certified by the Precast Concrete Institute (PCI). The manufacturer must ha ve a B4 Certification for Section 518: Pre-Stressed Concrete Members Page 403 Prestressed Deflected-Strand Br idge Member. Certifications mus t be maintained throughout the production of prestressed concrete structural members. Pro duction will immediately stop if at any time the manufacturer’s certification is revoked, regard less of the status of completion of contracted Work. Production will not be allowed to re-start until the necessary corrections are made and certification has been re-established. The Department will not be responsible for time, additional com pensation or other Project impacts due to lack of certification.

518.3.1 1 Approval of Plants and Equipment

The State Bridge Engineer or the Department’s Precast Inspector must approve plants and Equipment for manufacturing pre -stressed concrete members b efore the Contractor starts the pre-stressed concrete Work. The State Bridge Engineer or t he Department’s Precast Inspector may forbid unsatisfact ory machinery, Equipment, or ap purtenances.

518.3.2 Fabrication

518.3.2 1 Forms

The Contractor shall use forms that are smooth, mortar tight, a nd capable of withstanding the action of form vibrators. The Contractor shall accurately fabricate and secure the forms in position so that the cast member will present true, smooth, and even surfaces. The Contractor shall construct forms for interior cellular spac es with an approved Material that is watertight, resistant to breakage and deformation, and as lightweight as possible. The Contractor shall anchor interior forms to resist flotation or d isplacement during concrete placement. The design of interior and exterior forms shall not restrict the longitudinal movement of the member when the Contractor transfers the pre-st ressing force to the casting.

518.3.2 2 Placement of Reinforcing Bars and Appurtenances

The Contractor shall place and secure reinforcing bars, forms f or cored holes and cellular spaces with methods approved by the State Bridge Engineer. The Contractor shall pay particular attention to concrete cover requirements over reinfo rcing bars near and at ends of girders.

518.3.2 3 Tensioning

The Contractor shall apply tension to pre-stressing steel with hydraulic jacks to produce forces in accordance with th e approved Working Drawings. During strand stressing, the State Bridge Engineer or the Preca st Inspector may Accept individual wire failures, if no more than one (1) wire in any s trand is broken and the area of broken wires does not exceed two percent (2%) of the total area of the pre-stressing steel in the member. The Contractor shall stress the members in a sequence that prod uces a minimum of eccentric forces.

518.3.2 3.1 Tensioning Equipment

The Contractor shall apply stress to tendons using hydraulic ja cks that can provide and sustain the necessary forces and have either a pressure gauge o r a load cell for determining jacking stresses. If necessary, the Contractor shall use a pressure gauge with at least a six (6) inch diameter dial accompanied with a certified calibration chart. The Contractor shall calibrate each jack and its gauge as a unit with the cylinder extension i n the approximate position that it will be at final jacking force. If necessary, the Contractor shall calibrate a load cell and pr ovide it with an indicator to determine the pre-stressing force in the tendon. The Contracto r shall use a load cell range that does not include the lower ten percent (10%) of the Fabric ator's rated capacity to determine the jacking stress. The Contractor shall use a testing Laboratory approved by the S tate Bridge Engineer to calibrate the Equipment. The Contractor shall ensure that the Equipment has been calibrated within a year of the Work. The Precast Inspector may check cer tified calibration charts for the hydraulic jacks, pressure gages, or load cells used for tension ing pre-stressing steel before and during tensioning operations.

518.3.2 3.2 Measurement of Stress

The Contractor shall provide a record of gauge pressures and te ndon elongations for each tendon, for review and approval by the Department’s Precas t Inspector. The Contractor shall measure elongations to an accuracy of within 1/16 inch. The Contractor shall not cut off stressing tails of tendons until the Department's Precast Inspe ctor approves the stressing records. The Contractor shall use the gauge or load cell readings to det ermine the stress in the tendons during tensioning and verify with the measured elongati ons. The Contractor shall use the modul us of elasticity to calculate anticipated elongations of and base calculations for the nom inal area (provided by the Fab ricator per lot of tensioned steel), or as determined by a bench test of strands used in the Work. Before starting elongation readings, the Contractor shall tensi on the tendons to a preliminary force to eliminate take-up in the tensioning system . The Contractor shall ensure this preliminary force is between five (5) and 25% of the final jacking force. The Contractor shall measure the initial force with a dynamometer or with othe r approved methods. The Contractor shall mark each strand before the final stressing to permit measurement of elongation and to ensure that anchor wedges are set properly. The Contractor shall address a discrepancy in indicated stress between jack gauge pressure and elongation. If this occurs, the load used, as ind icated by the gauge pressure, will produce a slight overstress rather than understress. The Contr actor shall check the entire operation to determine the source of errors, if a discrepancy o ccurs between gauge pressure and elongation; more than five percent (5%) for tendons longer than 50 ft, or seven percent (7%) for tendons shorter than 50 ft. The Contractor shall corr ect errors before proceeding.

