00595.00 630 Section 00595 - Reinforced Concrete Box Culverts Description
00595.00 Scope - This Work consists of constructing cast -in-place reinforced concrete box culverts,
precas t reinforced concrete box culverts , precast segmental reinforced concrete box culverts, and precast reinforced concrete three -sided Structures to the lines, grades, and dimensions shown or directed. Each of these configurations of reinforced concrete box culvert is referred to as RCBC herein.
00595.02 Definitions :
Box Section - For precast reinforced concrete box culverts, the Box Section is the individual precast box culvert piece. For precast segmental reinforced concrete box culverts, the Box Sect ion is made of a top and bottom segment adjoined to form a complete box cross section unit. For precast reinforced concrete three- sided Structures, the Box Section is the individual precast three-sided Structure piece. Box Sections are placed and joined together to construct the reinforced concrete box culvert. Box Segment - For precast segmental reinforced concrete box culverts, the Box Segment is the individual piece (top slab, bottom slab, or U -shape) that is adjoined to the mating Box Segment to form a Box Section.
00595.03 Design of Precast Sections - Perform design according to the ODOT Bridge Desi gn
Manual and the current edition of AASHTO LRFD Bridge Design Specifications . Unless otherwise shown or specified, precast RCBC may be substituted in place of cast -in-place RCBC. Precast substitution is not permitted for headwalls, wingwalls, or for features show n as using cast-in-place concrete. Submit stamped design calculations and stamped Working Drawings, prepared by the manufacturer, according to 00150.35. Include the following information: Structural analysis methods, Structural design criteria and calcu lations, Structure detail shop drawings, Detailed plans including culvert geometry, Line and grade layout, Joint and connection details, and Lifting devices. Submit a stamped installation plan, according to 00150.35. Ensure the installation plan is consi stent with the Plans, Specifications and the manufacturer’s design. Include the following information: Methods and Equipment to be used for handling, Methods to ensure uniform bearing of the RCBC base, Culvert installation, and Requirements for construct ion loads. Do not begin precast culvert fabrication or construction before receiving written approval from the Engineer. 00595.40 631 Materials
00595.10 Cast -in-Place Materials - For cast -in-place RCBC, cast -in-place ends, and cast -in-place
wingwalls and aprons, furnish Material s meeting the following requirements: Reinforcement ............................................................................................ 00530 Concrete ..................................................................................................... 00540 Unless otherwise shown, provide Class 3300 - 1 1/2" or 3/4" portland cement concrete.
00595.11 Precast Materials - Furnish Material s meeting the following requirements :
Concrete ..................................................................................................... 02001 Deformed Bar Reinforcement ................................................................ 02510.10 Precast Reinforced Concrete Box Culverts .................................... ASTM C1577 Precast Segmental Reinforced Concrete Box Culverts .................. ASTM C1786 Precast Reinforced Concrete Three-Sided Structures ................... ASTM C1504 Unless otherwise shown f urnish joint seal ing material per manufacturer design and meeting one or more of the following requirements: External Sealing Band ...................................................................... ASTM C877 Preformed Flexible Joint Sealant ..................................................... ASTM C990 Rubber Gaskets ............................................................................. ASTM C1677 Elastomeric J oint Sealant ................................................................. ASTM C920 Unless otherwise shown, provide portland cement concrete according to the following: Property Value Air Entrainment 4.5 - 7.5% Compressive Strength 5000 psi Concrete Temperature 50 - 90 °F Construction
00595.40 Cast -in-Place - Construct cast -in-place RCBC, cast -in-place ends, and cast -in-place
wingwalls and aprons according to the following:
a.Reinforcement - Place reinforcing steel according to Section 00530.
b.Portland Cement Concrete - Place portland cement concrete according to Section 00540 and the following:
1.Placing Concrete - Allow base slabs or box culvert footings to set at least 12 hours before constructing the remainder of the box culvert. When constructing box culverts 4 feet or less in height, the sidewalls and top slab may be constructed as a monolith, with sidewalls constructed full height. If this method is used, place construction joints vertical and at right angles to the axis of the culvert. When constructing box culverts more than 4 feet in height, place concrete in the walls to at least the bottom elevation of the top slab. Allow 3 D ays before placing the top slab according to 00595.40(b)(2) . Construct each wingwall as a monolith. 00595.41
2.Removal of Forms and Falsewor k and Subsequent Loading - Remove forms and falsework and place subsequent loading according to Table 00540- 1.
3.Concrete Finish - Finish all exposed concrete surfaces with a general finish according to 00540.53(a).
00595.41 Precast - Fabricate precast boxes according to the following requirements unless detailed
otherwise: Precast Reinforced Concrete Box Culverts .................................... ASTM C1577 Precast Segmental Reinforced Concrete Box Culverts .................. ASTM C1786 Precast Reinforced Concrete Three-Sided Structures ................... ASTM C1504 Prepare at least three acceptance test cylinders per D ay for each concrete strength used in the production of Box Sections. Expose cylinders to the same curing conditions as the manufactured Box Sections and keep cylinders and Box Sections together until tested. Transport members from the casting yard only after the following conditions have been met: Not less than 7 Calendar Days after casting, Not less than 7 Calendar Days after all concrete Patching and repairing is complete, and After 2 8 Calendar Days compressive strengths have been achieved. When the compressive strength of the cylinders tested does not conform to the acceptance criteria stated in ASTM C1577, ASTM C1786, or ASTM C1504, as applicable to the precast culvert type, the Engineer may allow retesting based on compression testing of cores, reject the sections, or assess a price reduction according to 00150.25. Be responsible for the safety of precast members during all stages of construction. Provide watertight structural connections at all joints. Design the connections to provide transverse and longitudinal alignment, mechanical interlock, prevent leakage, and resist design loads. Connections for consideration include reinforced grouted keyways, doweled connections, reinforced shear key or tongue and groove mating surfaces with joint sealant, reinforced half -lap and shear plate, or other reviewed and accepted structural connections as appropriate. Align all joints. Staggered joints are not allowed. Place a continuous flexible watertight seal in the joint, on the sides and top, between each precast reinforced concrete Box Section. Install according to m anufacturer’s recommendations. Provide a 3/4 inch chamfer on all concrete edges unless otherwise n oted.
00595.42 Precast Fabrication Tolerances and Shop Assembly -
a.General - Fabricate individual RCBC sections meeting the permissible variations defined in the applicable ASTM listed in 00595.41.
b.Shop Assembly - Shop assemble, in the presence of the Engineer, adjacent full RCBC sections including precast footings, wingwalls, and tops. Match -mark adjacent sections before shipping. Use complete structure or progressive assembly. Provide a concrete foundation at the 00595.43 633 fabricating facilit y that provides a flat plane surface used for shop assembly. Assemble Box Sections meeting the tolerances of 00595.44.
c.Rejection - Sections not meeting fabrication or shop assembly tolerances will be rejected. The Inspector’s inspection of any Material, Work, or finished members will not prevent their subsequent rejection, if later found damaged or defective, nor relieve the Contractor of the responsibility to correct or replace the Work at no additional cost to the Agency.
d.Transport - Do not ship any RCBC section, precast wingwall, or precast footing without the Inspector’s label or marking.
00595.43 Defects in Precast Sections - Furnish repair Materials from the QPL according
to 02015.30. Submit proposed repair plans and revised installation plan to the Engineer for review and acceptance before performing the repairs. Provide written confirmation from the RCBC d esign engineer of record that the repair methods are appropriate. Repair or replace damaged precast sections at no additional cost to the Agency, according to the following criteria:
a.Repair Cracked or Damaged RCBC - Repair cracked or damaged RCBC sections when: Cracks 0.01 inch or wider and less than 12 inches long that do not pass through the wall or slab thickness. Surface defects including honeycomb, bleedout, or spalls less than 4 percent of surface area of the Box Section face where the defect is located, or multiple surface defects with cumulative area less than 10 percent of the Box Section surface where the defect is located. Chipped or spalled edges 1 inch and greater in depth from the end of the bell or spigot and not exceeding the depth of the joint provided the cumulative length of chip or damage is not more 50 percent of the RCBC span or rise, whichever is greater, and no individual length of chip or damage is more than 25 percent of the structure’s span or rise, whichever is greater. The repaired sealing surface shall be free of spalls, cracks, or imperfections that would adversely affect the per formance of the joint. Sections with chipped or spalled edges exceeding these values must be replaced.
b.Replace Cracked or Damaged RCBC - Replace damaged RCBC sections having defects that that cannot be adequately repaired to full function or design l ife. Rejectable defects include: Inadequate reinforcing cover. Cracks that are full depth of the slab or wall thickness. Any crack that would prevent making a satisfactory joint. Surface defects including honeycomb, bleedout, or spalls having depth greater than the size of the Coarse Aggregate, exposing reinforcing steel, and havi ng a defect area greater than 4 percent of surface area of the face where the defect is located, or multiple surface defects with cumulative area gr eater than 10 percent of the surface where the defect is located are cause for rejection.
c.Minor Defects - Acceptable minor defects not requiring repair: A single end crack that does not exceed the depth of the joint. Cracks less than 0.01 inch wide and not passing through the wal l or slab thickness. 00595.44 A crack greater than 0.01 inch wide and less than 12 inches long that does not pass through the wall or slab thickness.
