706.01 758 TABLE 70 5.27-1 CHEMICAL AND PHYS ICAL REQUIREMENTS Parameter Type C MgCO3, % ≥43 Sum of CaCO3 + Mg CO3, % by mass ≥ 98 Methylene blue value (mg/g) ≤ 3 Particle size distribution, minimum % passing No. 20 (850 μm) sieve 100 No. 50 (300 μm) sieve 80-100 No. 100 (150 μm) sieve No. 200 (75 μm) sieve 10-90 No. 325 (45 μm) sieve 5-70 706 CONCRETE AND CLA Y PIPE
706.01 Non-Reinforced Concrete Pipe. Provide non -reinforced concrete pipe
conforming to ASTM C 14 (ASTM C 14M), with the following modifications: 5.3 Does not apply. 6.2 Provide cementitious materials conforming to 701, except 701.07. 6.3 Provide aggregate conforming to the quality requirements of 703.02. 10.2 Ensure that the manufacture furnishes the number of pipe shown in the “Minimum Requirements for Sampling Materials” table, section 700. 10.3 In addition, perform external load crushing strength tests with hard rubber blocks on wood strips with plaster of paris bedding fillets. 13 Perform inspection at the project site. Obtain random samples from materials delivered to the project site or at other locations designated by the Laboratory. Ensure that the manufacturers of these ma terials are certified by the Office of Materials Management according to Supplement 1074. 15 Ensure that the markings also include “P” to denote non -reinforced pipe. Testing Equipment. Ensure that every manufacturer furnishing concrete pipe under these S pecifications furnishes all facilities and personnel needed to perform the tests.
706.02 Reinforced Concrete Circular Pipe . Provide reinforced concrete
circular pipe conforming to ASTM C 655 (ASTM C 655M), with the following modifications: 706.02 759 Ensure that the minimum D -Load of the reinforced concrete pipe is as follows: Size Minimum D-Load 12 in (300 mm) 2000 lb (100 kg) 15 in (375 mm) 2000 lb (100 kg) 18 in (450 mm) 1250 lb (62.5 kg) 21 in (525 mm) 1250 lb (62.5 kg) 24 in (600 mm) 1250 lb (62.5 kg) 27 in or larger (675 mm or larger) 1000 lb (50 kg) 1 In addition, ensure that this pipe is circular reinforced concrete pipe with circular or elliptical reinforcement, with and without quadrant and “S” strip reinforcement. 4.1 The acceptability of the pipe design is determined according to Section
10.All designs in ASTM C 76 (ASTM C 76M), Tables 2 through 5, inclusive, are accepted designs with the 0.01 -inch (0.3 mm) crack D -loads as follows: ASTM C 76 (ASTM C 76M) Table No. D-Load 0.01-inch Crack (0.3 mm) Crack 2 (Class II) 1000 lb (50 kg) 3 (Class III) 1350 lb (65 kg) 4 (Class IV) 2000 lb (100 kg) 5 (Class V) 3000 lb (140 kg) All designs in Tables 706.02 -1 through 706.02 -4 are accepted designs with noted 0.01 -inch (0.3 mm) crack and ultimate D-loads. For intermediate D - loads, in Tables 2 through 5 of ASTM C 76 (ASTM C 76M), steel areas for a given wall thickness may be interpolated between Tables 2 and 3, 3 and 4, and 4 and 5 for a size and D -load as accepted designs. Where different concret e strengths are listed in the tables, use the higher concrete. In addition, steel areas, interpolated as above between Table 706.02 -1 and Table 706.02 -2, 36 -inch (900 mm) through 108 -inch (2700 mm) using the higher concrete strength, and interpolation of the circumferential steel between Table 706.02 -3 and Table 706.02 -4 using the wall thickness and stirrup designs in Table 706.02 -4, are accepted designs. Pipe manufactured according to an accepted pipe design will be accepted, at the option of the Laborat ory, according to the basis of acceptance described in Section 4.1.1 or 4.1.2. Provide reinforced concrete pipe with S -stirrups according to Figure
706.02 1 (Figure 706.02 -1M) and the following requirements:
1.Provide steel conforming to 709.08, 709.10, 709.11, or 709.12. Ensure that the wall thickness, amount of circular reinforcement, S -stirrup system, and concrete strength comply with Tables 706.02 -2, 706.02 -3, and 706.02 -4. Ensure that the spacing center -to-center of adjacent inner rings of circumfe rential reinforcement in a cage does not exceed 4 inches (102 mm) for pipe up to and including pipe having a 4 inches (102 mm) wall thickness or exceed wall thicknesses for larger pipe and in no case exceed 6 inches (152 mm). 706.02 760 2. Ensure that each line of S -stirrups have a continuous “S” shape extending longitudinally from end to end of the pipe. Ensure that they extend from the inner cage toward the outer surface of the pipe for a distance not less than the minimum amplitude. Ensure that S -stirrups pass ar ound and are in contact with each inside circumferential member of the inner cage. Ensure that each line of S -stirrups lie essentially in a plane passing through the longitudinal axis of the pipe.
3.Where more than one length of stirrup material is used per line, make a lap round one circumferential member of the inner cage. Ensure that the ends of “S” shaped stirrups at splices include an outer bend. Do not use more than three lengths of “S” material in a line and ensure that the minimum length of a section of S -stirrups is 30 inches (0.76 m). Figure 706.02 -1 Illustrative Example of S -Stirrup Support System for 0.01 -inch Crack D-load 3000, 102 -inch diameter Pipe Minimum Area Per Support 0.053 square inch, 11 Lines Spaced @ 5 1/8 inches. For other classes and sizes, see Tables 706.02 -2, 3, and 4. Figure 706.02 -1M Illustrative Example of S -Stirrup Support System for 0.3 mm Crack D -Load 140.0, 2550 mm diameter Pipe Minimum Area per Support 34 mm2, 11 Lines Spaced @ 128 mm. For other classes and sizes, see Tables 706.02 -2M, 3M, and 4M. 706.02 761 TABLE 706.02 -1 TABLE 706.02 -1M 0.01-inch Crack D -Load 1000 0.3 mm Crack D -Load 50.0 Ultimate Strength D -Load 1500 Ultimate Strength D -Load 75.0 Internal Dia. of Pipe (inch) Wall Thick - ness (inch) Circular Reinforcement in Circular Pipe Internal Dia. of Pipe (mm) Wall Thick - ness (mm) Circular Reinforcement in Circular Pipe (in²/ft of pipe) (cm²/m of pipe) Inner Cage Outer Cage Inner Cage Outer Cage Reinforcing Steel
709.11 or 709.12 Only
Concrete Strength, 4000 psi Reinforcing Steel
709.11 or 709.12 Only
Concrete Strength, 27.6 MPa 36 4 0.09 0.07 900 100 1.9 1.5 42 4 1/2 0.11 0.08 1050 113 2.3 1.7 48 5 0.13 0.09 1200 125 2.8 1.9 54 5 1/2 0.16 0.12 1350 138 3.4 2.5 60 6 0.19 0.14 1500 150 4.0 3.0 66 6 1/2 0.21 0.16 1650 163 4.4 3.4 72 7 0.23 0.17 1800 175 4.9 3.6 78 7 1/2 0.25 0.19 1950 188 5.3 4.0 84 8 0.29 0.21 2100 200 6.1 4.4 90 8 0.33 0.24 2250 200 7.0 5.1 96 8 1/2 0.37 0.26 2400 213 7.8 5.5 Reinforcing Steel
709.11 or 709.12 Only
Concrete Strength, 5000 psi Reinforcing Steel
709.11 or 709.12 Only
Concrete Strength, 34.5 MPa 102 8 1/2 0.41 0.28 2550 213 8.7 5.9 108 9 0.47 0.30 2700 225 9.9 6.4 All Permitted Reinforcing Steel, Concrete Strength, 5000 psi All Permitted Reinforcing Steel, Concrete Strength, 34.5 MPa 114 9 1/2 0.56 0.42 2850 238 11.9 8.9 120 10 0.61 0.46 3000 250 12.9 9.7 126 10 1/2 0.65 0.49 3150 263 13.8 10.4 132 11 0.70 0.52 3300 275 14.8 11.0 144 12 0.80 0.60 3600 300 16.9 12.7 4.1.1 In addition, test the pipe designs covered by Tables 706.02 -1, 706.02 -2,
706.02 3, and 706.02 -4 and ASTM C 76 (ASTM C 76M), Tables 2 through 5, and
interpolated designs by the three -edge bearing method. When the test load on the pipe reaches 115 percent of the required 0.01 -inch (0 .3 mm) crack D -load without developing a 0.01 -inch (0.3 mm) or larger crack, accept the test specimen for strength. If any test specimen fails to pass this test, but attained the 0.01 -inch (0.3 mm) crack, continue the test until the ultimate D -load is rea ched. 4.1.2 In addition, accept pipe 54 inches (1350 mm) and larger in diameter covered by Tables 706.02 -1, 706.02 -2, 706.02 -3, and 706.02 -4, and ASTM C 76 (ASTM C 76M), Tables 2 through 5, and interpolated designs according to Section 12 and the following requirements: 706.02 762 1. When pipe from a plant has been approved by the Laboratory for a specified design and pipe from the same plant has wall and steel area not less than the approved pipe.