518.3.2 3.3 Tensioning Pre-tensioned Members

The Contractor may cast several members in a continuous line on the casting bed. Spools of pre-stressing strand are allowed two (2) splices with in the entire spool. The Contractor shall not use strands w ithin each pre-stressed concr ete member that have splices. The Contractor shall accurately locate and hold strands in posi tions in accordance with the Plans for each individual member. The Contractor shall mod ify the strand, if the State Section 518: Pre-Stressed Concrete Members Page 405 Bridge Engineer approves, to ensur e that the total pre-stressin g force and location of its center of application is not changed. The Contractor may anchor straight pre-tensioning strands at on e end of the casting bed and stress the other end with hydraulic jacks. The Contractor shall tension each individual strand to the required stress. The Contractor shall adopt a me thod for stressing draped strands that prevents significant stress loss between the jacki ng and anchor ends of the casting bed. If required to avoid significant stress loss, the Contractor shall stress draped strands from both ends of the casting bed. The Contractor shall stress or c heck pre-stressed strands for r equired stress within 24 h before placing concrete in the member. The Contractor shall not release or cut pre-tensioned strands u ntil cylinder tests indicate that the concrete in the member has reached the initial unit co mpressive strength. The Contractor shall remove side forms before releasing the strands . Strands may be flame cut to release stress. The Contractor shall release or cut the strand s in accordance with a previously approved sequence to avoid unbal anced forces in excess of that applied by one (1) strand. The Contractor shall trim strands in piles flush with the top a nd bottom of the piles.

518.3.2 4 Placement and Consolidation of Concrete

The Contractor shall place conc rete in accordance with Section 511, “Concrete Structures,” and Section 512, “Superstructure Concrete.” The Contractor shall not place concrete until the Precast Inspe ctor has inspected and approved the placement of the items to be embedded in the concr ete. The Contractor shall place and secure shoe plates on gi rders in the exact position i n accordance with the Plans. The Department will allow the pl acement of concrete in the bott om flange of precast box girders before placement of the interior form and reinforcing b ars in the upper portion of the members, if concrete placemen t is continuous for longer than 30 min. The Contractor shall use exter nal vibration for precast box gir ders or to eliminate internal honeycombing. The Contractor shall rigidly attach external vib rators to the forms in sufficient quantity so that the vibration extends throughout the entire le ngth of the member. The Contractor shall not use vibrating methods that cause segre gation. The Department may reject members with voids in piles or in the bottoms of gir ders and girders or over bearing points, or honeycombing sufficient to expose pre-stressing tend ons or reinforcement. The maximum allowable deviations from the dimensions and detail s shown in the Contract including camber and sweep will be the dimensional tol erances listed in the Manual for Quality Control for Plants and Production of Precast and Prestressed Concrete Products published by PCI, except as follows: 1. The tolerance on tipping and fl ushness of shoe plates within 1/16 inch. 2. The tolerance of steel diaphragms attachment holes shall be no greater than 1/16 inch.