00595.44 Precast Installation :
Perform excavation, bedding and leveling course preparation, and backfill according to 00510 and 00405 as applicable. Cushion RCBC installed over unyielding foundation, including concrete, to prevent non-uniform bearing with a minimum 3 inch deep bedding and leveling course of Granular Material meeting
00405.12 Spread the leveling course the width and length of the RCBC plus a minimum 6 inches
all around. A concrete slab as leveling course is not allowed. Use lifting, lowering, and pulling construction Equipment according to the written installation plan. Do not use excessive force or unapproved equipment to push Box Sections into place. Handle Box Sections with care and prevent damage from cracking, dragging, and impact. Ensure the prepared foundation surface provides uniform bearing and proper line and grade for the RCBC. Do not rut or disturb the prepared foundation bedding and leveling course. If bearing, line and grade are not achieved, remove the RCBC section and make foundation corrections. Maintain the ends of Box Sections free of any deleterious materials that would prevent proper joining or sealing of adjacent sections. Assemble Box Sections within the following tolerances: Horizontal and Vertical Joint Variation - The maximum variation between mating surfaces in any assembled transverse joint, between Box Sections before grouting, shall be no more than 1/2 inch. The joint width shall vary no more than 3/8 inch over the length of the joint. Longitudinal Surfaces - Fit Box Sections together to form a smooth, uniform line of sections. The variation between internal surfaces of two adjoining precast Box Sections shall not be more than 1/4 inch, measured with a 12-foot straight edge across joints. Measurement
00595.80 Measurement - The quantities of cast-in-place RCBC will be measured on the length
basis, along the centerline of the RCBC, from end to end as shown. The quantities of precast RCBC will be measured on the length basis along the centerline of the RCBC from end to end as shown, including cast in place ends. No measurement of quantities will be made for wingwalls and aprons. Estimated quantities of concrete and reinforcement for wingwalls and aprons will be listed in the Special Provisions. Payment
00595.90 Payment - The accepted quantities of Work performed under this Section will be paid for
at the Contract unit price, per unit of measurement, for the following items: Pay Item Unit of Measurement
a.Cast-In-Place Reinforced Concrete Box Culverts ................................. Foot
b.Precast Reinforced Concrete Box Culverts ........................................... Foot
c.Precast Split Reinforced Concrete Box Culverts ................................... Foot
d.Precast Reinforced Concrete Three-Sided Structures .......................... Foot
e.Wingwalls ......................................................................................... Lump Sum
f.Aprons ............................................................................................. Lump Sum 00595.90 Item (a) includes cast-in-place ends regardless of the type of box culvert constructed. Items (b), (c), and (d) includes cast-in-place ends. No separate or additional payment will be made for closure pours, weldments, or structure connection systems; this Work is included in payment made for the applicable items in which they are used. Payment will be payment in full for furnishing and placing all Materials, including reinforcement and concrete, and for furnishing all Equipment, labor, and Incidentals necessary to complete the Work as specified. 00596A.00 Section 00596A - Mechanically Stabilized Earth Retaining Walls Description 00596A.00 Scope - This Work consists of furnishing and constructing mechanically stabilized earth (MSE) retaining walls as shown and specified. 00596A.01 Proprietary MSE Walls - The Special Provisions will list the types and locations of preapproved proprietary MSE Retaining Wall Systems to be constructed. 00596A.02 Cost Reduction Proposals - According to 00140.70, cost reduction proposals will be considered for Proprietary Retaining Wall Systems that are preapproved by the Agency before Advertisement of the Project. 00596A.03 Definitions: Alternate Gabion Basket Joint Fasteners - Spiral binders, high tensile locking spring steel clips, or clamp-on ring type fasteners that are alternates to tie wire for assembling and joining gabion units. Appurtenances - Traffic barriers, guardrail, fences, non-standard coping, drainage Structures, sign supports, lighting supports, sound barriers, foundations, and utilities that are not part of the Retaining Wall System but are connected to, resting on, or passing through the Retaining Wall System. Batter - The Slope of the wall facing from vertical that is expressed as degrees, or as a ratio of the horizontal change in inches for each 12 inches of vertical change. A vertical face has a zero batter. Extensible Tensile Reinforcements - Geosynthetic reinforcement where the deformation under load is equal to or greater than that of the reinforced backfill. Inextensible Tensile Reinforcements - Steel reinforcement where the deformation under load is significantly less than that of the reinforced backfill. Manufacturer - The fabricator having exclusive production rights for a Proprietary Retaining Wall System. Mechanically Stabilized Earth Retaining Wall System - A gravity Retaining Wall System composed of wall facing and granular backfill reinforced with either extensible or inextensible Soil reinforcements connected to the facing elements. Nonproprietary Retaining Wall System - A Retaining Wall System that is not patented or trademarked and its details are shown. Piecemark - An alpha-numeric marking that identifies a specific type of retaining wall component. All components with the same Piecemark are considered identical. Piecemarks shown on the Working Drawings identify placement of the component. Preapproved Proprietary Retaining Wall System - A wall system that is listed in Appendix 15-D of the Geotechnical Design Manual (GDM). Preapproved Proprietary Retaining Wall System Options - Acceptable preapproved proprietary retaining walls listed in the Special Provisions when Proprietary Retaining Wall Systems are required. Preapproved Proprietary Retaining Wall System Alternates - Acceptable preapproved proprietary retaining walls listed in the Special Provisions when Nonproprietary Retaining Wall Systems are shown. 00596A.04 Proprietary Retaining Wall System - A Retaining Wall System that is protected by trademark, patent, or copyright and is produced or distributed by a Manufacturer having exclusive rights. Retained Backfill - Unreinforced backfill behind the back of MSE reinforced backfill. Retaining Wall System - An engineered system of structural and geotechnical components that restrains a mass of earth. The terms "Retaining Wall System", "retaining Structure", and "retaining wall" are used interchangeably. 00596A.04 Proprietary Retaining Walls - Submit the following at least 30 Calendar Days before beginning construction of proprietary retaining walls: Complete stamped Working Drawings and design calculations prepared by the manufacturer, according to 00150.35. Manufacturer's field construction manual, according to 00150.37. Manufacturer's field representative's name and qualifications. Field verify existing ground elevations and bottom of wall elevations before preparing and submitting Working Drawings. Obtain the Engineer's written approval before beginning construction of the wall system.
a.Working Drawings - Working Drawings shall meet the requirements of the Project documents and the AASHTO LRFD Bridge Design Specifications, as modified by the ODOT GDM, and shall be consistent with the preapproved Retaining Wall System. Include the following items in the Working Drawings, as applicable:
1.General Notes - Information for design and construction of the retaining wall.
2.Plan View: • Construction centerline and related horizontal curve data. • Centerline station and offset to the wall control line or face of wall including the beginning and end points of the retaining wall. • Location, type, and size of all appurtenances. • Location of Right-of-Way and easement boundaries, staged construction, designated Wetlands, and all other Highway Structures, features, or facilities, or other construction constraints. • Length, size, number, and layout of Soil reinforcements. • Wall stations where changes in the Soil reinforcement length occur.
3.Elevation View: • Wall vertical curve data and wall elevations at a sufficient number of points along the top of wall that defines the top of wall alignment. • Field-verified elevations of original and final ground lines along face of the wall and top of leveling pad. • Vertical dimensions of steps along the top of leveling pad. • Centerline stations and elevations at the beginning and end of the wall. 00596A.04 • Horizontal offsets. • Changes in the top of wall Slope. • Type and size of facing components. • Layout of MSE wall panels, including wall finish pattern.
4.Typical Sections: • Typical sections at intervals of 50 feet or less along the wall. • Wall construction and limits of reinforced backfill. • Locations, length, size, and number of Soil reinforcements. • Original and final ground lines across Typical Sections, including Roadways, Highway Structures, and other facilities. • Construction centerline stationing at each Typical Section.
5.Structural and Geometric Details: • Leveling pad details, showing depths and limits of proposed excavation beyond the Neat Lines of the wall. • Top of wall elements such as coping, traffic barrier, and impervious membrane. • Panel details. • Final front face batter. • Details of wedges, shims, clamps, or bracing. • Reinforcing bar bend details. • Surface and subsurface drainage details for the wall, including drainage swale, filters, drains, and collector and outlet pipes. • Wall facing and Soil reinforcement construction details at Utility and drainage facilities, overhead sign support footings, bridge abutments, piles, shafts, and other Structures. • Wall initiations and terminations. • Details for wall slip joints, curves, and for external, internal, and acute angle corners. • Maximum inclinations of wall backslope and foreslope. • Elevation, Slope, and width of wall bench in front of wall. • Locations of anticipated shoring.
6.Appurtenances: • Wall appurtenance details needed to construct the wall. • Wall appurtenance details that are required but not fully detailed on the Plans.
7.Facing Components: • Dimensions, including thickness. • Details necessary to construct the facing components. • Reinforcing steel in the component. • Location of tensile Soil reinforcement attachment devices embedded in the facing. • Class of concrete finish. 00596A.04 • Architectural treatment, if applicable.
8.Soil Reinforcements - Soil reinforcement dimensions and details necessary to construct the wall.
9.Wall Construction Methods and Construction Sequence: • Wall construction methods. • Construction sequence. • Locations of all shoring.
10.Materials and Quantity Summary List - All items of each wall.
b.Design Calculations - Design calculations shall meet the requirements of the Project documents and AASHTO LRFD Bridge Design Specifications, as modified by the ODOT GDM, and shall be consistent with the preapproved Retaining Wall System. Retaining wall design parameters will be listed in the Special Provisions. Include the following items in the design calculations, as applicable:
1.Design Limits: • Structural and geotechnical design input parameters and design assumptions. • Wall design loads, load combinations, load factors, and resistance factors for each limit state.
2.Methodology: • Design steps with a detailed design narrative explaining the design and demonstrating how the design meets all applicable design requirements. • Explanation of all symbols and variables used in the calculations. • Hand calculations verifying results of computer generated wall design. Hand calculations are not required if the MSEW ® version 3.0 or later software program is used to design the wall.
3.External Stability Calculations - Calculations showing that the Retaining Wall System meets external stability requirements, including overturning, sliding, and bearing capacity.
4.Internal Stability Calculations: • Calculations showing that the retaining wall meets internal stability requirements at each level of the wall. • Calculations showing adequate resistance against Soil reinforcement rupture, pullout, and, reinforcement-facing connection failure. • Calculations showing adequate structural resistance of facing elements. • Calculations showing all structural details meet internal stability requirements, including construction details to accommodate vertical and horizontal obstructions in the reinforced backfill.
5.Compound Stability - Calculations showing that the retaining wall meets compound stability requirements. 00596A.05
6.Appurtenances: • Design calculations for wall Appurtenances that are required but not fully detailed on the Plans. • Calculations for all appurtenance load effects on the wall.
c.Manufacturer's Field Construction Manual - The Manufacturer shall prepare a field construction manual that includes detailed instructions for constructing the retaining wall. 00596A.05 Nonproprietary Retaining Wall - Submit complete unstamped Working Drawings according to 00150.35 at least 30 Calendar Days before beginning construction of nonproprietary retaining walls. Field verify existing ground elevations and bottom of wall elevations before preparing and submitting Working Drawings. Obtain the Engineer's written approval before beginning construction of the wall system. Materials 00596A.10 General:
a.Proprietary Retaining Wall Systems - Provide all Proprietary Retaining Wall System components from the same wall manufacturer. If there are conflicts between the manufacturer's requirements and the Agency's requirements, the Agency's requirements prevail.
b.Nonproprietary Retaining Wall Systems - Provide Materials according to the applicable material Specifications.
c.Quality Control - Provide quality control according to Section 00165. 00596A.11 Backfill:
a.Gravel Leveling Pads Backfill - Furnish dense graded 1" - 0 or 3/4" - 0 Aggregate base Material for leveling pads meeting the requirements of 02630.10.
b.MSE Granular Wall Backfill - Furnish dense graded 3/4" - 0 Aggregate base Material for walls meeting the requirements of 02630.10 and the following:
1.Material Passing No. 200 Sieve - The amount of Material passing the No. 200 sieve shall not exceed 15 percent by weight. Test according to AASHTO T 11.
2.Plasticity Index - The plasticity index of the Material passing the No. 40 sieve shall not exceed 6. Test according to AASHTO T 90. 00596A.12
3.Electrochemical Properties:
a.Backfill with Steel Soil Reinforcement: Property Limits Test Procedure pH 5.0 - 10.0 AASHTO T 289 Resistivity* 5,000 Ω-cm (min.) AASHTO T 288 * Backfill Material with resistivity between 5,000 Ω-cm and 3,000 Ω-cm is acceptable if it meets the following: Property Limits Test Procedure Chlorides 100 PPM (max.) AASHTO T 291 Sulfates 200 PPM (max.) AASHTO T 290
b.Backfill with Geosynthetic Soil Reinforcement: Property Limits Test Procedure pH 4.5 - 9.0* AASHTO T 289 * 3.0 - 10.0 for temporary retaining walls.
4.Organic Content - The organic content of material finer than the No. 10 sieve shall not exceed 1.0 percent. Test according to AASHTO T 267.
c.Modular Block Core and Drainage Backfill - Furnish 3/4" - No. 4 PCC Aggregate Material meeting the requirements of 02690.20(a) through (e).
d.Pipe Drain Backfill - Furnish granular drain backfill Material for drainage pipes meeting the requirements of 00430.11.
e.Gabion Basket Fill - Furnish a durable 4 to 8 inch size Rock Material meeting the requirements of 00390.11(b). 00596A.12 Concrete:
a.Cast-in-Place Concrete for Leveling Pads - Furnish Commercial Grade Concrete for leveling pads meeting the requirements of Section 00440.
b.Dry Cast Concrete Modular Block Facing - Furnish dry cast concrete blocks with the following properties:
1.Aggregate, Strength, Freeze-Thaw Durability, Unit Weight, and Water Absorption: • Aggregate meeting the requirements of ASTM C33. • Blocks meeting the requirements of ASTM C1372. • The average of three coupons or cores have a minimum compressive strength of 4,000 psi as tested according to ASTM C140. • Individual coupons or cores have a minimum compressive strength of 3,500 psi as tested according to ASTM C140. • A minimum oven-dry unit weight of 125 pcf as tested according to ASTM C140. 00596A.12 • Test, no longer than 18 months before delivery, freeze-thaw durability of five test specimens made with the same materials, concrete mix design, manufacturing process, and curing method that will be used on the Project. At least four of the five test specimens shall have a weight loss of not more than 1 percent of the block's initial weight after 150 freeze-thaw cycles as tested according to ASTM C1262. • A maximum water absorption of 1 percent above the water absorption of the sublot of blocks that were produced and passed the freeze thaw test. For the water absorption testing, do not use the same blocks used for the freeze-thaw test.