2.When it has been established that two or more plants have complied with the above requirements for the class and size under consideration, and the plant under consideration has established compliance with the above requirements for an adjacent size, and the wall and steel area are not less than the pipe tested at the two plants. 6.1.2.1 Provide cement according to 701. 6.1.2.2 Provide fly ash according to 701.13 6.1.3 Provide aggregates conforming to the quality requirements of 703.02. 6.1.5 Provide steel according to 709.08, 709.10, 709.11, or 709.12. 6.2.4 Ensure that no more than two holes are cast, drilled, or otherwise neatly made in the shell of each piece of pipe for the purpose of handling or laying. Taper the holes unless drilled, and before backfilling, fill the tapered holes with portland cement mortar, precas t concrete plugs secured with portland cement mortar, or a device on the Department’s Approved List specifically designed for filling the hole. Fill drilled holes with portland cement mortar. 7.1 and 7.3 In addition, perform strength tests using methods described in ASTM C 497 (ASTM C 497M). 10.1 In addition, ensure that pipe designs covered by Tables 706.02 -1,
706.02 2, 706.02 -3, and 706.02 -4 and ASTM C 76 (ASTM C 76M) Tables 2 through
5 have the number of samples selected as shown in the “Minimum Requir ements for Sampling Materials” table for each size, class, and production lot (pipe of the same size and class made from the same materials and by the same process and approximately the same production date) for test. 706.02 763 TABLE 706.02 -2 0.01-inch Crack D -Load 1350 Ultimate Strength D -Load 2000 Internal Dia. of Pipe (inch) Wall Thick - ness (inch) Circular Reinforcement in Circular Pipe S-Stirrups (in²/ft of pipe) Minimum Area per Support Element Number of Lines [1] Longitudinal Spacing Circumferential Spacing on Inner Cage Minimum Amplitude of Stirrups [2] Inner Cage Outer Cage Reinforcing Steel 709.11 or 709.12 Only Concrete Strength, 4000 psi 36 4 0.12 0.09 42 4 1/2 0.15 0.11 48 5 0.17 0.12 54 5 1/2 0.21 0.16 60 6 0.26 0.20 66 6 1/2 0.30 0.21 72 7 0.35 0.24 78 7 1/2 0.40 0.27 84 8 0.47 0.30 Reinforcing Steel 709.11 or 709.12 Only Concrete Strength, 5000 psi 90 8 0.64 0.35 96 8 1/2 0.80 0.40 102 8 1/2 0.96 0.44 108 9 1.07 0.47 (in²) (inch) (inch) (inch) All Permitted Reinforcing Steel, Concrete Strength, 5000 psi 114 9 1/2 0.69 0.52 0.041 5 2 6 1/8 6 5/8 120 10 0.74 0.55 0.041 5 2 6 1/2 7 1/8 126 10 1/2 0.79 0.60 0.041 5 2 6 7/8 7 5/8 132 11 0.85 0.64 0.041 5 2 7 1/4 8 1/8 144 12 0.97 0.73 0.041 5 2 8 9 1/8 [1] Number of lines in the table indicates the number of longitudinal lines required in each top and bottom portion of the pipe. The area of each support element in a pipe is two times the cross - sectional area of the S -stirrups wire used. There shall be an equal number of these lines of S - stirrups on either side of the mid -point of both the top and bottom of the pipe. See Figure
706.02 1.
[2] The amplitude is the overall w idth of the line of stirrups. 706.02 764 TABLE 706.02 -2M 0.3 mm Crack D -Load 65.0 Ultimate Strength D -Load 100.0 Internal Dia. of Pipe (mm) Wall Thick - ness (mm) Circular Reinforcement in Circular Pipe S-Stirrups (cm²/m of pipe) Minimum Area per Support Element Number of Lines [1] Longitudinal Spacing Circumferential Spacing on Inner Cage Minimum Amplitude of Stirrups [2] Inner Cage Outer Cage Reinforcing Steel 709.11 or 709.12 Only Concrete Strength, 27.6 MPa 900 100 2.5 1.9 1050 113 3.2 2.3 1200 125 3.6 2.5 1350 138 4.4 3.4 1500 150 5.5 4.2 1650 163 6.4 4.4 1800 175 7.4 5.1 1950 188 8.5 5.7 2100 200 9.9 6.4 Reinforcing Steel 709.11 or 709.12 Only Concrete Strength, 34.5 MPa 2250 200 13.5 7.4 2400 213 16.9 8.5 2550 213 20.3 9.3 2700 225 22.6 9.9 (mm²) (mm) (mm) (mm) All Permitted Reinforcing Steel, Concrete Strength, 34.5 MPa 2850 238 14.6 11.0 26 5 50 156 168 3000 250 15.7 11.6 26 5 50 165 181 3150 263 16.7 12.7 26 5 50 175 194 3300 275 18.0 13.5 26 5 50 184 206 3600 300 20.5 15.5 26 5 50 203 232 [1] Number of lines in the table indicates the number of longitudinal lines required in each top and bottom portion of the pipe. The area of each support element in a pipe is two times the cross - sectional area of the S -stirrups wire used. There shall be an equal number of these lines of S - stirrups on either side of the mid -point of both the top and bottom of the pipe. See Figure
706.02 1m.