518.3.2 5 Finishing Concrete Surfaces

The Contractor shall score top surfaces of girders transversely over the entire flange width to a minimum depth of 1/4 inch and a maximum of 3/8 inch. The Contractor shall clean the top surface of girders after initial set to remove laitance , dirt and debris and to provide a The Contractor shall finish the top surface of precast box gird ers and piles by over filling the forms, vibrating, and striking off with a metal plated stri ke board. On the final forward movement of the strike board, the Contractor shall carry excess mortar ahead to completely fill the form. After striking off the concrete, the Contractor shal l finish the surface to a true plane. The Contractor shall ensure that surface irregularities do not exceed 9/16 inch per ten (10) ft. Unless otherwise shown in the Contract, the Contractor shall gi ve the top surface of the precast box girders a final br oomed finish to produce transvers e corrugations. If the Contract requires the Contractor to embed the ends of pr e-stressed concrete girders in concrete diaphragms, the ends of the girders do not require hand finishing after removal of forms. If the Contract does not require the Contrac tor to extend strands for field or shop bending to provide continuity reinforcement, the Contracto r shall cut the strands three

518.3.2 6 Curing

The Contractor shall steam cure or water cure precast, pre-stre ssed members. The Contractor shall not use a curing temperature greater than 160 o F. The Contractor shall uniformly increase the temperature to the maximum temperature o ver a period not less than seven (7) hours. The Contractor shall additionally uniformly r educe the curing temperature such that at least seven (7) hours are required to reduce the t emperature of the curing environment. The Contractor shall perform steam curing in accordance with Se ction 517, “Precast Concrete Structures.” The Contractor shall perform water curing in accordance with Se ction 511, “Concrete Structures.”

518.3.2 7 Tolerances

The maximum allowable deviations from the dimension and details shown in the Contract are listed in the Manual for Quality Control for Plants and Production of Structural Precast Concrete Products , most current version, published by the PCI.

518.3.2 8 Lifting, Handling, Storing and Transporting Precast M embers

The Contractor shall not handle members until after applying th e pre-stressing force. The Contractor shall, at all times, keep webs of pre-stressed g irders vertical and keep the long axis approximately level. The Contractor shall keep the p oints of support and direction of reactions in accordance with approved Working Drawings. The Contractor shall limit the camber growth to a value not to exceed the predicted camber at erection dimension by t wo (2) inches at the time of d eck slab placement for pre- stressed girders greater than 54 inches in depth. Limit camber growth to one (1) inch for pre- stressed girder 54 inches or less. Camber growth is to be limi ted by methods such as weighting, fabrication schedulin g or other Acceptable means. T he Contractor shall submit Plan for review to the State Bridge Engineer prior to limiting camber growth. The Plan must be prepared by a Professional Engineer licensed in the State of Ne w Mexico. The Contractor shall lift girders for handling, transport and e rection by means of devices designed or recommended by the Fabricator and approved by the S tate Bridge Engineer prior to use. The Contractor shall not crack, spall, or otherwise damage memb ers during lifting, handling, hauling, storing, erecting, or transporting. The Con tractor shall replace members damaged by improper handling. The Contractor shall not transport members to the job site unti l the required ultimate compressive concrete strength is attained.

518.3.3 Bracing for Girders

The Contractor shall tie and brace the girders immediately afte r erection to prevent overturning. The Contractor sha ll leave ties and bracing in pl ace until the girders are permanently secured for lateral stability. If steel girder dia phragms are used, the Contractor shall install diaphragms during girder erection.

518.3.4 Grouting Keyways in Precast Box Girders

The keyways between adjacent precast box girders shall be grout ed per Section 521, “Non-Shrink Mortar.” The non-shrink mortar shall be commercial pre-blended non-shrink mortar that the Contractor only has to add water. The non-shri nk mortar shall be from the Department’s Approved Product List.