2.Portland Cement - Portland cement meeting the requirements of 02010.10.
3.Blended Hydraulic Cement - Blended hydraulic cement meeting the requirements of 02010.20.
4.Tolerances - Manufacture within the following geometric tolerances: • Molded length and width dimensions within ± 1/8 inch of the block manufacturer's nominal length and width dimensions. • Molded height dimension within ± 1/16 inch of the block manufacturer's nominal height dimension. • Rear height does not exceed the front height. • Top and bottom face groove dimensions within the tolerances specified by the manufacturer.
5.Color - Consistent natural color of dry cast concrete.
6.Finish - Split-face units that, when viewed from a distance of 10 feet under diffused light, chips, cracks, and other imperfections are not detectable.
7.Acceptance of Blocks - Acceptance will be determined on tolerances, visual inspection, compressive strength, water absorption, freeze-thaw durability, and unit weight. Acceptance of compressive strength, water absorption, and unit weight will be based on production sublots. The maximum number of blocks per production sublot is 2,000 blocks. Test blocks at the frequency of one set for each production sublot. Acceptance of freeze-thaw durability will be based on the freeze-thaw testing requirements of 00596A.12(b)(1).
8.Marking - Indicate the date of manufacture and the production sublot number on each sublot of dry cast concrete blocks.
9.Handling, Storing, and Shipping - Do not allow chipping, discoloration, cracks, or fractures during handling, storing and shipping.
10.Rejection - Blocks not meeting the requirements of this Subsection will be rejected.
c.Wet Cast Concrete Modular Block Facing - Furnish wet cast concrete blocks with the following properties:
1.Concrete - Commercial Grade Concrete meeting the requirements of Section 00440.
2.Marking - The rear face of each block is scribed with the date of manufacture, the production sublot number, and the Piecemark.
3.Color - Consistent natural color of wet cast concrete. 00596A.12
4.Finish - Smooth-face units that, when viewed from a distance of 10 feet under diffused light, chips, cracks, and other imperfections are not detectable.
5.Tolerance - Molded length and width dimensions within 1/4 inch of the manufacturer's dimensions. Molded height dimension within 1/8 inch of the manufacturer's dimension.
6.Handling, Storing, and Shipping - Do not allow chipping, discoloration, cracks, or fractures during handling, storing, and shipping.
7.Acceptance of Blocks - Acceptance will be determined by tolerances, visual inspection, and concrete strength. Concrete strength will be based on production sublots. A production sublot is 20 blocks or a single Day's production, whichever is less. The production sublot will be represented by a single compressive strength sample of one set of cylinders.
8.Rejection - Blocks not meeting requirements of this Subsection, or that exhibit any of the following defects, will be rejected: • Honeycombed or open texture concrete. • Extreme color variation on front face of block.
d.Cast-in-Place Concrete Panel Facing - Furnish Class 4000 - 3/4 structural concrete for cast-in-place concrete panel facings meeting the requirements of Section 02001.
e.Precast Concrete Panel Facing - Furnish precast concrete panel facings with the following properties:
1.Portland Cement Concrete - Furnish structural concrete as directed in the Special Provisions.
2.Casting - Set Soil reinforcement connection devices on the rear face of the precast panel and secure them for concrete placement and consolidation. Do not allow loop embeds, tie strips, or other devices used to connect Soil reinforcements to facing panels to contact the face panel reinforcement steel. Place concrete in each panel without interruption and consolidate with an approved vibrator. Use a release agent throughout the casting operation.
3.Supporting and Curing - Maintain full support, cure the panels, and do not strip or remove the forms from the units until the concrete has obtained a minimum compressive strength of at least 1,000 psi.
4.Finish - Finish the panel front face with a general surface finish according to 00540.53(a). Screed the panel back face to eliminate surface distortions and open pockets of Aggregate.
5.Tolerance - Manufacture within the following tolerances:
a.Panel Dimensions - Within ± 1/2 inch between diagonals. Within ± 3/16 inch for all other panel dimensions.
b.Soil Reinforcement Connection Devices: • Tie strip connection devices within ± 1 inch of the plan location. • Loop embeds within ± 3/16 inch of the plan location. • Retention slots within ± 1 inch of the plan location. Slot openings shall not exceed 1/8 inch. Check all slot openings with a Manufacturer supplied feeler gauge according 00596A.13 to the manufacturer's recommendations. Panels from which the feeler gauge is pulled from the slot will be rejected.
c.Panel Face - Smooth formed surfaces within ± 3/32 inch when measured with a 3-foot straightedge. Textured-finish surfaces within ± 3/16 inch when measured with a 3-foot straightedge.
d.Rear Face - Rear surface distortions within ± 1/4 inch.
6.Acceptance of Panel Concrete Strength - Acceptance will be according to 00540.17 except: • Acceptance of concrete strength will be determined based on production sublots. A production sublot will consist of either 40 panels or a single Day's production, whichever is less. Cast one set of cylinders for each production sublot. • Precast panel concrete strength may be conditionally accepted if the 7-Day initial strength exceeds 85 percent of the required 28-Day strength. Final acceptance of precast panel concrete strength will be based on the required 28-Day test results.
7.Marking - On the rear face of each panel scribe the date of manufacture, the production sublot number, and the Piecemark.
8.Handling, Storing, and Shipping - Do not allow chipping, discoloration, cracks, fractures, and connecting device damage during handling, storing, and shipping. Support stored panels on firm blocking.
9.Rejection - Panels not meeting the requirements of this Subsection will be rejected.
f.Cast-In-Place Concrete Coping - Furnish Class 3300 - 3/4 structural concrete for cast-in-place concrete coping meeting the requirements of Section 02001. 00596A.13 Steel:
a.Steel Reinforcement for Concrete - Furnish steel reinforcement for concrete meeting the requirements of Section 00530.
b.Steel Components - Furnish steel components meeting the requirements of Section 00560 and the following:
1.Soil Reinforcing Strips - Hot rolled from bars to the required shape and dimensions meeting the requirements of AASHTO M 223 Grade 65 (ASTM A572) and galvanized according to AASHTO M 111 (ASTM A123) to a minimum thickness of 3.4 mils.
2.Soil Reinforcing Mesh: • Shop fabricated welded wire reinforcement from cold drawn steel wire meeting the requirements of AASHTO M 32 (ASTM A82), welded into the finished mesh according to AASHTO M 55 (ASTM A185) and galvanized after fabrication according to AASHTO M 111 (ASTM A123) to a minimum thickness of 3.4 mils. • Twisted mesh Soil reinforcing mesh meeting the requirements of Section 02340.
3.Tie Strips - Shop-fabricated hot rolled steel meeting the requirements of ASTM A1011 Grade 50 and galvanized according AASHTO M 111 (ASTM A123) to a minimum thickness 3.4 mils. 00596A.31
4.Fasteners - Galvanized high-strength bolts meeting the requirements of 02560.20.
5.Connector Pins and Mat Bars - Fabricated from cold drawn steel wire meeting the requirements of AASHTO M 32 (ASTM A82) and galvanized according to AASHTO M 111 (ASTM A123) to a minimum thickness of 3.4 mils.
c.Gabion Baskets - Furnish gabion baskets meeting the requirements of Section 02340. 00596A.14 Geosynthetics:
a.Geotextile Filter Layer for Subsurface Drainage Systems - Furnish Type 1 drainage geotextile according to Section 02320.
b.Gabion Facing Geotextile Filter - Furnish Type 2 riprap geotextile for gabion wall filter according to Section 02320.
c.Precast Concrete Facing Panel Joint Cover - Furnish Type 1 drainage geotextile for concrete wall facings according to Section 02320.
d.Modular Block Drainage Fill Geotextile Filter - Furnish Type 1 drainage geotextile according to Section 02320.
e.Welded Wire Facing Geotextile Filter - Furnish Type 1 drainage geotextile according to Section 02320.
f.Geosynthetic Soil Reinforcements:
1.Geotextile - Provide geotextile according to Section 02320.
2.Geogrid - Provide geogrid according to Section 02320. 00596A.15 Elastomeric Bearing Pads for Precast Concrete Facing Panels - In horizontal and diagonal joints between precast concrete panels, furnish the grade, size, number and type of bearing pads shown in the stamped Working Drawings and design calculations prepared by the Manufacturer. Determine the stiffness, size, and number of bearing pads so that the final joint opening is 3/4 inch ± 1/8 inch or as shown. 00596A.16 Concrete Modular Block Facing Connection Devices - Furnish concrete modular block connection devices as directed in the Special Provisions. Labor 00596A.30 Quality Control Personnel - Provide technicians with CAgT, CDT, and CEBT certifications. 00596A.31 Manufacturer's Representative Qualifications and Duties - Provide a Manufacturer's representative meeting the following qualifications: Is a licensed professional engineer in the State of Oregon or, when the licensed professional engineer is in "responsible charge" of the Work, an unlicensed designee assigned by the licensed professional engineer. Has been trained by the Manufacturer in the construction, installation, and inspection of the selected Proprietary Retaining Wall System. 00596A.40 The Manufacturer's representative is required to perform the following duties:
a.Preconstruction Conference - Meet with the Engineer and all Contractor supervisory personnel and Subcontractors involved in construction of the proprietary retaining wall at the preconstruction conference to discuss methods of accomplishing all phases of Work required to construct the proprietary retaining wall.
b.Initial Wall Construction - Be present at the retaining wall construction site and provide technical assistance to the Contractor and Engineer during all wall construction activities from the beginning of wall construction until at least 10 percent of the total wall length is successfully installed and backfilled to a height of at least 10 feet, or the actual wall height, whichever is less. Submit daily field observation reports no later than noon of the next Day of wall construction. Include the following information in the daily field observation reports: Date of observation. Description of wall construction observed and on-site technical assistance provided to the Contractor for proper construction procedures according to the Manufacturer’s field construction manual. Documentation of all communications with the Contractor and Engineer. Name and signature.
c.Remaining Wall Construction - Be available by phone or in person as needed throughout the remaining construction of the proprietary retaining wall to provide technical assistance to the Contractor and Engineer.
d.Final Field Observation Meeting - Conduct a final field observation meeting after completing retaining wall construction with the Engineer and Contractor. Submit a final field observation meeting report that includes the following information within 5 Calendar Days after the final field observation meeting: Date of observation. Documentation of all retaining wall deficiencies. Recommendation to accept or reject the retaining wall construction. Provide a stamped final report to the Engineer no later than 10 Calendar Days after the final field observation meeting. Include the following information in the final report: Preconstruction meeting minutes. All daily field observation reports. Transcripts of all communications with the Contractor and the Engineer during the remaining wall construction phase. Final field observation report. Construction 00596A.40 General:
a.Proprietary Retaining Walls - Construct proprietary retaining walls according to Agency requirements, Manufacturer's Working Drawings, and the Manufacturer's field construction manual. If the Manufacturer's Working Drawings or the Manufacturer's field construction manual conflict with Agency requirements, Agency requirements take precedence. 00596A.42 Follow instructions and recommendations of the representative if approved by the Engineer.