[2] The amplitude is the overall width of the line of stirrups. 706.02 765 TABLE 706.02 -3 0.01-inch Crack D -Load 2000 Ultimate Strength D -Load 3000 Internal Dia. of Pipe Wall Thick - ness Circular Reinforcement in Circular Pipe (in²/ft of pipe) S-Stirrups Minimum Area per Support Element Number of Lines [1] Longitudinal Spacing Circum. Spacing on Inner Cage Min. Amplitude of Stirrups [2] (inch) (inch) Inner Cage Outer Cage (in²) (inch) (inch) (inch) Concrete Strength, 5000 psi 78 7 1/2 0.69 0.52 0.029 11 2 4 1/8 4 5/8 84 8 0.74 0.56 0.029 11 2 4 5/8 5 1/8 90 8 0.85 0.63 0.031 11 2 4 5/8 5 1/8 96 8 1/2 0.91 0.69 0.034 11 2 5 1/8 5 5/8 102 8 1/2 1.02 0.77 0.041 12 2 5 1/8 5 5/8 108 9 1.07 0.80 0.045 11 2 5 5/8 6 1/8 114 9 1/2 1.02 0.77 0.048 11 2 6 1/8 6 5/8 120 10 1.10 0.82 0.051 11 2 6 1/2 7 1/8 126 10 1/2 1.17 0.88 0.055 11 2 6 7/8 7 5/8 132 11 1.25 0.94 0.058 11 2 7 1/4 8 1/8 144 12 1.42 1.07 0.065 11 2 8 9 1/8 [1] and [2] Refer to footnotes in Table 706.02 -2 706.02 766 TABLE 706.02 -3M 0.3 mm Crack D -Load 100 Ultimate Strength D -Load 150 Internal Dia. of Pipe Wall Thick - ness Circular Reinforcement in Circular Pipe (cm²/m of pipe) S-Stirrups Minimum Area per Support Element Number of Lines [1] Longitudinal Spacing Circum. Spacing on Inner Cage Min. Amplitude of Stirrups [2] (mm) (mm) Inner Cage Outer Cage (mm²) (mm) (mm) (mm) Concrete Strength, 34.5 MPa 1950 188 14.6 11.0 19 11 50 105 117 2100 200 15.7 11.9 19 11 50 117 130 2250 200 18.0 13.3 20 11 50 117 130 2400 213 19.3 14.6 22 11 50 130 143 2550 213 21.6 16.3 26 12 50 130 143 2700 225 22.6 16.9 29 11 50 143 156 2850 238 21.6 16.3 31 11 50 156 168 3000 250 22.3 17.4 33 11 50 165 181 3150 263 24.8 18.6 35 11 50 175 194 3300 275 26.5 19.9 37 11 50 184 206 3600 300 30.1 22.6 42 11 50 203 232 [1] and [2] Refer to footnotes in Table 706.02 -2M 706.02 767 TABLE 706.02 -4 0.01-inch Crack D -Load 3000 Ultimate Strength D -Load 3750 Internal Dia. of Pipe (inch) Wall Thick - ness (inch) Circular Reinforcement in Circular Pipe S-Stirrups Minimum Area per Support Element Number of Lines [1] Longitudinal Spacing Circum. Spacing on Inner Cage Minimum Amplitude of Stirrups [2] (in²/ft of pipe) Inner Cage Outer Cage Concrete Strength, 6000 psi 6 1 3/4 0.07 -- 8 1 3/4 0.07 -- 10 1 3/4 0.07 -- 54 5 1/2 0.86 0.62 60 6 0.95 0.68 (in²) (inch) (inch) (inch) Concrete Strength, 5000 psi 54 5 1/2 0.64 0.48 0.029 15 2 2 1/8 2 5/8 60 6 0.70 0.53 0.029 14 2 2 5/8 3 1/8 66 6 1/2 0.79 0.59 0.029 13 2 3 1/8 3 5/8 72 7 0.87 0.66 0.029 12 2 3 5/8 4 1/8 78 7 1/2 0.92 0.69 0.031 11 2 4 1/8 4 5/8 84 8 0.99 0.74 0.034 11 2 4 5/8 5 1/8 90 8 1.13 0.85 0.041 11 2 4 5/8 5 1/8 96 8 1/2 1.20 0.90 0.045 11 2 5 1/8 5 5/8 102 8 1/2 1.34 1.00 0.053 11 2 5 1/8 5 5/8 108 9 1.51 1.13 0.063 11 2 5 5/8 6 1/8 114 9 1/2 1.51 1.13 0.064 11 2 6 1/8 6 5/8 120 10 1.62 1.21 0.068 11 2 6 1/2 7 1/8 126 10 1/2 1.73 1.30 0.072 11 2 6 7/8 7 5/8 132 11 1.84 1.38 0.076 11 2 7 1/4 8 1/8 144 12 2.09 1.57 0.085 11 2 8 9 1/8 [1] and [2] Refer to footnotes in Table 706.02 -2 706.02 768 TABLE 706.02 -4M 0.3 mm Crack D -Load 140.0 Ultimate Strength D -Load 175.0 Internal Dia. of Pipe (mm) Wall Thick - ness (mm) Circular Reinforcement in Circular Pipe S-Stirrups Minimum Area per Support Element Number of Lines [1] Longitudinal Spacing Circum. Spacing on Inner Cage Minimum Amplitude of Stirrups [2] (cm²/m of pipe) Inner Cage Outer Cage Concrete Strength, 41.4 MPa 150 44 1.5 -- 200 44 1.5 -- 250 44 1.5 -- 1350 138 18.2 13.1 1500 150 20.1 14.4 (mm²) (mm) (mm) (mm) Concrete Strength, 34.5 MPa 1350 138 13.5 10.2 19 15 50 54 67 1500 150 14.8 11.2 19 14 50 37 79 1650 163 16.7 12.5 19 13 50 79 92 1800 175 18.4 14.0 19 12 50 92 105 1950 188 19.5 14.6 20 11 50 105 117 2100 200 21.0 15.7 22 11 50 117 130 2250 200 23.9 18.0 26 11 50 117 130 2400 213 25.4 19.1 29 11 50 130 143 2550 213 28.4 21.2 34 11 50 130 143 2700 225 32.0 23.9 41 11 50 143 156 2850 238 32.0 23.9 41 11 50 156 168 3000 250 34.3 25.6 44 11 50 165 181 3150 263 36.6 27.5 46 11 50 175 194 3200 275 38.9 29.2 49 11 50 184 206 3600 300 44.2 33.2 55 11 50 203 232 [1] and [2] Refer to footnotes in Table 706.02 -2M 11.1 Perform compression tests on cores according to ASTM C 497 (ASTM C 497M). 11.3 Does not apply. 12 Perform inspection at the project site. Obtain random samples from material delivered to the project site or at other locations designated by the Laboratory. 16 Furnish materials from suppliers certified according to Supplement 1074. 17 In addition, after the capital letter “D,” designate the D -load, the design wall thickness in millimeters (inches expressed as a decimal). Ensure that pipe with S-stirrups ha ve the symbol “S”. Ensure that pipe requiring axis orientation without lift holes (i.e., stirrup pipe, quadrant reinforced pipe, elliptically reinforced pipe) has the centerline of the crown of the pipe marked inside and outside with the symbol “TB”. Mar k pipe with quadrant steel with the symbol “Q”. Mark pipe with elliptical 706.03 769 reinforcement with the symbol “E”. Mark pipe with deformed wire reinforcement required in the design with the symbol “DF”.
706.03 Reinforced Concrete Pipe, Epoxy Coated. Provide T ype A reinforced
concrete epoxy coated pipe conforming to 706.02 and Type B conforming to 706.04, with the following modification: In the plant, prepare the interior barrel and joint surface areas of the concrete pipe to remove all forms of oil, laitance, and other deleterious materials and then line them with a high -build, polyamide -cured, two -component coal tar epoxy coating, Military Specification DOD -P-23236A (SH). Spray the lining compound to obtain a continuous and relatively uniform and smooth linin g with a minimum dry film thickness of 0.03 inch (760 µm). Ensure that all coated pipe are free of surface irregularities such as air bubbles, delamination, lumping, sagging, blistering, pinholing, or porosity, in the coating film.
706.04 Reinforced Concr ete Elliptical Culvert, Storm Drain, and Sewer
Pipe . Provide reinforced concrete elliptical culvert, storm drain, and sewer pipe conforming to ASTM C 507 (ASTM C 507M), with the following modifications: 4.1 Delete Class HE -A. Table 706.04 -1 includes addi tional design requirements. 5.1 All materials, processes of manufacture, and finished pipe are subject to inspection and approval by the Department. When directed by the Laboratory, the manufacturer will cut holes in sections of the finished pipe for insp ection. 6.2.1 Provide cement according to 701, except 701.07. 6.2.2 Provide fly ash according to 701. 6.3 Provide aggregates conforming to the quality requirements of 703.02. 6.5 Provide steel according 709.08, 709.10, 709.11, or 709.12. 7.2 In addition, m anufacture horizontal elliptical pipe HE -II and HE -III using the design requirements of Table 706.04 -1. 8.1 In addition, ensure that pipe made in accordance with 706.04 -1 has three lines of reinforcement of elliptical shape. Place the outer and inner line s of reinforcement so that the nominal protective covering of the concrete over the reinforcement in the barrel of the pipe is 1 inch (25 mm) subject to the variations permitted in Section 12.5. Ensure that the third or middle line is in contact with and fastened securely to the inner line at the vertical axis of the pipe both top and bottom and to the outer line at the horizontal axis on both sides. Ensure that the length of the middle line is the average of the length of the inner and outer line. Ensur e that the middle line is of an elliptical shape and runs smoothly between the specified points of contact with the inner and outer lines. 10 Ensure that no more than two holes are cast, drilled, or otherwise neatly made in the shell of each piece of pipe for the purpose of handling or laying. Taper the holes unless drilled, and before backfilling, fill the tapered holes with portland cement mortar, precast concrete plugs secured with portland cement mortar, or a device on the Department’s Approved List sp ecifically designed for filling the hole. Fill drilled holes with portland cement mortar . 706.04 770 11.2 Select the specified number of pipe, as noted in the “Minimum Requirements for Sampling Materials” table, for the purpose of test at the plant and at random fr om the lot to be shipped or at the project site from the pipe delivered and that are pipe that would not otherwise be rejected under these Specifications. Test pipe according to Section 5.1.1 except the Laboratory may accept pipe 54 inches (1350 mm) and l arger in diameter according to Section 5.1.2 and the following requirements:
1.When pipe from a plant has been approved by the Laboratory for a specified design, pipe from the same plant with wall and steel area not less than the approved pipe may be appr oved by means of tests on cores verifying absorption, strength, wall, and steel area.