518.3.5 Quality Control and Quality Assurance

518.3.5 1 Working Drawings

The Contractor shall furnish Working Drawings in conformity wi th Subsection 105.2, “Plans and Working Draw ings” for all Pre-stressed Concrete Memb ers. The Working Drawings that are submitted to the NMDOT shall contain the endo rsement seal of a Professional Engineer licensed in the State of New Mexico and w ith five (5) years experience with prestressed concrete experience. NMDOT review of the Work ing Drawings does not relieve the Contractor of the responsibility for the adequacy o f the prestressed members. The Contractor shall submit supporting calculations for the Working Drawings. The Contractor shall allow 30 Days for review and Acceptance of Working Drawin gs and calculations. Any re-submittals will require an additional 14 Days for review. The Working Drawings shall include the following: 1. All unit dimensions. 2. Location, size, and type of prestressing strands. 3. Initial and final jacking forces. 4. Location, description, and detail of structural reinforcing items. 5. Location of all hold-down devices. 6. Location and shop drawings of all steel items. Shop drawing s shall be per AASHTO/NSBA G1.3, Shop Drawing Presentation Guidelines. 7. Details for steel diaphragm connections. 8. Blockout and keyway dimensions, if any. 9. Location and detail of debonded strands. Section 518: Pre-Stressed Concrete Members Page 408 10. Rebar schedule per ACI Detailing Manual SP-66. 11. Framing Plan with the Fabricators mark numbers. 12. Embeds for overhang brackets and permanent steel deck forms . 13. Stresses in the top and bottom of the pre-stressed concrete members during detensioning of the strands. 14. The predicted girder shortening, camber at release, and cam ber at 90 Days. 15. Detail Drawings, written procedures, and calculations for t he special design such as camber control using prestressing top strands. 16. Handling, storing and transportation details.

518.3.5 2 Notification of Fabrication for Pre-stressed Concrete Members

1. Start of Work. Prior to beginning the Work, the Contractor shall provide wri tten notice to the Quality Assurance (QA) Representative, as defined in Subsection

518.3.5 3, “Inspection of Pre-stressed Concrete Members” so tha t QA services may

be provided. The written notice s hall be received at least sev en (7) Days before fabrication begins. The anticipated production schedule, including the start of Wor k, phase Work and shipment dates shall be submitted in writing to the QA Represen tative before any Work begins. Fabrication shall not be started until the Workin g Drawings submittal have been returned with the NMDOT Engineer’s review stamp, indi cating Reviewed, no exception taken; or review ed, revise as noted and delivered to the Contractor’s site of fabrication. 2. Production Schedule Changes. Accelerated changes to the proposed production schedule, including start of Work, phase Work, and shipment dat es, shall require advance written notification be pr ovided to the QA Representati ve. The written notice of change shall be received at least 48 hours before fab rication begins, unless otherwise approved in writing by the QA Representative. 3. Notice of Shipment . The QA Representative shall be notified in writing, at least 72 hours before shipment of prestressed members to the job site. 4. Notification. Failure to notify the designated QA Representative as describ ed in this section may be cause for rejection.