b.Nonproprietary Retaining Walls - Construct nonproprietary retaining walls as shown. 00596A.41 Excavation and Foundation Preparation - Perform excavation and prepare and backfill wall foundations according to Section 00510 and the following: Grade the foundation level for a width equal to the combined width of the bottom Soil reinforcements plus the facing component thickness plus 1.0 foot on each side. Place backfill Material in nearly horizontal layers not more than 8 inches thick. Compact the entire surface of each layer with at least three Coverages, using Equipment made specifically for compaction. Routing hauling and grading Equipment over the surface is not acceptable for compaction. Do not construct backfill when the backfill, the foundation, or the embankment on which it would be placed is frozen, or unstable. 00596A.42 Leveling Pads:
a.Cast-in-Place Leveling Pads - Construct cast-in-place leveling pads with: Unreinforced concrete. A width of at least the block front face to block back face plus 12 inches (6 inches on each side of the facing units). A thickness of 6 inches ± 1/4 inch. A location tolerance of ± 1 inch of the design location. A top pad tolerance of ± 1/8 inch of the design elevation. Cure cast-in-place leveling pads at least 12 hours before placing the wall facing.
b.Gravel Leveling Pads - Construct gravel leveling pads with: A width of at least the width of the facing plus 12 inches (6 inches on each side of the facing units). A thickness of at least 6 inches. A location tolerance of ± 1 inch of the design location. A top pad tolerance of ± 1/8 inch of the design elevation. Compact gravel leveling pads in 3 to 4 inch Lifts using a minimum of three Passes of a walk behind vibratory plate compactor with a gross static weight of not less than 125 pounds and a total compaction static plus dynamic force of not less than 2,000 pounds.
c.Leveling Pad Types - Construct the following types of leveling pads: Leveling Pads for Precast Concrete Panel Facing - Unreinforced cast-in-place concrete leveling pad at each facing foundation level. Leveling Pads for Dry Cast Modular Concrete Block Facing - Unreinforced cast-in-place concrete leveling pad or a gravel leveling pad at each facing foundation level. Leveling Pads for Wet Cast Modular Concrete Block Facing - Unreinforced cast-in-place concrete leveling pad or a gravel leveling pad at each facing foundation level. 00596A.43 Leveling Pads for Gabion Unit Facing - Unreinforced cast-in-place concrete leveling pad or a gravel leveling pad at each facing foundation. Leveling Pads for Welded Wire Facing - Unreinforced cast-in-place concrete leveling pad or a gravel leveling pad at each facing foundation level. Leveling Pads for Cast-in-Place Concrete Facing - Unreinforced cast-in-place concrete leveling pad at each facing foundation level. 00596A.43 Subsurface Drainage - Install subsurface drainage before constructing walls. 00596A.44 Erecting Wall Facing:
a.Dry Cast Modular Concrete Block Facing:
1.Placement - Begin placing the first course of blocks on top of and in full contact with the lowest foundation level of the leveling pad. Level and align all blocks. Lay blocks as close together as possible and parallel to the straight or curved line of the wall face. Place blocks in vertical or battered positions as shown. Level each course block-to-block and front-to-back. Set each block on the blocks below without rocking. Correct high areas by grinding or shimming with approved shims. Do not use shims within 1 inch of the front face. Do not exceed a shim stack thickness of 1/16 inch. Stack all blocks in a running bond pattern with each block spanning the joint below. Place MSE granular wall backfill with each course of blocks. When shown, place modular block core backfill and drainage fill backfill, and install drainage fill geotextile and shear pins with each course of blocks. Install Soil reinforcements and connect them to the facing. Remove all backfill that is on top of the blocks before installing the next course of blocks or Soil reinforcements. Attach the top row of dry cast concrete blocks or cap blocks to the underlying blocks with an adhesive from the QPL. Clean the finished exposed wall face of all foreign material deposits.
2.Tolerances: • First course of wall facing located within ± 1/4 inch of the design horizontal alignment. • Final out of plane concavity or convexity of the front face within ± 3/4 inch in 10 feet. • Final deviation from the design Batter within ± 1 1/4 inch for each 10 feet of wall height. • Outward leaning Batter is zero. • Each course of blocks within ± 1/16 inch of level when checked with a 4-foot straightedge level. • Out of plane offset between consecutive rows within 3/4 inch of the planned offset. • Finished top of wall elevation within ± 1 inch of the design elevation.
b.Wet Cast Modular Concrete Block Facing:
1.Placement - Begin placing the first course of blocks on top of and in full contact with the lowest foundation level of the leveling pad. Level and align all blocks. Lay blocks as close together as possible and parallel to the straight or curved line of the wall face. Place blocks in vertical or battered positions as shown. Level and set each block on the blocks below without rocking. Correct high areas by grinding or shimming with approved shims. Do not use shims within 1 inch of the front face. Do not exceed a shim stack thickness of 1/8 inch. Stack all blocks in a running bond pattern with each block spanning the joint below. 00596A.44 Place MSE granular wall backfill with each course of blocks. When shown, place modular block core backfill and drainage fill backfill, and install drainage fill geotextile with each course of blocks. Install Soil reinforcements and connect them to the facing. Remove all backfill that is on top of the blocks before installing the next course of blocks or Soil reinforcements. Install Soil reinforcements and connect them to the facing. Clean the finished exposed wall face of all foreign material deposits.
2.Tolerances: • First course of wall facing located within ± 1/4 inch of the design horizontal alignment. • Final out of plane concavity or convexity of the front face within ± 3/4 inch in 10 feet. • Final deviation from the design Batter within ± 1 1/4 inch for each 10 feet of wall height. • Outward leaning Batter is zero. • Each course of blocks within ± 1/8 inch of level when checked with a 4-foot straightedge level. • Front-to-back tilting within ± 1/4 inch of the design Batter when measured with a straightedge level long enough to span the entire front-to-back distance of the block. • Out of plane offset between consecutive rows within ± 3/4 inch from the planned offset. • Finished top of wall elevation within ± 1 inch of design elevation.
c.Precast Concrete Panel Facing:
1.Placement - Maintain vertical alignment with temporary wedges, clamps, or bracing when placing fill material. Use at least two, but not more than three rows of panel wedges in place at all times during wall construction. Place panel joint geotextile and MSE granular wall backfill with each level of panels. Install Soil reinforcements and connect them to the facing.
2.Tolerances: • First course of wall facing located within ± 1/4 inch of the design horizontal alignment. • Final out of plane concavity or convexity of the front face within ± 3/4 inch in 10 feet. • Final deviation from the design Batter within ± 1/2 inch for each 10 feet of wall height. • Outward leaning Batter is zero. • Out of plane offset at panel joints within ± 1/2 inch. • Final joint openings between adjacent facing panel units within ± 1 inch. • Finished top of wall elevation within ± 1 inch of design elevation. Reconstruct wall sections not conforming to these tolerances at no additional cost to the Agency.
d.Cast-in-Place Concrete Fascia with Welded Wire Walls:
1.Placement - Place cast-in-place concrete fascia after the welded wire walls and backfill are completed to full height, and after anticipated settlement has taken place. Construct cast-in-place fascia and connect to welded wire wall as shown. Maintain vertical and continuous alignment of all expansion joints and deep score joints from bottom to top of wall. Horizontal joints are not allowed.
2.Tolerances: • First course of wall facing located within ± 1/4 inch of the design horizontal alignment. 00596A.44 • Final out of plane concavity or convexity within ± 3/4 inch in 10 feet. • Final deviation from the design Batter within ± 1 inch for each 10 feet of wall height. • Outward leaning Batter is zero. • Out of plane offset at panel joints within ± 1/2 inch. • Finished top of wall elevation within ± 1 inch of design elevation.
e.Welded Wire Facing:
1.Placement - Erect welded wire wall facing including Soil reinforcements and other associated elements according to the wall Manufacturer's field construction manual. Begin placing the first course of welded wire reinforcement on top of and in full contact with the lowest foundation level of the leveling pad. Level and align all welded wire reinforcement. Place welded wire wall geotextile filter and MSE granular wall backfill with each level of welded wire facing. Install Soil reinforcements and connect them to the facing. Place remaining courses in vertical or battered positions as shown.
2.Tolerances: • First course of wall welded wire reinforcement facing located within ± 1/4 inch of the design horizontal alignment. • Final out of plane concavity or convexity within ± 2 inches in 10 feet. • Final deviation from the design Batter within ± 1 inch for each 10 feet of wall height. • Outward leaning Batter is zero. • Out of plane offset between consecutive rows within ± 1 inch of the planned offset. • Finished top of wall elevation within ± 1 inch of design elevation.
f.Gabion Basket Facing:
1.Placement - Use the same style of mesh for the gabion panel bases, ends, sides, diaphragms, and lids. Use the same method of joining the edges of a single gabion unit. Use the same method of tying successive gabion units and Soil reinforcement together throughout each Structure. Place gabion facing geotextile filter and MSE granular wall backfill with each level of gabion facing. Install Soil reinforcements and connect them to the facing. Place remaining courses in vertical or battered positions as shown.
2.Tolerances: • First course of gabion basket facing within ± 1/4 inch of the design horizontal alignment. • Final out of plane concavity or convexity within ± 2 inches in 10 feet. • Final deviation from the design Batter within ± 1 inch for each 10 feet of wall height. • Outward leaning Batter is zero. • Out of plane offset between consecutive rows within ± 1 inch from the planned offset. • Finished top of wall elevation within ± 1 inch of design elevation.
g.Wrapped-Face Construction (Temporary Geotextile Reinforced Wrapped-Face MSE Retaining Wall):
1.Placement - Geotextile wrapped-face construction shall be according to Section 00350 and the ODOT GDM. 00596A.46
2.Tolerances: • Along base, construct face of wall within 2 inches (horizontally) of location staked on the ground. • Place geotextile Soil reinforcement and tail geotextile sheets vertically within 1 inch of elevation shown on Plans. • Maximum outward bulge of the face between Soil reinforcement layers shall not exceed 6 inches. • Final out of plane concavity or convexity within 5 inches in 10 feet. • Final deviation from the design Batter within 3 inches for each 10 feet of wall height. • Outward leaning Batter is zero. • Finished top of wall elevation within 2 inches of design elevation. 00596A.45 Geotextile Placement:
a.Precast Concrete Facing Panel Joint Cover Geotextile - Cover all joints, gaps, and openings on the back side of walls with at least 12 inch wide precast concrete facing panel joint cover geotextile centered over the joints, gaps, and openings. Attach with an approved adhesive. Apply adhesive to the wall panel before applying the geotextile to the panel. Overlap geotextile seams at least 4 inches.
b.Gabion Facing Riprap Geotextile Filter - Install gabion facing riprap geotextile filter according to Section 00350 except place geotextile against the back of the gabion wall before placing backfill Material and provide at least 12 inch overlaps.
c.Modular Block Facing Drainage Fill Geotextile Filter - Install modular block facing drainage fill geotextile according to 00350.41.
d.Welded Wire Wall Geotextile Filter - Install welded wire wall facing geotextile according to 00350.41. 00596A.46 Soil Reinforcement Placement - Connect all Soil reinforcement to the wall facing units as shown. Field cut Soil reinforcement only when shown. Submit stamped Working Drawings and calculations according to 00150.35 if field conditions require splaying or skewing of Soil reinforcement or for other obstruction avoidance methods. Do not misalign wall facings or damage Soil reinforcements when placing reinforced backfill Material. Remove and replace all misaligned wall facings or damaged Soil reinforcements at no additional cost to the Agency.