2.When it has been established that two or more plants have complied with the above requirements for the class and size under consideration and the plant under considera tion has established compliance with the above requirements for an adjacent size, and the wall and steel area are not less than the pipe tested at the two plants. 11.3.1 Ensure that the load to produce a 0.01 -inch (0.3 mm) crack and the ultimate load as d etermined by ASTM C 497 (ASTM C 497M) three -edge bearing method, is not less than shown in Tables 1, 2, and 706.04 -1. The ultimate strength test may be waived when the test load on the pipe reaches 115 percent of the required 0.01-inch (0.3 mm) crack D -load without developing a 0.01 -inch (0.3 mm) or larger crack. 11.4 Perform compression tests for satisfying the minimum specified concrete strength requirement from cores drilled from the wall of the pipe. Ensure that the diameter of the core is such that t he capped height to diameter or L/D ratio lies between one and two. Ensure that the cores are secured, prepared for testing, and tested by methods prescribed in the appropriate sections of ASTM C 497 (ASTM C 497M). Ensure that the compressive strength of each core tested is equal to or greater than the design strength of the concrete. If a core does not meet the required strength, test another core from the same pipe. If this core does not meet the required strength, the Department may reject the pipe. Make additional tests on other pipe to determine the acceptability of the lot. When the cores cut from a section of pipe successfully meet the strength test requirement, ensure that the core holes are plugged and sealed by the manufacturer in a manner su ch that the pipe section will meet all of the test requirements of these Specifications. 11.9 Does not apply.
11.10 Does not apply.
14 Perform inspection at the project site. Obtain random samples from material delivered to the project site or at other l ocations designated by the laboratory. Ensure manufacturers of these materials are certified according to Supplement 1074. 16 In addition, place the plant location on each pipe, and for pipe manufactured to design requirements of 706.04 -1 place the lett er “A” after the pipe 706.05 771 class. Ensure that the markings are legible and indented in the pipe section or painted on with waterproof paint. TABLE 706.04 -1 DESI GN REQUIREMENTS FOR HORIZONTAL ELLIPTICA L PIPE Equiv. Round Size (inch) Rise (inch) Span (inch) Minimum Wall Thickness (inch) Minimum Reinforcement (in²/ft) HE-II HE-III D-Loads 0.01 = 1000 0.01 = 1350 Utl. = 1500 Utl. = 2000 78 63 × 98 8 3 lines totaling 0.87 3 lines totaling 1.23 84 68 × 106 8 1/2 3 lines totaling 0.97 3 lines totaling 1.33 90 72 × 113 9 3 lines totaling 1.03 3 lines totaling 1.43 96 77 × 121 9 1/2 3 lines totaling 1.13 3 lines totaling 1.54 102 82 × 128 9 3/4 3 lines totaling 1.23 3 lines totaling 1.70 108 87 × 136 10 3 lines totaling 1.43 3 lines totaling 1.85 The test load in lb/ft equals D -load × nominal inside span in feet. Concrete strength=5000 psi. TABLE 706.04 -1M DES IGN REQUIREMENTS FOR HORIZONTAL ELLIPTICA L PIPE Equiv. Round Size (mm) Rise (mm) Span (mm) Minimum Wall Thickness (mm) Minimum Reinforcement (cm²/m) HE-II HE-III D-Loads 0.03 = 50.0 0.03 = 65.0 Utl. = 75.0 Utl. = 100.0 1950 1585 2495 200 3 lines totaling 18.4 3 lines totaling 26.0 2100 1705 2690 213 3 lines totaling 20.5 3 lines totaling 28.2 2250 1830 2880 225 3 lines totaling 21.8 3 lines totaling 30.3 2400 1950 3070 238 3 lines totaling 23.9 3 lines totaling 32.6 2550 2075 3265 244 3 lines totaling 26.0 3 lines totaling 36.0 2700 2195 3455 250 3 lines totaling 30.3 3 lines totaling 39.2 The test load in kN/m equals D -load × nominal inside span in mm. Concrete strength=34.5 MPa.
706.05 Precast Reinforced Concrete Box Sections. Provide precast reinforced
concrete box section conforming to ASTM C 1577, with the following modifications: Ensure that manufacturers of precast concrete members are certified by the Laboratory according to Supplement 1073. 6.2.1 Provide cement according to 701, except 701.07. 6.2.2 Provide fly ash according to 701. 6.2.4.9 Provide Carbonate Micro -Fines according to 7 05.27 and Table 499.03 - 2. 6.3 Provide aggregates conforming to the quality requirements of 703.02. 706.05 772 6.5 Provide reinforcement according to 709.10 or 709.12. Provide longitudinal distribution reinforcement according to 709.01, 709.10 or 709.12. 7.1 For th e following box sizes, span by rise, refer to ASTM C1577: 8x4, 5, 6, 7; 10x5, 6, 7, 8, 9; and 12x4, 6, 8, 10 feet. For the following box sizes, span by rise, refer to SS940: 14x4, 5, 6, 7, 8, 9, 10; 16x4, 5, 6, 7, 8, 9, 10; 18x4, 5, 6, 7, 8, 9, 10; and 20 x4, 5, 6, 7, 8, 9, 10 feet. 9.1 Provide hardened concrete that contains a minimum of 4 percent entrained air for wet -cast sections with spans less than 14 feet (4200 mm) and for all sections with spans 14 feet (4200 mm) and greater. 9.4 Lift holes are not permitted. Use handling devices that do not require a hole through the box. 10.1 Verify concrete strength using cylinders. Do not ship items before the design strength of the concrete is reached. 11.5 A minimum cover of 1/2 inch (13 mm) over both circumf erential and longitudinal reinforcement is required at the mating surfaces of joints. 15 In addition, mark the identification of the plant on each box section. For box sections 14 feet (4200 mm) or greater, mark the reinforcing steel areas for the section on each box section. Place the manufacturers’ name and required product information on the inside of the box section within the top one -half of the culvert. 706.051 Precast Reinforced Concrete Three -Sided Flat Topped Culverts. Provide precast concrete t hree-sided flat topped culverts according to ASTM C 1504, with the following modifications: Provide flat deck culvert structures with a minimum clear span (measured normal to the structure at the bottom of the haunch) of 14 feet (4200 mm) and a minimum opening rise (measured from bottom of leg to bottom of deck at the centerline of the structure) of 4 feet (1200 mm); and a maximum clear span of 34 feet (10,200 mm) and maximum opening rising of 10 feet (3000 mm). Ensure that the minimum wall and deck thickn esses is 10 inches (250 mm) and 12 inches (300 mm) respectively, measured under the haunch normal to the structure and at the centerline of the span measured perpendicular to the structure. Ensure manufacturers of precast concrete members are certified acc ording to Supplement 1073.
5.Ensure the manufacturer submits design calculations, a structural load rating and shop drawings according to 611.04. Ensure the shop drawings include the following:
1.Load rate the structure according to the requirements of section 900 of the Department’s Bridge Design Manual.
2.All material specifications.
3.All plan view.
4.All elevation view.
5.All headwall and wingwall attachment requirements.
6.All dimensions. 706.05 773 7. All maintenance of traffic phases.