518.3.5 3 Inspection of Pre-stressed Concrete Members

1. Quality Control and Quality Assurance . Quality Control (QC) of prestressed concrete fabrication is the respon sibility of the Contractor. The Contractor shall designate a QC Manager who shall be responsible for product qua lity requirements as defined in the Specifications and the Contractor’s approved QC Plan (QCP). The QC Manager shall possess and maintain certification at Level II minimum, from the Prestressed Concrete Institute (PCI), and shall have one (1) ye ar minimum of construction related experience. The QC Manager shall not be s upervised by the Contractor’s production section. Quality Assurance and product Acceptance are the prerogatives of the NMDOT. The Department’s Precast Inspector will be the QA Representativ e and acts for and in behalf of the NMDOT on all matters within the scope of the C ontract documents. QA administration will be performed to the extent necessary to assure Contract compliance. Repeated out of tolerance Work, including dimensional Non-Conf ormance, shall be considered as recurri ng deficiencies. Recu rring deficiencies s hall be considered as Section 518: Pre-Stressed Concrete Members Page 409 evidence that required QC is not being provided. When the QA R epresentative determines that fabrication operat ions are producing recurring defects that do not conform to the Contract and the QCP requirements, the Contracto r will be notified that the present Work is unacceptable. Work shall not continue until the QC Manager has submitted a written proposal addressing corrective procedures that the Contractor will take to prevent r ecurrence of the Non-conformin g Work. Fabrication shall not resume until the proposal has been reviewed and Accep ted in writing by the QA Representative. 2. Quality Control Plan (QCP). The Contractor shall submit a written QCP to the QA Representative prior to the beginning of fabrication. The QCP shall be reviewed and approved in writing by the Contractor’s QC Manager. The QC P shall list all methods utilized by the Contractor to ensure that the Work conf orms to Contract requirements. The QC section is responsible for establishing t he QCP, as well as conformance to the QCP. Fabrication shall not begin until the QCP has been reviewed and Accepted in writing by the QA Representative. If Work methods for a specific Project or product are not list ed in the original QCP, the Contractor shall submit written addenda addressing the prop osed methods that are necessary to meet Contract requirements. Fabrication shall not begin until the addenda have been reviewed and Accepted in writing by the QA Re presentative. The QCP shall address the following: a. Names and qualifications of the QC Manager and personnel con ducting inspection and testing. This list shall be updated when change s in personnel occur. Copies of the training certificates of the personnel co nducting inspection and testing shall be su bmitted to QA Representative. b. List of Material Suppliers and certified testing laboratorie s used; the list shall be updated when vendors change. c. Materials sampling and testing schedule, showing testing met hods and frequencies. d. QC inspection methods and pr ocedures for all stages of fabri cation operations. e. Methods for curing produc ts and test specimens. f. Method and sequence for tensioning strands, including method s used for verifying equal distribut ion of jacking forces. g. Method and sequence of detensioning strands. h. Written report format for Materials sampling, testing, and i nspection for all phases of the Work. i. Copies of all concrete mix designs to be used, including mix design computations and test data. j. Provisions for fabrication oper ations during cold, windy, or hot weather conditions. k. Procedures for patching sm all production holes and holes lef t by strand hold- down devices. l. Procedures for identifying, evaluating and reporting defects , including dimensional Non-Conformance, di scovered during QC/QA inspection s and testing. m. Procedures for notifying the QA Representative and the State Bridge Engineer of structural defects, and submi ttal of written proposal for re pairs. 3. Frequency. QC inspection and testing at all intervals of forming, tensio ning, steel and concrete placement, curing, and storage operations shall be performed in accordance with the Accepted QCP and Contract requirements. Th e QCP shall Section 518: Pre-Stressed Concrete Members Page 410 contain provisions for incr eased frequencies of inspection and testing when operations or products do not conform to the Contract. 4. Written Records and Reports . The QC Manager shall review and submit the following completed records and reports to the QA Representativ e before the product receives Acceptanc e by the QC section: a. Prestressing Steel - Tensioning reports for each setup, show ing the jacking force calculations; initial and final jacking force used; calcu lated and final net measured elongation; applicable stressing corrections for seati ng, slippage, shortening, rotation movement, and temperature; Certified Mill Test Reports for prestressing steel used. b. Concrete - A daily report of each mix design used, showing t he fresh concrete slump, temperature, unit weigh t, and air content (if specified) . The daily report shall also include the following data: i. Date and time of casting. ii. Bed and setup location. iii. Ambient conditions. iv. Total cubic yards placed; v. Girder mark and unique sub-mark identifications. vi. Actual product curing tem perature charts or graphs. vii. Actual curing enclosure humidity charts or graphs. viii. Average release strength in psi. ix. Date and time of release strength. x. Copies of individual batch t ickets when requested by the QA Representative. c. Pre-pour Inspection Records shall include the items to be ch ecked as listed in the QCP. d. Post-pour Inspection Records shall include the items to be c hecked as listed in the QCP. These records shall include all discovered variances from product dimensional tolerances. e. Report of minor repairs made to each individual product. f. The following written records shall be submitted to the QA R epresentative before product shipment: i. Length measurement of girders within three (3) Days prior to shipping. ii. Product camber measurement within seven (7) Days prior to s hipping.

518.4 Method of Measurement

Pre-stressed concrete members will be measured by the linear f oot.

518.5 Basis of Payment

Pay Item Pay Unit Pre-stressed Concrete Member Type Linear Foot

518.5.1 Work Included In Payment

The following items will be considered as included in the paym ent for the main item(s) and will not be measured or paid for separately: Section 518: Pre-Stressed Concrete Members Page 411 1. Prestressing steel, reinforcing steel and embedded steel ite m s f o r p r e c a s t prestressed concrete Bridge members. 2. The Quality Control and Quality Assurance requirements. 3. Shipping and erecting Pre-stressed Concrete members. The development of the Contractor Quality Control Plan shall b e included in the payment and is considered incidental to the completion of this Bid Item . All references to Section 901.2, “Contractor Quality Control” are for reference only and no separate measurement will be made. Section 519: Shotcrete Page 412