a.Inextensible Soil Reinforcement Components - Place the Soil reinforcement components normal to the face of the wall. Connect all reinforcements to the wall facing units as shown. At each Soil reinforcement level, level and compact backfill to the grade of the connection before placing the next level of Soil reinforcement. Install the Soil reinforcement no lower than the connection elevation but no more than 2 inches above the connection elevation. Maintain at least 3 inches of vertical separation between overlapping Soil reinforcements. To avoid vertical obstructions along a horizontal plane at the reinforcing level, a deviation up to 15 degrees from normal to the wall face (splay angle) may be allowed for strip reinforcements with bolted connections. Grid reinforcements may be splayed up to 15 degrees if the connection is properly designed and fabricated to accommodate the splay and is approved by the Agency. To avoid horizontal obstructions, it is permissible to deflect Soil reinforcements up to 15 degrees along a vertical plane normal to the wall face (vertical skew). Soil reinforcement deflections shall be gradual and smooth to avoid damage to the steel galvanization. 00596A.47
b.Extensible Soil Reinforcement Components - Orient geogrid Soil reinforcements with the highest strength axis perpendicular to the face of the wall. Connect all reinforcements to the wall facing units as shown. Use geogrid Soil reinforcements that are continuous throughout their embedment lengths. Do not splice connections along the highest strength axis. Do not cut geogrid Soil reinforcements unless approved. Place geogrid Soil reinforcement directly on the compacted backfill horizontal surface. Before placing a subsequent layer of backfill, pull the geogrid Soil reinforcement taut and maintain tautness until the layer of backfill is placed. Install the geogrid Soil reinforcement no lower than the connection elevation but no more than 2 inches above the connection elevation. Maintain at least 3 inches of vertical separation between overlapping geogrid Soil reinforcement where geogrid Soil reinforcement layers overlap. 00596A.47 Reinforced Backfill Placement and Compaction:
a.Concrete Modular Block Facing - Complete all drainage fill, core fill, and block opening fill before proceeding to the next level. Do not construct backfill higher than the installed facing blocks.
b.Soil Reinforcement - Place backfill material by moving Equipment parallel to or away from the wall facing. Do not brake suddenly or make sharp turning movements. On extensible Soil reinforcement: Maintain the reinforcement in a taut condition. Do not operate Equipment on it until at least 6 inches of backfill is placed over it. On inextensible Soil reinforcement: Maintain reinforcement perpendicular to the wall face. Do not operate Equipment on it until at least 3 inches of backfill is placed over it.
c.Compaction - Meet the following requirements:
1.Maximum Density and Optimum Moisture Content - Determine maximum density and optimum moisture content of the MSE granular backfill material according to AASHTO T 99 Standard Proctor Method A, with coarse particle correction according to ODOT TM 223.
2.Moisture Content - Prepare the reinforced backfill material to within minus 4 percent to plus 2 percent of optimum moisture content at the time of compacting. Add water to material that does not contain sufficient moisture and thoroughly mix. Remove excess moisture by manipulation, aeration, drainage, or other means before compacting.
3.Density:
a.Reinforced Backfill Placed 3 Feet or More Behind Wall Facing Units - Compact reinforced backfill that is placed 3 feet or more behind wall facing units to 95 percent of maximum density determined by the nuclear gauge testing method.
b.Reinforced Backfill Placed Within 3 Feet Behind Wall Facing Units - Compact reinforced backfill that is placed within 3 feet behind wall facing units to 95 percent of maximum density determined by the test pad testing method. Use walk-behind vibratory rollers or vibratory plate compactors that have sufficient static and dynamic forces to achieve compaction without causing distortion of the wall facing units and keeping the wall facing units 00596A.80 within the tolerances listed in 00596A.44. Compact backfill within this zone by making at least three compaction Passes.
c.Spread Footing for Bridge Abutment on MSE Retaining Wall - Compact reinforced backfill that is placed in the spread footing foundation support zone to 100 percent of maximum density determined by the nuclear gauge testing method. The spread footing foundation support zone is defined by the following limits: • Extends to a depth which is twice the footing width or 6 feet, whichever is greater. • Extends laterally the width of the footing beyond the bottom edge of the footing in all directions. When the bridge spread footing is located less than the width of one spread footing from the MSE wall, the spread footing foundation support zone between the spread footing and MSE wall may be reduced to: • A minimum of 18 inches when steel Soil reinforcements are used. • A minimum of 36 inches when geogrid Soil reinforcements are used.
4.Testing Methods and Frequency:
a.Nuclear Gauge Method - Test in-place field density according to AASHTO T 310. Test at the frequency required in the ODOT Manual of Field Test Procedures.
b.Test Pad Method - Determine the number of compaction Passes necessary to achieve the specified density by constructing a test pad that is at least 5 feet wide, 15 feet long, and 2 feet deep. Construct test pad fill in layers no more than 8 inches thick using the same Equipment and methods that will be used to compact the wall backfill. Perform at least one density test according to AASHTO T 310 on each test pad layer. Construct and test a new test pad when changes in material occur or different Equipment is used during the construction of the wall backfill.
5.Deflection Requirement - Conduct at least one deflection test, witnessed by the Engineer, on each compacted layer of backfill placed 3 feet or more behind wall facing units according to ODOT TM 158. If the tested layer exhibits yielding, deflection, reaction, or pumping, rework the area to provide acceptable test results before placing the next layer. Maintenance 00596A.60 Protecting Work - Protect and repair Work as follows: Do not allow runoff from adjacent areas to enter the wall construction site during construction operations. At the end of each Day's operation, direct potential runoff away from the wall by sloping the last Lift of backfill away from the wall facing. Rework and repair all damaged Subgrade areas to the depth where undamaged Work is encountered. Measurement 00596A.80 Measurement - The quantities of Work performed under this Section will be measured according to the following: No measurement of quantities will be made for retaining walls. Estimated quantities of nonproprietary retaining walls will be listed in the Special Provisions. 00596A.90 The quantities of Type "F" traffic barrier coping with moment slab will be measured on the length basis, from end to end of coping. The quantities of sidewalk coping will be measured on the area basis, from end to end and from top of curb to exterior edge of coping. Excavation below elevations shown will be measured according to 00510.80(b). Payment 00596A.90 Payment - The accepted quantities of Work performed under this Section will be paid for at the Contract unit price, per unit of measurement, for the following items: Pay Item Unit of Measurement
a.Retaining Wall, MSE ....................................................................... Lump Sum
b.____ Inch Type "F" Traffic Barrier Coping with Moment Slab .............. Foot
c.Sidewalk Coping ........................................................................... Square Foot In item (b), the height of barrier will be inserted in the blank. Payment will be payment in full for furnishing and placing all Materials, and for furnishing all Equipment, labor, and Incidentals necessary to complete the Work as specified. Excavation below elevations shown will be paid for according to 00510.90(c). No separate or additional payment will be made for: Manufacturer's representative excavation, shoring, leveling pads, and specified backfill wall drainage and filter systems Soil reinforcement cast-in-place and precast standard coping 00596B.03 Section 00596B - Prefabricated Modular Retaining Walls Description 00596B.00 Scope - This Work consists of furnishing and constructing prefabricated modular gravity retaining walls as shown and specified. 00596B.01 Proprietary Prefabricated Modular Walls - The Special Provisions will list the types and locations of preapproved proprietary prefabricated modular Proprietary Retaining Wall Systems to be constructed. 00596B.02 Cost Reduction Proposals - According to 00140.70, cost reduction proposals will be considered for Proprietary Retaining Wall Systems that are preapproved by the Agency before Advertisement of the Project. 00596B.03 Definitions: Alternate Gabion Basket Joint Fasteners - Spiral binders or high tensile locking spring steel clip or clamp-on ring type fasteners specified as an alternate to tie wire for assembling and joining gabion units. Appurtenances - Traffic barriers, guardrail, fences, non-standard coping, drainage Structures, sign supports, lighting supports, sound barriers, foundations, and utilities that are not part of the Retaining Wall System but are connected to, resting on, or passing through the Retaining Wall System. Batter - The Slope of the wall facing from vertical that is expressed as degrees, or as a ratio of the horizontal change in inches for each 12 inches of vertical change. A vertical face has a zero Batter. Bin Wall - A prefabricated modular gravity Retaining Wall System type composed of metal or precast concrete modules backfilled with Granular Material. Crib Wall - A prefabricated modular gravity Retaining Wall System type composed of interlocking longitudinal and transverse beams made of precast reinforced concrete and backfilled with Granular Material. Dry Cast Concrete Block Gravity Wall - A prefabricated modular gravity Retaining Wall System type composed of dry cast concrete blocks without Soil reinforcements. Gabion Gravity Wall - A prefabricated modular gravity Retaining Wall System type composed of assembled wire baskets that are connected together and filled with specified Rock. Manufacturer - The fabricator having exclusive production rights for a Proprietary Retaining Wall System. Nonproprietary Retaining Wall System - A Retaining Wall System that is not patented or trademarked and its details are shown. Piecemark - An alpha-numeric marking that identifies a specific type of retaining wall component. All components with the same Piecemark are considered identical. Piecemarks shown on the Working Drawings identify placement of the component. Preapproved Proprietary Retaining Wall System - A wall system that is listed in Appendix 15-D of the Geotechnical Design Manual (GDM). 00596B.04 Preapproved Proprietary Retaining Wall System Options - Acceptable preapproved proprietary retaining walls listed in 00596B.01 when Proprietary Retaining Wall Systems are required. Preapproved Proprietary Retaining Wall System Alternates - Acceptable preapproved proprietary retaining walls listed in 00596B.01 when Nonproprietary Retaining Wall Systems are shown. Prefabricated Modular Retaining Wall System - A basic gravity Retaining Wall System type composed of solid or hollow prefabricated concrete or steel modules. Hollow modules are typically backfilled with Granular Material. Prefabricated modular retaining walls include metal and precast concrete bin, precast concrete crib, gabion, dry cast concrete block, and wet cast concrete block gravity retaining walls. Proprietary Retaining Wall System - A Retaining Wall System that is protected by trademark, patent, or copyright and is produced or distributed by a Manufacturer having exclusive rights. Retained Backfill - Unreinforced backfill within a distance of H/2 behind the back of the wall, where H is the total height of the wall excluding the leveling pad or footing. Retaining Wall System - An engineered system of structural and geotechnical components that restrains a mass of earth. The terms "Retaining Wall System", "retaining Structure", and "retaining wall" are used interchangeably. Wet Cast Concrete Block Gravity Wall - A gravity Retaining Wall System type composed of wet cast concrete blocks without Soil reinforcements. 00596B.04 Proprietary Retaining Walls - Submit the following at least 30 Calendar Days before beginning construction of proprietary retaining walls: Complete stamped Working Drawings and design calculations prepared by the Manufacturer, according to 00150.35. Manufacturer's field construction manual, according to 00150.37. Manufacturer's field representative's name and qualifications. Field verify existing ground elevations and bottom of wall elevations before preparing and submitting Working Drawings. Obtain the Engineer's written approval before beginning construction of the wall system.
a.Working Drawings - Working Drawings shall meet the requirements of the Project documents and the AASHTO LRFD Bridge Design Specifications, as modified by the ODOT GDM, and shall be consistent with the preapproved Retaining Wall System. Include the following items in the Working Drawings, as applicable:
1.General Notes - Information for design and construction of the retaining wall.
2.Plan View: • Construction centerline and related horizontal curve data. • Centerline station and offset to the wall control line or face of wall including the beginning and end points of the retaining wall. • Location, type and size of all Appurtenances. 00596B.04 • Location of Right-of-Way and easement boundaries, staged construction, designated Wetlands, and all other Highway Structures, features, or facilities or other construction constraints.
3.Elevation View: • Wall vertical curve data and wall elevations at a sufficient number of points along the top of wall that defines the top of wall alignment. • Field verified elevations of original and final ground lines and foundation bearing elevation along face of the wall. • Vertical dimensions of steps along the wall base (foundation bearing elevation). • Centerline stations and elevations at the beginning and end of the wall. • Horizontal offsets. • Changes in the top of wall Slope. • Layout of prefabricated modular units. • Architectural treatment.
4.Typical Sections: • Typical sections at intervals of 50 feet or less along the wall. • Wall construction limits. • Original and final ground lines across Typical Sections, including Roadways, Highway Structures, and other facilities. • Construction centerline stationing at each Typical Section.