8.All section sizes.
9.All design handling strength. The manufacturer may modify an approved shop drawing and resubmit for approval to the Department. Ensure that the shop drawings also include the following special information as required:
1.For top mounted guardr ail, show the guardrail plate and bolt locations in the plan view. Ensure that holes are a minimum of 6 inches (150 mm) from a joint.
2.For side mounted guardrail, show additional reinforcing details according to the plan details. 6.2.1 Provide cement ac cording to 701, except 701.07. 6.2.2 Provide fly ash according to 70113. 6.2.4.9 Provide Carbonate Micro -Fines according to 70 5.27 and Table 499.03 - 2. 6.3 Provide aggregates conforming to the quality requirements of 703.02. 6.4 Use chemical admixtures acco rding to 705.12. Use a corrosion inhibitor unless epoxy coated reinforcing steel is used. An approved list of corrosion inhibiting admixtures is on file at the Laboratory. Manufacturers should recognize that the corrosion inhibitors and admixtures may h ave an effect on strength, entrained air content, workability, etc. of their concrete mixes. The manufacturers choice of one of these corrosion inhibitors does not alleviate meeting all design requirements of this structure. 6.4.1 Provide air -entraining a dmixture according to 705.10. 6.5 Provide epoxy coated reinforcement according to 709.00, Grade 60 (Grade 420), or 709.14. In lieu of epoxy coated reinforcement, an approved corrosion inhibiting admixture may be added to the concrete at the approved dosag e; and provide reinforcement according to 709.01, 709.03 or 709.05; Grade 60 (Grade 420) or 709.08, 709.10, 709.11 or 709.12. Provide epoxy or galvanized coated connections when connecting a precast structural unit into a cast -in-place structural component or between segments of adjacent precast structural units either manufactured as separate units or across construction joints when manufactured as one unit. Provide epoxy coated reinforcement according to 709.00 or 709.14, when these connections are design ed using reinforcing steel. Provide galvanized coatings according to 711.02, when these connections are designed using connection plates, hardware or concrete inserts. 7.1 Design according to AASHTO LRFD Bridge Design Specifications , Section 12.14. Include a future wearing surface loading of 60 psf. 7.2 Ensure that the concrete cover dimension over reinforcement is a minimum of 2 inches (50 mm) in the slab and in the exterior of the leg. Ensure that 706.05 774 the interior of the leg reinforcement cover tapers from 1 inch (25 mm) at the bottom of the leg to 2 inches (50 mm) at the bottom of the haunch. Ensure that the ends of longitudinal reinforcement have a minimum cover of 1/2 inch (13 mm), and spacers used to position the reinforcement are plastic or epoxy coated steel regardless of whether a corrosion inhibiting admixture is used. 8 Ensure that the top slab is produced with a keyway joint. The keyway provides a void volume equivalent to that of 12 inches (300 mm) prestressed beam as per Standard Construction Dra wing PSBD -2-07. Ensure that the joint in the leg sections is designed to produce a shear key or inter -locking joint. Ensure that non - adjoining outside legs are flat. Sandblast the joint surfaces to the satisfaction of the Department, or a 2000 pounds pe r square inch (14 MPa) water blast no more than 14 days prior to shipping. Ensure that the culvert is designed such that the sections when laid together will make a continuous line with a smooth interior free of appreciable irregularities, all compatible with the permissible variations of Section 11. 9 Application of membrane waterproofing at any location other than the final location shown on the plans is prohibited. 9.1 Ensure that the aggregate, cement, and water are manufactured in conformance with 499 .06 and 499.07. Ensure that the temperature requirements of 511.08 and 511.15 are met. Ensure that the proportion of cement itious and carbonate micro -fines is not less than 564 pounds per cubic yard (335 kg/m3) of concrete. If used, add the corrosion inhibitor as an aqueous solution. Consider the water in the solution as mixing water for the purpose of determining the w/c ratio of concrete. 9.2 Cure the three -sided sections in the forms for the length of time required to obtai n the specified minimum design handling strength as defined in the shop drawings. Test a cylinder to check each section’s design handling strength. Repeat this test as often as needed. Only one cylinder passing will ensure that the design handling stren gth has been met. If the shop drawing shows no design handling strengths, then the minimum handling strength is assumed to be 100 percent of the design strength. Ensure that the curing then continues either in or out of the forms until the specified mini mum design strength is met. 9.2.1 Steam curing is an accelerated cure by low pressure steam or radiant heat within a suitable insulated enclosure to contain the live steam or heat. The initial application of the steam or heat is from two to four hours aft er the final placement of concrete to allow the initial set to take place. If retarders are used, increase the waiting period to 4 to 6 hours. As an alternative, determine the actual time of initial set according to ASTM C 403. Do not start curing until the actual time to initial set has elapsed. During the waiting period, ensure that the temperature within the curing enclosure is not less than 50 F (10 C). 706.05 775 During the initial application of live steam or radiant heat, ensure that the ambient temperature within the curing enclosure increases at an average rate not exceeding 40 F (22 C) per hour until the curing temperature is reached. Ensure that the maximu m curing temperature does not exceed 150 F (65 C). Hold the design temperature until the concrete has reached the desired design strength. Do not direct the application of live steam on the concrete forms so as to cause localized high temperatures. 9.2.2 Provide water curing according to 511.15 and 511.17, Method A. 9.2.3 Provide membrane curing according to 511.16, Method B. 9.3 Ensure that all forms are in place until the design handling strength is met. 9.4 Holes for handling or setting are not permi tted. Do not move members before the design handling strength of the concrete is reached, or shipped before the design strength of the concrete is reached. Ensure that the manufacturers have equipment necessary to handle and transport the pieces without damaging them. 10 Ensure that the hardened concrete contains a minimum of 4 percent entrained air. 10.2.1 Keep the cylinders and matching culvert section together to guarantee the cylinders are matched with the corresponding culvert section; or, upon agree ment by the Department, keep the cylinders at a location that will provide the same environment as the culvert sections. 10.2.2 For each section of the culvert, produce and mark at least four cylinders so that they are identifiable with the matching culve rt section. 10.2.3 Conform to Supplement 1073 for acceptance. 10.2.3.1 Ensure that cylinder strengths conform to Supplement 1073. 10.4 Plug the core holes by using a concrete that is the same as that used in the section and cured in ac cording to Section 9.2, or by a non -shrink grout that exceeds the concrete design strength. 11 The design in the plan reflects the external top slab elevation of the structure. If the structure supplied has a deck thicker than the plan design, eliminate the difference between the design top slab elevation and the supplied top slab elevation by a reducing the leg length. The Department may approve alternate methods to eliminate the difference between the design top slab elevation and the supplied top slab elevation. The Department will not approve a change in the top slab elevation from that shown on the plans. The clear span shown is the minimum for the structure. The manufacturer may provide a clear span greater than that shown. Base the exact footer locations for both the elevation and offset on the manufacturer’s shop drawings. Ensure that these footer locations are such that the centerline of the leg at the bottom of the haunch matches the centerline of the footer. All changes to the project resul ting from the manufacturer’s dimensional changes in the structure are at no charge to the Department. 706.05 776 Ensure that the sections are free of fractures spalls and chips. Ensure that all surfaces have a smooth and regular finish being defined as a 1/4 -inch variation within 4 feet (6 mm variation within 1.2 m). 11.1 Ensure that the slab and walls are perpendicular with a diagonal difference of not more than 0.5 percent. Ensure that the length of each section is within 1/2 inch (13 mm) of the design length. C onsider the length is the average of the length measured at each side and at the middle of the three -sided section. 11.4 Ensure that the maximum variation in the position of the reinforcement is 3/8 inch (9 mm), except that the cover over the reinforcement for the external surface of the top slab is not less than 2 inches (50 mm). The above tolerances or cover requirements do not apply to mating surfaces at the joint. 11.5 Resubmit any change in reinforcement from the shop drawings for approval. 12 Make re pairs according to the Department’s requirements. The Department will not make additional payments for culvert repairs. Repairs are acceptable if, in the opinion of the Department, the repairs are sound, properly finished, and cured. 13 Perform inspectio n at the project site. Furnish precast concrete components from suppliers certified according to Supplement 1073. 14 Form seams and slight surface irregularities that are expected from a wood panel forming system will not be cause for rejection. In addi tion, hairline cracks less than 0.01 inch (0.25 mm) are not cause for rejection. 15.1 Ensure that the location of the product marking is on the interior of the three -sided section 1 foot (300 mm) below the leg haunch. Add the product marking upon removal of the forms. The manufacturer may be required to repeat the product markings before the project is final. 706.052 Precast Reinforced Concrete Arch Sections . Provide precast reinforced concrete arch sections according to ASTM C 1504, with the following modifications: This item shall consist of manufacturing precast reinforced concrete arch sections for culverts. Ensure that manufacturers of precast concrete members are certified according to Supplement 1073. 5 Ensure the manufacturer submits design calcu lations, a structural load rating and shop drawings according to 611.04. Ensure the shop drawings include the following:
1.Load rate the structure according to the requirements of section 900 of the Department’s Bridge Design Manual. 706.05 777 2. All material spec ifications.
3.All plan view.
4.All elevation view.
5.All headwall and wingwall attachment requirements.
6.All dimensions.
7.All maintenance of traffic phases.
8.All section sizes.
9.All design handling strength. The manufacturer may modify an appr oved shop drawing and resubmit for approval to the Department. Ensure that the shop drawings also include the following special information as required:
1.For top mounted guardrail, the guardrail plate and bolt locations are shown in the plan view. Hole s shall be a minimum of 6 inches (150 mm) from a joint.
2.The corrosion inhibitor being used, if any, and dosage rate. Dosage rate will be approved by the Laboratory. 6.2.1 Provide cement according to 701, except 701.07. 6.2.2 Provide fly ash according to 701.13. 6.2.4.9 Provide carbonate micro -fines according to 70 5.27 and Table 499.03 - 2. 6.3 Provide aggregates conforming to the quality requirements of 703.02. 6.4 Use chemical admixtures according to 705.12. Use a corrosion inhibitor unless epoxy coate d reinforcing steel is used. An approved list of corrosion inhibiting admixtures is on file at the Laboratory. Manufacturers should recognize that the corrosion inhibitors and admixtures may have an effect on strength, entrained air content, workability, etc. of their concrete mixes. The manufacturers choice of one of these corrosion inhibitors does not alleviate meeting all design requirements of this structure. 6.4.1 Provide air -entraining admixture according to 705.10. 6.5 Provide epoxy coated reinfor cement according to 709.00, Grade 60 (Grade 420), or 709.14. In lieu of epoxy coated reinforcement, an approved corrosion inhibiting admixture may be added to the concrete at the approved dosage; and provide reinforcement according to 709.01, 709.03 or 70 9.05; Grade 60 (Grade 420) or 709.08, 709.10, 709.11 or 709.12. Provide epoxy or galvanized coated connections when connecting a precast structural unit into a cast -in-place structural component or between segments of adjacent precast structural units eith er manufactured as separate units or across construction joints when manufactured as one unit. Provide epoxy coated reinforcement according to 709.00 or 709.14, when these connections are designed using reinforcing steel. Provide galvanized coatings accord ing to 711.02, when these connections are designed using connection plates, hardware or concrete inserts. 706.05 778 7.1 Design according to AASHTO LRFD Bridge Design Specifications , Section 12.14. Include a future wearing surface loading of 60 psf. 7.2 Ensure that the concrete cover dimension over the outside circumferential reinforcement is a minimum of 2 inches (50 mm). Ensure that the concrete cover dimension over the inside circumferential reinforcement is a minimum of 1 1/2 inches (38 mm). The clear distance of the end circumferential wires shall not be less than 1 inch (25 mm) nor more than 2 inches (50 mm) from the ends of the sections. Reinforcement shall be assembled utilizing single or multiple layers of welded wire fabric (three -layer maximum), or utili zing a single layer of deformed billet -steel bars. The welded wire fabric shall be composed of circumferential and longitudinal wires and shall contain sufficient longitudinal wires extending through the section to maintain the shape and position of reinf orcement. Longitudinal distribution reinforcement may be welded wire fabric or deformed billet -steel bars. The ends of the longitudinal distribution reinforcement shall be not more than 3 inches (75 mm) from the ends of the sections. The outside and ins ide circumferential reinforcing steel for the corners of the culvert shall be bent to such an angle that it is approximately equal to the configuration of the culverts outside corner. 7.3 Tension splices in the circumferential reinforcement shall not be ma de. For splices other than tension splices, the overlap shall be a minimum of 12 inches (300 mm) for welded wire fabric or deformed billet steel bars. The spacing center - to-center of the circumferential wires in a wire fabric sheet shall be not less than 2 inches (50 mm) or more than 4 inches (100 mm). For the wire fabric, the spacing center -to-center of the longitudinal wire shall not be more than 8 inches (200 mm). The spacing center -to-center of the longitudinal distribution steel for either line of reinforcing in the top slab shall be not more than 16 inches (410 mm). 8.1 Ensure the sections are produced with butt ends. The ends of the sections shall be such that when the sections are laid together they will make a continuous line of sections with a smooth interior free of appreciable irregularities, all compatible with the permissible variations in these Specifications. Provide a chamfer on the outside surface at the sections joint to form a void for a 7/8 1 3/8 - inch (24 34 mm) flexible plastic gasket 706.14. 9 Application of membrane waterproofing on the arch section at any location other than the final location shown on the plans is prohibited. 9.1 Ensure that the aggregate, cement, and water are manufactured according to 499.06 and 499.07. Ensure that the temperature requirements of 511.08 and 511.15 are met. Ensure that the proportion of cement itious and carbonate micrio -fines is not less than 564 pounds per cubic yard (335 kg/m3) of concrete. If used, add the co rrosion inhibitor as an aqueous solution. Consider the water in the solution as mixing water for the purpose of determining the water - cement ratio of concrete. 706.05 779 9.2 Cure the arch sections in the forms for the length of time required to obtain the specified minimum design handling strength as defined in the shop drawings. Test a cylinder to check each section’s design handling strength. Repeat this test as often as needed. Only one cylinder passing will ensure that the design handling strength has been me t. If the shop drawing shows no design handling strengths, then the minimum handling strength is assumed to be 100 percent of the design strength. Ensure that the curing then continues either in or out of the forms until the specified minimum design stre ngth is met. 9.2.1 Steam curing is an accelerated cure by low pressure steam or radiant heat within a suitable insulated enclosure to contain the live steam or heat. The initial application of the steam or heat is from 2 to 4 hours after the final placeme nt of concrete to allow the initial set to take place. If retarders are used, increase the waiting period to 4 to 6 hours. As an alternative, determine the actual time of initial set according to ASTM C 403. Do not start curing until the actual time to initial set has elapsed. During the waiting period, ensure that the temperature within the curing enclosure is not less than 50 F (10 C). During the initial application of live steam or radiant heat, ensure that the ambient temperature within the curin g enclosure increases at an average rate not exceeding 40 F (22 C) per hour until the curing temperature is reached. Ensure that the maximum curing temperature does not exceed 150 F (65 C). Hold the design temperature until the concrete has reached t he desired design strength. Do not direct the application of live steam on the concrete forms so as to cause localized high temperatures. 9.2.2 Provide water curing according to 511.15 and 511.17, Method A. 9.3 Ensure that all forms are in place until the design handling strength is met. Holes for handling or setting are not permitted. Do not move members before the design handling strength of the concrete is reached, or shipped before the design strength of the concrete is reached. Ensur e that the manufacturers have equipment necessary to handle and transport the pieces without damaging them. 10 Ensure that the hardened concrete contains a minimum of 4 percent entrained air. 10.2.1 Keep the cylinders and matching culvert section together to guarantee the cylinders are matched with the corresponding culvert section; or, upon agreement by the Department, keep the cylinders at a location that will provide the same environment as the culvert sections. 10.2.2 For each section of the culvert, produce and mark at least four cylinders so that they are identifiable with the matching culvert section. 10.2.3 Conform to Supplement 1073 for acceptance. 10.2.3.1 Ensure that cylinder strengths conform to Supplement 1073. 706.05 780 10.4 Plug t he core holes by using a concrete that is the same as that used in the section and cured according to Section 9.2, or by a non -shrink grout that exceeds the concrete design strength. 11.0 The under -run in length of a section shall not be more than 1/2 inch (13 mm). All changes to the project resulting from the manufacturer’s dimensional changes in the structure are at no charge to the Department. Ensure that the sections are free of fractures spalls and chips. Ensure that all surfaces have a smooth and regular finish being defined as a 1/4 inch variation within 4 feet (6 mm variation within 1.2 m). 11.1 The internal dimensions shall vary not more than 1 percent from the design dimensions or more than 38 mm (1 1/2 inches), whichever is less. The haunch d imensions shall vary not more than 19 mm (3/4 inch) from the design dimension. 11.4 Ensure that the maximum variation in the position of the reinforcement is 3/8 inch (9 mm), except that the cover over the reinforcement for the external surface of the top slab is not less than 2 inches (50 mm). The above tolerances or cover requirements do not apply to mating surfaces at the joint. 11.5 Resubmit any change in reinforcement from the shop drawings for approval. 12.0 Make repairs according to the Department’s requirements. The Department will not make additional payments for culvert repairs. Repairs are acceptable if, in the opinion of the Department, the repairs are sound, properly finished, and cured. 13.0 Perform inspection at the project site. Furnish precast concrete components from suppliers certified according to Supplement 1073. 14.0 Form seams and slight surface irregularities that are expected from a wood panel forming system will not be cause for rejection. In addition, hairline cracks less tha n 0.01 inch (0.25 mm) will not be cause for rejection. 15.1 Ensure that the location of the product marking is on the interior of the arch section 1 foot (300 mm) below the leg haunch. Add the product marking upon removal of the forms. The manufacturer m ay be required to repeat the product markings before the project is final. 706.053 Precast Reinforced Concrete Round Sections . Provide precast reinforced concrete elliptical and circular arch sections according to ASTM C 1504, with the following modificat ions: This item shall consist of manufacturing precast reinforced concrete elliptical and circular arch sections for culverts. 706.05 781 Ensure that manufacturers of precast concrete members are certified according to Supplement 1073.