5.Structural and Geometric Details: • Leveling pad details, showing depths and limits of proposed excavation beyond the Neat Lines of the wall. • Prefabricate modular unit details. • Final front face Batter. • Reinforcing bar bend details. • Surface and subsurface drainage details for the wall. • Prefabricated modular unit construction details at Utility and drainage facilities, overhead sign support footings, guardrails, traffic barriers, piles, shafts, or other Structures. • Maximum inclinations of wall backslope and foreslope. • Elevation, Slope, and width of wall bench in front of wall. • Locations of anticipated shoring.
6.Appurtenances: • Wall appurtenance details needed to construct the wall. • Wall appurtenance details that are required but not fully detailed on the Plans.
7.Wall Construction Methods and Construction Sequence: • Wall construction methods. 00596B.05 • Construction sequence. • Locations of all shoring.
8.Materials and Quantity Summary List - All items of each wall.
b.Design Calculations - Design calculations shall meet the requirements of the Project documents and AASHTO LRFD Bridge Design Specifications, as modified by the ODOT GDM, and shall be consistent with the preapproved Retaining Wall System. Include the following items in the design calculations, as applicable:
1.Design Limits: • Structural and geotechnical design input parameters and design assumptions. • Wall design loads, load combinations, load factors, and resistance factors for each limit state.
2.Methodology: • Design steps with a detailed design narrative explaining the design and demonstrating how the design meets all applicable design requirements. • Explanation of all symbols and variables used in the calculations. • A set of hand calculations verifying typical computer generated output.
3.External Stability Calculations - Calculations showing that the Retaining Wall System meets external stability requirements, including overturning, sliding, and bearing capacity.
4.Internal Stability Calculations: • Calculations showing that the retaining wall meets internal stability requirements at each level of the wall. • Calculations showing adequate structural resistance of prefabricated modular units.
5.Compound Stability - Calculations showing that the retaining wall meets compound stability requirements.
6.Appurtenances: • Design calculations for wall Appurtenances that are required but not fully detailed on the Plans. • Calculations for all appurtenance load effects on the wall. Retaining wall design parameters will be listed in the Special Provisions.
c.Manufacturer's Field Construction Manual - The Manufacturer shall prepare a field construction manual that includes detailed instructions for constructing the retaining wall. 00596B.05 Nonproprietary Retaining Wall Submittals - Submit complete unstamped Working Drawings according to 00150.35 at least 30 Calendar Days before beginning construction of nonproprietary retaining walls. Field verify existing ground elevations and bottom of wall elevations before preparing and submitting Working Drawings. Obtain the Engineer's written approval before beginning construction of the wall system. 00596B.12 Materials 00596B.10 General:
a.Proprietary Retaining Wall Systems - Provide all Proprietary Retaining Wall System components from the same wall Manufacturer. If there are conflicts between the Manufacturer's requirements and the Agency's requirements, the Agency's requirements prevail.
b.Nonproprietary Retaining Wall Systems - Provide Materials according to the applicable material Specifications.
c.Quality Control - Provide quality control according to Section 00165. 00596B.11 Backfill:
a.Gravel Leveling Pads Backfill - Furnish dense graded 1" - 0 or the 3/4" - 0 Aggregate base Material for leveling pads meeting the requirements of 02630.10.
b.Modular Block Core and Drainage Backfill - Furnish 3/4" - No. 4 PCC Aggregate Material meeting the requirements of 02690.20(a) through (e).
c.Gabion Basket Fill - Furnish a durable well graded 4 to 8 inch size Rock Material meeting the requirements of 00390.11(b).
d.Retaining Wall Granular Backfill - Furnish dense graded 1" - 0 or 3/4" - 0 Aggregate base Material meeting the requirements of 02630.10 and the following:
1.Material Passing No. 200 Sieve - The amount of material passing the No. 200 sieve shall not exceed 15 percent by weight. Test according to AASHTO T 11.
2.Plasticity Index - The plasticity index of the material passing the No. 40 sieve shall not exceed 6. Test according to AASHTO T 90.
e.Pipe Drain Backfill - Furnish granular drain backfill Material for drainage pipes meeting the requirements of 00430.11. 00596B.12 Concrete:
a.Cast-in-Place Concrete for Leveling Pads - Furnish Commercial Grade Concrete for leveling pads meeting the requirements of Section 00440.
b.Precast Concrete Bin Units - Furnish precast concrete bin units with the following properties:
1.Portland Cement Concrete - Class 4000 - 3/4 structural concrete meeting the requirements of Section 00540.
2.Casting - Place concrete in each bin unit without interruption and consolidate with an approved vibrator. Use a release agent throughout the casting operation.
3.Supporting and Curing - Maintain full support, cure the units, and do not strip or remove the forms from the units until the concrete has obtained a minimum compressive strength of at least 1,000 psi.
4.Finish - Finish the bin unit front face with a general surface finish according to 00540.53(a). 00596B.12
5.Tolerances - Manufacture units within the following tolerances:
a.Unit Dimensions - Within ± 1/2 inch between diagonals. Within ± 3/16 inch for all other unit dimensions.
b.Unit Face - Smooth formed surfaces within ± 3/32 inch when measured with a 3-foot straightedge. Textured-finished surfaces within ± 3/16 inch when measured with a 3-foot straightedge.
6.Acceptance of Bin Unit Concrete Strength - Acceptance will be according to 00540.17, except acceptance of concrete strength will be determined based on production sublots. A production sublot will consist of either 10 units or a single Day's production, whichever is less. Cast one set of cylinders for each production sublot. The concrete strength of a production sublot will be represented by a single compressive strength test on a cylinder.
7.Marking - On the rear face of each unit scribe the date of manufacture, the production sublot number, and the Piecemark.
8.Handling, Storing, and Shipping - Do not allow chipping, discoloration, cracks, fractures and connecting device damage during handling, storing, and shipping. Support stored units on firm blocking.
9.Rejection - Units not meeting the requirements of this Subsection will be rejected.
c.Dry Cast Concrete Blocks - Furnish dry cast concrete blocks with the following properties:
1.Aggregate, Strength, Freeze-Thaw Durability, Unit Weight, and Water Absorption: • Aggregate meeting the requirements of ASTM C33. • Blocks meeting the requirements of ASTM C1372. • The average of three coupons or cores have a minimum compressive strength of 4,000 psi as tested according to ASTM C140. • Individual coupons or cores have a minimum compressive strength of 3,500 psi as tested according to ASTM C140. • A minimum oven-dry unit weight of 125 pcf as tested according to ASTM C140. • Test, no longer than 18 months before delivery, freeze-thaw durability of five test specimens made with the same materials, concrete mix design, manufacturing process, and curing method that will be used on the Project. At least four of the five test specimens shall have a weight loss of not more than 1 percent of the block's initial weight after 150 freeze-thaw cycles as tested according to ASTM C1262. • A maximum water absorption of 1 percent above the water absorption of the sublot of blocks that were produced and passed the freeze-thaw test. For the water absorption testing, do not use the same blocks used for the freeze-thaw test.
2.Portland Cement - Portland cement meeting the requirements of 02010.10.
3.Blended Hydraulic Cement - Blended hydraulic cement meeting the requirements of 02010.20.
4.Tolerances - Manufacture within the following geometric tolerances: • Molded length and width dimensions within ± 1/8 inch of the block Manufacturer's nominal length and width dimensions. 00596B.12 • Molded height dimension within ± 1/16 inch of the block Manufacturer's nominal height dimension. • Rear height does not exceed the front height. • Top and bottom face groove dimensions within the tolerances specified by the Manufacturer.
5.Color - Consistent natural color of dry cast concrete.
6.Finish - Split-face units that when viewed from a distance of 10 feet under diffused light, chips, cracks, and other imperfections are not detectable.
7.Acceptance of Blocks - Acceptance will be determined on tolerances, visual inspection, compressive strength, water absorption, freeze-thaw durability, and unit weight. Acceptance of compressive strength, water absorption, and unit weight will be based on production sublots. The maximum number of blocks per production sublot is 2,000 blocks. Test blocks at the frequency of one set for each production sublot. Acceptance of freeze-thaw durability will be based on the freeze-thaw testing requirements of 00596B.12(c)(1).
8.Marking - Indicate the date of manufacture and the production sublot number on each sublot of dry cast concrete blocks.
9.Handling, Storage, and Shipping - Do not allow chipping, discoloration, cracks, or fractures during handling, storing and shipping.
10.Rejection - Blocks not meeting the requirements of this Subsection will be rejected.
d.Wet Cast Concrete Blocks - Furnish wet cast concrete blocks with the following properties:
1.Concrete - Commercial Grade Concrete meeting the requirements of Section 00440.
2.Marking - The rear face of each block is scribed with the date of manufacture, the production sublot number, and the Piecemark.
3.Color - Consistent natural color of wet cast concrete.
4.Finish - Smooth-face blocks that, when viewed from a distance of 10 feet under diffused light, chips, cracks, and other imperfections are not detectable.
5.Tolerances - Molded length and width dimensions within 1/4 inch of the Manufacturer's dimensions. Molded height dimension within 1/8 inch of the Manufacturer's dimension.
6.Handling, Storing, and Shipping - Do not allow chipping, discoloration, cracks, or fractures during handling, storing, and shipping.
7.Acceptance of Blocks - Acceptance will be determined by tolerances, visual inspection, and concrete strength. Concrete strength will be based on production sublots. A production sublot is 20 blocks or a single Day's production, whichever is less. The production sublot will be represented by a single compressive strength sample of one set of cylinders.
8.Rejection - Blocks not meeting the requirements of this Subsection, or that exhibit any of the following defects will be rejected: • Honeycombed or open texture concrete. • Extreme color variation on front face of block. 00596B.13
e.Precast Concrete Crib Walls - Furnish precast concrete Crib Walls with the following properties:
1.Portland Cement Concrete - Furnish Class 4000 - 3/4 structural concrete meeting the requirements of Section 00540.
2.Color - Consistent natural color of wet cast concrete.
3.Finish - Smooth Crib Wall members that, when viewed from a distance of 10 feet under diffused light, chips, cracks, and other imperfections are not detectable.
4.Tolerances - Manufactured within ± 1/8 inch of the Manufacturer's nominal dimensions.
5.Handling, Storing, and Shipping - Do not allow chipping, discoloration, cracks, or fractures during handling, storing, and shipping.
6.Acceptance of Concrete Strength - Acceptance of concrete strength will be determined based on production sublots. A production sublot will consist of either 100 Crib Wall members or a single Day's production, whichever is less. Cast one set of cylinders for each production sublot. The concrete strength of a production sublot will be represented by a single compressive strength test on a cylinder.