5.Ensure the manufacturer subm its design calculations, a structural load rating and shop drawings according to 611.04. Ensure the shop drawings include the following:
1.Load rate the structure according to the requirements of section 900 of the Department’s Bridge Design Manual.
2.All material specifications.
3.Plan view.
4.Elevation views.
5.Headwall and wingwall attachment requirements.
6.Dimensions.
7.All maintenance of traffic phases.
8.Section sizes.
9.Design handling strength. The manufacturer may modify an approved sh op drawing and resubmit for approval to the Department. Ensure that the shop drawings also include the following special information as required:
1.For top mounted guardrail, the guardrail plate and bolt locations are shown in the plan view. Holes shall be a minimum of 6 inches (150 mm) from a joint.
2.The corrosion inhibitor being used, if any, and dosage rate. Dosage rate will be approved by the La boratory. 6.2.1 In addition, provide cement according to 701, except 701.07. 6.2.2 Provide fly ash conforming to 701.13. 6.2.4.9 Provide carbonate micro -fines according to 70 5.27 and Table 499.03 - 2. 6.3 Provide aggregates conforming to the qualit y requirements of 703.02. 6.4 Use chemical admixtures conforming to 705.12. Use a corrosion inhibitor unless epoxy coated reinforcing steel is used. An approved list of corrosion inhibiting admixtures is on file at the Laboratory. Manufacturers should reco gnize that the corrosion inhibitors and admixtures may have an effect on strength, entrained air content, workability, etc. of their concrete mixes. The manufacturer’s choice of one of these corrosion inhibitors does not alleviate meeting all design requir ements of this structure. 6.4.1 Provide air -entraining admixture conforming to 705.10. 6.5 Provide epoxy coated reinforcement according to 709.00, Grade 60 (Grade 420), or 709.14. In lieu of epoxy coated reinforcement, an approved corrosion inhibiting admi xture may be added to the concrete at the approved dosage; and provide reinforcement according to 709.01, 709.03 or 709.05; Grade 60 (Grade 420) or 709.08, 709.10, 709.11 or 709.12. Provide epoxy or galvanized coated connections when connecting a precast s tructural unit into a cast -in-place structural 706.05 782 component or between segments of adjacent precast structural units either manufactured as separate units or across construction joints when manufactured as one unit. Provide epoxy coated reinforcement accordin g to 709.00 or 709.14, when these connections are designed using reinforcing steel. Provide galvanized coatings according to 711.02, when these connections are designed using connection plates, hardware or concrete inserts. 7.1 Modify the first sentence as follows: Design according to AASHTO LRFD Bridge Design Specifications , Section 12.14. Include a future wearing surface loading of 60 psf. 7.2 Ensure that the concrete cover dimension over the outside circumferential reinforcement is a minimum of 2 inches (50 mm). Ensure that the concrete cover dimension over the inside circumferential reinforcement is a minimum of 1 1/2 inches (38 mm). The clear distance of the end circumferential wires shall not be less than 1 inch (25 mm) nor more than 2 inches (50 mm) f rom the ends of the sections. Reinforcement shall be assembled utilizing single or multiple layers of welded wire fabric (three -layer maximum), or utilizing a single layer of deformed billet -steel bars. The welded wire fabric shall be composed of circumfer ential and longitudinal wires and shall contain sufficient longitudinal wires extending through the section to maintain the shape and position of reinforcement. Longitudinal distribution reinforcement may be welded wire fabric or deformed billet -steel bars . The ends of the longitudinal distribution reinforcement shall be not more than 3 inches (75 mm) from the ends of the sections. Form the outside and inside circumferential reinforcing steel for the arch such that it is approximately equal to the configur ation of the arch shape. 7.3 In addition, tension splices in the circumferential reinforcement shall not be made. For splices other than tension splices, the overlap shall be a minimum of 12 inches (300 mm) for welded wire fabric or deformed billet steel b ars. The spacing center -to-center of the circumferential wires in a wire fabric sheet shall be not less than 2 inches (50 mm) or more than 4 inches (100 mm). For the wire fabric, the spacing center -to-center of the longitudinal wire shall not be more than 8 inches (200 mm). The spacing center -to-center of the longitudinal distribution steel for either line of reinforcing in the top slab shall be not more than 16 inches (410 mm). 8.1 Ensure the sections are produced with butt ends. The ends of the sections shall be such that when the sections are laid together they will make a continuous line of sections with a smooth interior free of appreciable irregularities, all compatible with the permissible variations in these Specifications and section 11 of ASTM C 15 04. Provide a 3/4 × 3/4 inch (19 × 19 mm) minimum chamfer on the inside and outside surface at the sections joint. Ensure that the design of the arch in its final constructed location is structurally continuous throughout the arch unit providing for flexur al, compressive and shear force transfers. For arches that gain structural continuity by a cast in place closure at the project site, provide concrete with the same compressive strength as the precast arch. In addition, the cast in place closure shall prov ide continuity in the transverse direction (90 degrees to the span) along the lay length of the arches. 706.05 783 9.1 Ensure that the aggregate, cement, and water are manufactured according to 499.06 and 499.07. Ensure that the temperature requirements o f 511.08 and 511.15 are met. Ensure that the proportion of cement itious and carbonate micro -fines is not less than 564 pounds per cubic yard (335 kg/m³) of concrete. If used, add the corrosion inhibitor as an aqueous solution. Consider th e water in the solution as mixing water for the purpose of determining the water - cement ratio of concrete. 9.2 Cure the arch sections in the forms for the length of time required to obtain the specified minimum design handling strength as defined in the sh op drawings. Test a cylinder to check each section’s design handling strength. Repeat this test as often as needed. Only one cylinder passing will ensure that the design handling strength has been met. If the shop drawing shows no design handling strengths , then the minimum handling strength is assumed to be 100 percent of the design strength. Ensure that the curing then continues either in or out of the forms until the specified minimum design strength is met. 9.2.1 Steam curing is an accelerated cure by l ow pressure steam or radiant heat within a suitable insulated enclosure to contain the live steam or heat. The initial application of the steam or heat is from 2 to 4 hours after the final placement of concrete to allow the initial set to take place. If re tarders are used, increase the waiting period to 4 to 6 hours. As an alternative, determine the actual time of initial set according to ASTM C 403. Do not start curing until the actual time to initial set has elapsed. During the waiting period, ensure tha t the temperature within the curing enclosure is not less than 50 °F (10 °C). During the initial application of live steam or radiant heat, ensure that the ambient temperature within the curing enclosure increases at an average rate not exceeding 40 °F (2 2 °C) per hour until the curing temperature is reached. Ensure that the maximum curing temperature does not exceed 150 °F (65 °C). Hold the design temperature until the concrete has reached the desired design strength. Do not direct the application of liv e steam on the concrete forms so as to cause localized high temperatures. 9.2.2 Provide water curing according to 511.15 and 511.17, Method A. 9.3 Ensure that all forms are in place until the design handling strength is met. Holes for handling or setting are not permitted. Do not move members before the design handling strength of the concrete is reached, or shipped before the design strength of the concrete is reached. Ensure that the manufacturers have equipment necessary to handle an d transport the pieces without damaging them. 10 Ensure that the hardened concrete contains a minimum of 4 percent entrained air. 10.1 Cores drilled from the section are not permitted. 706.05 784 10.2.1 Keep the cylinders and matching arch section together to guarant ee the cylinders are matched with the corresponding culvert section; or, upon agreement by the Department, keep the cylinders at a location that will provide the same environment as the arch sections. 10.2.2 For each section of the arch structure, produce and mark at least four cylinders so that they are identifiable with the matching arch section. 10.2.3 Conform to Supplement 1073 for acceptance. 10.2.3.1 Ensure that cylinder strengths conform to Supplement 1073. 11.0 The under -run in length of a section s hall not be more than 1/2 inch (13 mm). All changes to the project resulting from the manufacturer’s dimensional changes in the structure are at no charge to the Department. Ensure that the sections are free of fractures spalls and chips. Ensure that all surfaces have a smooth and regular finish being defined as a 1/4 inch variation within 4 feet (6 mm variation within 1.2 m). 11.1 The internal dimensions shall vary not more than 1 percent from the design dimensions or more than 1 1/2 inches (38 mm), whic hever is less. The haunch dimensions shall vary not more than 3/4 inch (19 mm) from the design dimension. 11.4 Ensure that the maximum variation in the position of the reinforcement is 3/8 inch (9 mm), except that the cover over the reinforcement for the e xternal surface of the top is not less than 2 inches (50 mm). The above tolerances or cover requirements do not apply to mating surfaces at the joint. 11.5 Resubmit any change in reinforcement from the shop drawings for approval. 11.6 All interior and exte rior arch surfaces shall have a smooth steel form finish. 12.0 Make repairs according to the Department’s requirements. The Department will not make additional payments for arch repairs. Repairs are acceptable if, in the opinion of the Department, the repa irs are sound, properly finished, and cured. 13.0 The Department may perform inspection at the plant conforming to Supplement 1073 but final inspection and acceptance will be at the project site. Furnish precast concrete components from suppliers certifi ed according to Supplement 1073. 14.0 Form seams and slight surface irregularities that are expected from a steel panel forming system will not be cause for rejection. In addition, hairline cracks less than 0.01 inch (0.25 mm) will not be cause for rejecti on. 15.1 Ensure that the location of the product marking is on the interior of the arch section 4 feet (1.2 m) above the base of the arch. Measure the 4 feet (1.2 m) from the base of the arch along the circumference of the interior surface. Add the produc t marking upon removal of the forms. 706.06 785 The manufacturer may be required to repeat the product markings before the project is final.
706.06 Perforated Concrete Pipe. Provide perforated concrete pipe according
to ASTM C 444 (ASTM C 444M), and 706.01 or 706.0 2. Ensure manufacturers providing materials are certified according to Supplement 1074.
706.07 Concrete Drain Tile. Provide extra -quality concrete drain tile
according to ASTM C 412 (ASTM C 412M), with the following modifications: Ensure manufacturers pro viding materials are certified according to Supplement 1074. 4.0 This specification covers extra -quality concrete drain tile only. 5.1(3) Does not apply. 6.2.1 Provide cement according to 701, except 701.07. 6.2.2 Provide fly ash according to 701.13 6.3 Provide aggregate conforming to the quality requirements of 703.02. 8.1 Perform inspection at the project site. Obtain random samples from material delivered to the project site or at other locations designated by the Laboratory. Ensure manufacturers pro viding materials are certified according to Supplement 1074. Testing. Ensure that the manufacturer furnishes all facilities and personnel to carry out the tests.
706.08 Vitrified Clay Pipe. Provide vitrified clay pipe according to ASTM C
700, with the following modifications: Furnish materials according to the Department’s QPL . 14.0 Perform all tests except hydrostatic according to ASTM C 301. 15.0 Perform inspection at the project site. O btain random samples from material delivered to the project site or at other locations designated by the Laboratory.
706.09 Clay Drain Tile. Provide extra -quality clay drain tile according to
ASTM C 4, with the following modifications: 6.1 Perform inspection at the project site. Obtain random samples from material delivered to the project site or at other locations designated by the Laboratory. 11, 12, and 13 Ensure that the manufacturer furnishes all facilities and personnel to carry out the tests. Furnish materials according to the Department’s QPL .
706.10 Bituminous Pipe Joint Filler . Provide cold applied, mineral filled, joint
sealing compound for joints of bell and spigot, or tongue and groove sew er; or drain pipe conforming to the following: 706.11 786 A. Composition. Provide a steam -refined petroleum asphalt or a refined coal tar, dissolved in a suitable solvent, and containing an appropriate stiffener.
B.General Requirement. Provide a bituminous plastic cement that has a smooth, uniform mixture, not thickened or livered, and that shows a separation easily overcome by stirring. Ensure that the material is of such consistency and properties that it is readily applied with a trowel, a putty knife, or with a caulking gun without pulling or drawing. Provide a material that when applied to metal, concrete, or vitrified clay surfaces, exhibits good adhesive and cohesive properties and has only slight shrinkage after curing. Provide a material that is not dama ged by exposure to below freezing temperatures.
C.Detail Requirements. Provide materials conforming to the following requirements:
1.When applied in a layer 1/16 to 1/8 -inch (1.6 to 3.2 mm) thick on a tinned metal panel and cured at room temperature for 24 hours, the bituminous plastic cement shall set to a tough, plastic coating, free from blisters. Minimum Maximum
2.Grease Cone Penetration (unworked, 150 grams, 25 C, 5 sec, ASTM D 217, mm/10 175 250
3.Weight, kg/L 1.17 --
4.Non-volatile, 10 g, 105 to 110 C, 24 hrs, % 75 --
5.Ash, by ignition, % 25 45 Furnish materials according to the Department’s QPL .
706.11 Resilient and Flexible Gasket Joints . Provide resilient and flexible
gasket joints for concrete pipe according to ASTM C 443 (ASTM C 443M). Furnish materials according to the Department’s QPL .
706.12 Resilient and Flexible Joints . Provide resilient and flexible joints for
vitrified clay pipe according to ASTM C 425. Furnish materials according to the Department’s QPL .
706.13 Precast Reinforced Concrete Manhole Riser Sections, Flat Slab
Tops, Catch Basins and Inlet Tops, and Portable Barriers . Provide precast reinforced concrete manhole riser sections, flat slab tops, catch basins and inlet tops, and portable barriers according to ASTM C 478 (ASTM C 478M), with the following modifications: 1.1 Provide precast catch basin tops where permitted by the plans. 4.1.2.1 Provide cement according to 701, except 701.07. 4.1.2.2 Provide fly ash according to 701.13. 4.1.4 Provide aggregate conforming to the quality requirements of 703.02.
Source: Ohio Construction and Material Specifications, 2019 Edition. Pages 0–0 of 928.