7.Rejection - Crib units not meeting the requirements of this Subsection will be rejected. 00596B.13 Steel:
a.Steel Reinforcement for Concrete - Furnish steel reinforcement for concrete meeting the requirements of Section 00530.
b.Metal Bin Gravity Walls - Furnish metal Bin Walls meeting the requirements of Section 02350.
c.Gabion Baskets - Furnish gabion baskets meeting the requirements of Section 02340. 00596B.14 Geosynthetics:
a.Geotextile Filter Layer for Subsurface Drainage Systems - Furnish Type 1 drainage geotextile according to Section 02320.
b.Geotextile Filter Layer Between Backfill and Gabion Walls - Furnish Type 2 riprap geotextile according to Section 02320.
c.Geotextile Filter Layer Between Backfill and Other Prefabricated Modular Walls - Furnish Type 1 or Type 2 drainage geotextile according to Section 02320.
d.Modular Block Drainage Fill Geotextile Filter - Furnish Type 1 drainage geotextile according to Section 02320. Labor 00596B.30 Quality Control Personnel - Provide technicians with CAgT and CDT certifications. 00596B.31 Manufacturer's Field Representative Qualifications and Duties - Provide a Manufacturer's field representative meeting the following minimum qualifications: 00596B.31 Is a licensed professional engineer in the State of Oregon. Has been trained and certified by the manufacture in the construction, installation, and inspection of the selected Proprietary Retaining Wall System. The times that the Manufacturer's field representative is required to be present or available and the duties of the Manufacturer's field representative are:
a.Preconstruction Conference - Meet with the Engineer and all Contractor supervisory personnel and Subcontractors involved in construction of the proprietary retaining wall at the preconstruction conference to discuss methods of accomplishing all phases of Work required to construct the proprietary retaining wall.
b.Initial Wall Construction - Be present at the retaining wall construction site and provide technical assistance to the Contractor and Engineer during all wall construction activities from the beginning of wall construction until at least 10 percent of the total wall length is successfully installed and backfilled to a height of at least 10 feet, or the actual wall height, whichever is less. Submit daily field observation reports no later than noon of the next Calendar Day. Include the following information in the daily field observation reports: Date of observation. Description of all Work observed and whether or not the Work was acceptable. Documentation of all communications with the Contractor and Engineer. Name and signature.
c.Remaining Wall Construction - Be available by phone or in person as needed throughout the remaining construction of the proprietary retaining wall to provide technical assistance to the Contractor and Engineer.
d.Final Field Observations - Conduct a final field observation of the completed retaining wall construction with the Engineer and Contractor. Submit a final field observation report that includes the following information 1 Calendar Day after the final field observation: Date of observation. Documentation of all retaining wall deficiencies. Recommendation to accept or reject the retaining wall construction. Provide a stamped final report to the Engineer no later than 10 Calendar Days after the final field observation of the retaining wall. Include the following information in the final report: Preconstruction meeting minutes. All daily field observation reports. Transcripts of all communications with the Contractor and the Engineer during the remaining wall construction phase. Final field observation report. 00596B.40 Construction 00596B.40 General:
a.Proprietary Retaining Walls - Construct proprietary retaining walls according to Agency requirements, Manufacturer's Working Drawings, and the Manufacturer's field construction manual. If the Manufacturer's Working Drawings or the Manufacturer's field construction manual conflict with Agency requirements, Agency requirements shall take precedence. Follow instructions and recommendations of the representative if approved by the Engineer.
b.Nonproprietary Retaining Walls - Construct nonproprietary retaining walls as shown. 00596B.41 Excavation and Foundation Preparation - Perform excavation and prepare and backfill wall foundations according to Section 00510 and the following: Grade the foundation level for a width equal to the width of the wall base plus 1.0 foot on each side. Do not reinforce backfill for over-excavated foundations without prior approval. Place backfill Material in nearly horizontal layers not more than 8 inches thick. Compact the entire surface of each layer with at least three Coverages, using Equipment made specifically for compaction. Routing hauling and grading Equipment over the surface is not acceptable for compaction. Do not construct backfill when the backfill, the foundation, or the embankment on which it would be placed is frozen, or unstable. 00596B.42 Leveling Pads:
a.Cast-in-Place Leveling Pads - Construct cast-in-place leveling pads with: Unreinforced concrete. A width of at least the block front face to block back face plus 12 inches (6 inches on each side of the facing units). A thickness of 6 inches ± 1/4 inch. A location tolerance of ± 1 inch of the design location. A top pad tolerance of ± 1/8 inch of the design elevation. Cure cast-in-place leveling pads at least 12 hours before placing the wall units.
b.Gravel Leveling Pads - Construct gravel leveling pads with: A width of at least the width of the wall facing plus 12 inches (6 inches on each side of the facing units). A thickness of at least 6 inches. A location tolerance of ± 1 inch of the design location. A top pad tolerance of ± 1/8 inch of the design elevation. Compact gravel leveling pads in 3 to 4 inch Lifts using a minimum of three Passes of a walk behind vibratory plate compactor with a gross static weight of not less than 125 pounds and a total compaction static plus dynamic force of not less than 2,000 pounds. 00596B.43 Subsurface Drainage - Install subsurface drainage before constructing walls. 00596B.44 00596B.44 Erecting Walls:
a.Dry Cast Concrete Block Walls:
1.Placement - Begin placing the first course of blocks on top of and in full contact with the lowest foundation level of the leveling pad. Level and align all blocks. Lay blocks as close together as possible and parallel to the straight or curved line of the wall face. Place blocks in vertical or battered positions as shown. Level each course block-to-block and front-to-back. Set each block on the blocks below without rocking. Correct high areas by grinding or shimming with approved shims. Do not use shims within 1 inch of the front face. Do not exceed a shim stack thickness of 1/16 inch. Stack all blocks in a running bond pattern with each block spanning the joint below. Place retaining wall granular backfill with each course of blocks. When shown, place modular block core backfill and drainage fill backfill, and install drainage fill geotextile and shear pins with each course of blocks. Remove all backfill that is on top of the blocks before installing the next course of blocks or Soil reinforcements. Attach the top row of dry cast concrete blocks or cap blocks to the underlying blocks with an adhesive from the QPL. Clean the finished exposed wall face of all foreign material deposits.
2.Tolerances: • First course of wall blocks located within ± 1/4 inch of the design horizontal alignment. • Final out of plane concavity or convexity of the front face within ± 3/4 inch in 10 feet. • Final deviation from the design Batter within ± 1 1/4 inch for each 10 feet of wall height. • Outward leaning Batter is zero. • Each course of blocks within ± 1/16 inch of level when checked with a 4-foot straightedge level. • Out of plane offset between consecutive rows within 3/4 inch of the planned offset. • Finished top of wall elevation within ± 1 inch of the design elevation.
b.Wet Cast Concrete Block Walls:
1.Placement - Begin placing the first course of blocks on top of and in full contact with the lowest foundation level of the leveling pad. Level and align all blocks. Lay blocks as close together as possible and parallel to the straight or curved line of the wall face. Place blocks in vertical or battered positions as shown. Level and set each block on the blocks below without rocking. Correct high areas by grinding or shimming with approved shims. Do not use shims within 1 inch of the front face. Do not exceed a shim stack thickness of 1/8 inch. Stack all blocks in a running bond pattern with each block spanning the joint below. Place retaining wall granular backfill with each course of blocks. When shown, place modular block core backfill and drainage fill backfill, and install drainage fill geotextile and shear pins with each course of blocks. Remove all backfill that is on top of the blocks before installing the next course of blocks or Soil reinforcements. Clean the finished exposed wall face of all foreign material deposits.
2.Tolerances: • First course of wall blocks located within ± 1/4 inch of the design horizontal alignment. • Final out of plane concavity or convexity of the front face within ± 3/4 inch in 10 feet. • Final deviation from the design Batter within ± 1 1/4 inch for each 10 feet of wall height. 00596B.44 • Outward leaning Batter is zero. • Each course of blocks within ± 1/8 inch of level when checked with a 4-foot straightedge level. • Front-to-back tilting within ± 1/4 inch of the design Batter when measured with a straightedge level long enough to span the entire front-to-back distance of the block. • Out of plane offset between consecutive rows within ± 3/4 inch from the planned offset. • Finished top of wall elevation within ± 1 inch of design elevation.
c.Gabion Walls:
1.General - Select and use: • The same style of mesh for the gabion panel bases, ends, sides, diaphragms, and lids. • The same method of joining the edges of a single gabion unit. • The same method of tying successive gabion units together throughout each Structure. Place riprap geotextile according to Section 00350 and the following: • Minimum overlap shall be 12 inches. • Against the back of the gabion wall before placing backfill Material.
2.Assembly - Assemble each style of gabion by rotating the panels into position and joining the vertical edges with tie wire or alternate fasteners. If twisted wire panels are tied with tie wire, join the selvage vertical edges with alternating single and double loops at 4 inch nominal spacing. If welded wire panels are tied with tie wire, pass the tie wire through each mesh opening along the vertical edges joint and secure with a half hitch locked loop. Leave no openings greater than 4 3/4 inches (line dimension) along the edges or at corners of tied or spiral bound gabions of either mesh style. Crimp the edges of spiral binding wire to secure the spiral in place. If high tensile fasteners are used instead of tie wire, install one fastener in each mesh opening according to the Manufacturer's recommendations.
3.Placement - Set the empty gabions in place and connect each gabion to the adjacent gabion along the top and vertical edges with tie wire or spiral binders. Connect each layer of gabions to the underlying layer along the front, back and sides with tie wire or spiral binders in the same manner as specified for assembly of baskets. Common wall construction is not allowed. Before filling each gabion with Rock, remove all kinks and folds in the wire fabric and properly align all baskets. Remove all temporary clips and fasteners. The assembled gabion baskets may be placed in tension before filling. Concurrently with the filling of the baskets, place retaining wall granular backfill around the assembled baskets to the limits shown. Maintain the outside backfill approximately level with the inside fill. 00596B.44
4.Basket Filling - Place Rock by hand or machine. Maintain basket alignment, avoiding bulges, and fill with minimum voids. Provide an exposed Rock surface that is smooth, neat appearing, and has no sharp edges projecting through the wire mesh. Place the Rock in layers to allow placement of internal connecting wires in each outside cell of the Structure or when directed at the following intervals: • None required for 1 foot high baskets. • At the one half point for 1 1/2 foot high baskets. • At one third points for 3 foot high baskets. Fill the basket so the lid will bear on the Rock when it is closed. Secure the lid to the sides, ends, and diaphragms with tie wire or spiral binders in the same manner as assembling the baskets.
5.Repairs - During construction, repair and secure all breakage of the wire mesh that results in mesh or joint openings larger than 4 3/4 inches (line dimension). Make repairs using 13 1/2 gauge galvanized tie wire as directed. Repair damaged PVC coated wire in a manner that provides the same degree of corrosion resistance as the undamaged wire, according to the Manufacturer's recommended repair procedures and as approved.
6.Tolerances: • First course of gabion units within ± 1/4 inch of the design horizontal alignment. • Final out of plane concavity or convexity within ± 2 inches in 10 feet. • Final deviation from the design Batter within ± 1 inch for each 10 feet of wall height. • Outward leaning Batter is zero. • Out of plane offset between consecutive rows within ± 1 inch from the planned offset.
d.Metal Bin and Precast Concrete Bin Walls:
1.Placement - Begin placing the first course of Bin Wall units on top of and in full contact with the prepared leveling pad surface. Concurrently with the assembly of the bins, place retaining wall granular backfill within and around the bins of the assembled wall to the limits shown. Maintain the outside backfill approximately level with the inside backfill.
2.Tolerances: • First course of units within ± 1/4 inch of the design horizontal alignment. • Final out of plane concavity or convexity within ± 1 1/4 inches in 10 feet. • Final deviation from the design Batter within ± 1 inch for each 10 feet of wall height. • Outward leaning Batter is zero. • Out of plane offset between consecutive rows within ± 1 inch from the planned offset.
e.Precast Concrete Crib Walls:
1.Placement - Begin placing the first course of Crib Wall units on top of and in full contact with the prepared leveling pad surface. Concurrently with the assembly of the cribs, place retaining wall granular backfill within and around the cribs of the assembled wall to the limits shown. 00596B.45 Maintain the outside backfill approximately level with the inside backfill. Fill depressions of stringers and spacers and compact without displacing them from line and Batter.
2.Tolerances: • First course of units within ± 1/4 inch of the design horizontal alignment. • Final out of plane concavity or convexity within ± 1 1/4 inches in 10 feet. • Final deviation from the design Batter within ± 1 inch for each 10 feet of wall height. • Outward leaning Batter is zero. • Out of plane offset between consecutive rows within ± 1 inch from the planned offset. 00596B.45 Geotextile Placement - Install geotextiles according to Section 00350 and as shown. 00596B.47 Backfill Placement:
a.General - Do not misalign wall units or damage wall components when placing backfill Material. Remove and replace all misaligned or damaged wall materials at no additional cost to the Agency.
b.Compaction - Meet the following requirements:
1.Equipment - Provide the following compaction Equipment:
a.Backfill In and Within 3 Feet Behind Wall Units - Walk behind vibratory roller compactor with a single smooth drum, vibratory plate compactor, or rammer/tamper plate compactor; each with a gross static weight of not more than 1,000 pounds and a total compaction static plus dynamic force of not more than 5,000 pounds.
b.Backfill More Than 3 Feet Behind Wall Units - Vibratory roller compactor with a single smooth drum, vibratory plate compactor, or rammer/tamper plate compactor.
2.Maximum Density and Optimum Moisture Content - Determine maximum density and optimum moisture content of the retaining wall granular backfill material according to AASHTO T 99 Standard Proctor Method A, with coarse particle correction according to ODOT TM 223.
3.Moisture Content - Prepare backfill material to within minus 4 percent to plus 2 percent of optimum moisture content at the time of compacting. Add water to material that does not contain sufficient moisture and thoroughly mix. Remove excess moisture by manipulation, aeration, drainage, or other means before compacting.
4.Density:
a.Backfill In and Within 3 Feet Behind Wall Units - Compact to 95 percent of maximum density using the required number of Passes determined according to 00596B.47(b)(5)(a).
b.Backfill More Than 3 Feet Behind Wall Units - Compact to 95 percent of maximum density determined according to 00596B.47(b)(5)(b).
5.Testing Methods and Frequency:
a.Test Pad Method - Before placing the wall backfill, determine the number of Passes necessary to achieve the specified density by constructing a test pad that is at least 5 feet wide, 15 feet long, and 3 feet in final depth. Construct test pad fill in layers no more than 8 inches thick using the same Equipment and methods that will be used to compact the wall 00596B.90 backfill. Perform at least one density test according to AASHTO T 310 on each test pad layer. Construct and test a new test pad when changes in material occur or different Equipment is used during the construction of the wall backfill, except a new test pad is not required for modular block drainage backfill.
b.Nuclear Gauge Method - Test in-place field density according to AASHTO T 310. Test at the frequency required in the ODOT Manual of Field Test Procedures.
6.Deflection Requirement - Conduct at least one deflection test, witnessed by the Engineer on each compacted layer of backfill according to ODOT TM 158. If the tested layer exhibits yielding, deflection, reaction, or pumping, rework the area to provide acceptable test results before placing the next layer. Maintenance 00596B.60 Protecting Work - Protect and repair Work as follows: Do not allow runoff from adjacent areas to enter the wall construction site during construction operations. At the end of each Day's operation, direct potential runoff away from the wall by sloping the last Lift of backfill away from the wall. Rework and repair all damaged Subgrade areas to the depth where undamaged Work is encountered. Measurement 00596B.80 Measurement - The quantities of Work performed under this Section will be measured according to the following: No measurement of quantities will be made for retaining walls. Estimated quantities of nonproprietary retaining walls will be listed in the Special Provisions. The quantities of Type "F" traffic barrier coping with moment slab will be measured on the length basis, from end to end of coping. The quantities of sidewalk coping will be measured on the area basis, from end to end and from top of curb to exterior edge of coping. Excavation below elevations shown will be measured according to 00510.80(b). Payment 00596B.90 Payment - The accepted quantities of Work performed under this Section will be paid for at the Contract unit price, per unit of measurement, for the following items: Pay Item Unit of Measurement
a.Retaining Wall, Prefabricated Modular Gravity ............................... Lump Sum
b.____ Inch Type "F" Traffic Barrier Coping with Moment Slab .............. Foot
c.Sidewalk Coping ........................................................................... Square Foot In item (b), the height of barrier will be inserted in the blank. 00596B.90 Payment will be payment in full for furnishing and placing all Materials, and for furnishing all Equipment, labor, and Incidentals necessary to complete the Work as specified. Excavation below elevations shown will be paid for according to 00510.90(c). No separate or additional payment will be made for: Manufacturer's representative excavation, shoring, leveling pads, and specified backfill wall drainage and filter systems cast-in-place and precast standard coping 00596C.10 Section 00596C - Cast-In-Place Concrete Retaining Walls Description 00596C.00 Scope - This Work consists of furnishing and constructing nonproprietary cast-in-place concrete retaining walls as shown and specified. 00596C.02 Cost Reduction Proposals - According to 00140.70, cost reduction proposals will be considered for Proprietary Retaining Wall Systems that are preapproved by the Agency before Advertisement of the Project. 00596C.03 Definitions: Batter - The Slope of the wall face from vertical that is expressed as degrees or as a ratio of the horizontal change in inches for each 12 inches of vertical change. A vertical face has a zero Batter. Nonproprietary Retaining Wall System - A Retaining Wall System that is not a patented or trademarked and its details are shown. Proprietary Retaining Wall System - A Retaining Wall System that is protected by trademark, patent, or copyright and is produced or distributed by a manufacturer having exclusive rights. Retained Backfill - Backfill within a distance of H/2 behind the rear face of a retaining wall. H is the total height of the wall excluding the footing. Retaining Wall System - An engineered system of structural and geotechnical components that restrains a mass of earth. The terms Retaining Wall System, retaining Structure, and retaining wall are used interchangeably. Rigid Gravity Retaining Wall System - A retaining wall composed of monolithic cast-in-place concrete with a nominal amount of reinforcement placed near exposed faces that depends on concrete self-weight for stability. Semi-Gravity Cantilever Retaining Wall System - A retaining wall composed of a cast-in-place reinforced concrete flexural stem and base slabs that resist the moments and shears to which they are subjected and depends on concrete self-weight and from the weight of backfill over its heel for stability. 00596C.05 Submittals - Submit complete Working Drawings according to 00150.35 at least 30 Calendar Days before beginning construction of cast-in-place retaining walls, including the following: Unstamped Working Drawings for the cast-in-place walls. Stamped Working Drawings and calculations for excavation shoring. Stamped Working Drawings and calculations for wall formwork. Field verify existing ground elevations and bottom of wall elevations before preparing and submitting Working Drawings. Obtain the Engineer's written approval before beginning construction of the wall system. Materials 00596C.10 Quality Control - Provide quality control according to Section 00165. 00596C.11 00596C.11 Backfill:
a.Retaining Wall Granular Backfill - Furnish dense graded 1" - 0 or 3/4" - 0 Aggregate base Material for walls meeting the requirements of 02630.10 and the following:
1.Material Passing No. 200 Sieve - The amount of material passing the No. 200 sieve shall not exceed 15 percent by weight. Test according to AASHTO T 11.
2.Plasticity Index - The plasticity index of the material passing the No. 40 sieve shall not exceed 6. Test according to AASHTO T 90.
b.Pipe Drain Backfill - Furnish granular drain backfill Material for drainage pipes meeting the requirements of 00430.11. 00596C.12 Concrete:
a.Cast-in-Place Concrete for Rigid Gravity Retaining Walls - Furnish Commercial Grade Concrete meeting the requirements of to Section 00440.
b.Cast-in-Place Concrete for Semi-Gravity Cantilever Retaining Walls - Furnish Class 4000 - 3/4 structural concrete meeting the requirements of Section 00540. 00596C.13 Steel - Furnish steel reinforcement for concrete meeting the requirements of Section 00530. 00596C.14 Geosynthetics - Furnish Type 1 drainage geotextile for subsurface drainage systems according to Section 02320. 00596C.15 Piles - Furnish piling meeting the requirements of Section 00520. Labor 00596C.30 Quality Control Personnel - Provide technicians with CAgT and CDT certifications. Construction 00596C.40 General - Construct cast-in-place concrete retaining walls as shown. 00596C.41 Excavation and Foundation Preparation - Perform excavation and prepare backfill wall foundations according to Section 00510 and the following: Grade the foundation level for a width equal to the combined width of the wall footing plus 1.0 foot on each side. Place backfill material in nearly horizontal layers not more than 8 inches thick. Do not construct backfill when the backfill, the foundation, or the embankment on which it would be placed is frozen, or unstable. 00596C.42 Compaction - Compact according to the following:
a.Equipment - Provide the following compaction Equipment:
1.Backfill Within 3 Feet Behind Wall - Walk behind vibratory roller compactor with a single smooth drum, vibratory plate compactor, or rammer/tamper plate compactor; each with a gross 00596C.43 static weight of not more than 1,000 pounds and a total compaction static plus dynamic force of not more than 5,000 pounds.
2.Backfill More Than 3 Feet Behind Wall - Vibratory roller compactor with a single smooth drum, vibratory plate compactor, or rammer/tamper plate compactor.
b.Maximum Density and Optimum Moisture Content - Determine maximum density and optimum moisture content of the retaining wall granular backfill material according to AASHTO T 99 Standard Proctor Method A, with coarse particle correction according to ODOT TM 223.
c.Moisture Content - Prepare the retaining wall granular backfill material to within minus 4 percent to plus 2 percent of optimum moisture content at the time of compacting. Add water to material that does not contain sufficient moisture and thoroughly mix. Remove excess moisture by manipulation, aeration, drainage, or other means before compacting.
d.Density:
1.Backfill Within 3 Feet Behind Wall - Compact to 95 percent of maximum density using the required number of Passes determined according to 00596C.42(e)(1).
2.Backfill More Than 3 Feet Behind Wall - Compact to 95 percent of maximum density determined according to 00596C.42(e)(2).
e.Testing Methods and Frequency:
1.Test Pad Method - Before placing the wall backfill, determine the number of Passes necessary to achieve the specified density by constructing a test pad that is at least 5 feet wide, 15 feet long, and 3 feet in final depth. Construct test pad fill in layers no more than 8 inches thick using the same Equipment and methods that will be used to compact the wall backfill. Perform at least one density test according to AASHTO T 310 on each test pad layer. Construct and test a new test pad when changes in material occur or different Equipment is used during the construction of the wall backfill.
2.Nuclear Gauge Method - Test in-place field density according to AASHTO T 310. Test at the frequency required in the ODOT Manual of Field Test Procedures.
f.Deflection Requirement - Conduct at least one deflection test, witnessed by the Engineer on each compacted layer of backfill according to ODOT TM 158. If the tested layer exhibits yielding, deflection, reaction, or pumping, rework the area to provide acceptable test results before placing the next layer. 00596C.43 Wall Construction:
a.Wall Drainage - Construct wall drainage according to Section 00430.
b.Cast-in-Place Concrete Gravity Retaining Walls - Construct cast-in-place concrete gravity retaining walls as shown.
c.Cast-in-Place Semi-Gravity Cantilever Retaining Walls - Construct cast-in-place concrete semi-gravity retaining walls as shown. 00596C.80 Measurement 00596C.80 Measurement - The quantities of Work performed under this Section will be measured according to the following: No measurement of quantities will be made for retaining walls. Estimated quantity of retaining walls will be listed in the Special Provisions. The quantities of Type "F" traffic barrier coping with moment slab will be measured on the length basis, from end to end of coping. The quantities of sidewalk coping will be measured on the area basis, from end to end and from top of curb to exterior edge of coping. Excavation below elevations shown will be measured according to 00510.80(b). Payment 00596C.90 Payment - The accepted quantities of Work performed under this Section will be paid for at the Contract unit price, per unit of measurement, for the following items: Pay Item Unit of Measurement
a.Retaining Wall, Cast-In-Place Concrete Rigid Gravity ..................... Lump Sum
b.Retaining Wall, Cast-In-Place Concrete Semi-Gravity Cantilever ... Lump Sum
c.____ Inch Type "F" Traffic Barrier Coping with Moment Slab .............. Foot
d.Sidewalk Coping ........................................................................... Square Foot In item (c), the height of barrier will be inserted in the blank. Payment will be payment in full for furnishing and placing all Materials, and for furnishing all Equipment, labor, and Incidentals necessary to complete the Work as specified. Excavation below elevations shown will be paid for according to 00510.90(c). No separate or additional payment will be made for: excavation, shoring, and specified backfill wall drainage and filter systems concrete and reinforcement for concrete 00597.11
Reinforced Concrete Box Culverts in other states
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Source: Oregon Standard Specifications for Construction, 2024 Edition. Pages 696–740 of 1,268. View official source ↗