1085PRECAST REINFORCED CONCRETE BOX CULVERT

1085.1DESCRIPTION—This work is the manufacture, storage, delivery, installation, and assembly of

precast reinforced concrete box culvert segments into one continuous unit.

1085.2MATERIAL—

and Washers. Section 1105.02(d)

Furnish, test, and place cement concrete as specified in Section 7 14.7; except, with a minimum 28 -day compressive strength of 5,000 pounds per square inch or as shown on the approved shop drawings . Provide concrete as specified in Section 704 and meeting the specified compressive strength or other requirements shown on the approved shop drawings. AASHTO M 259/M 259M or M 273/M 273M; except, modify Section 11, Permissible Variations according to Form TR-28 and as follows:

• 11.1 Internal Dimensions. Do not allow the internal dimensions to vary from design by more than 1% with a maximum variation of 1 inch. Do not allow the internal diagonal dimensions to vary by more than 1 inch. Do not allow the haunch dimensions to vary more than 1/4 inch from design dimensions.

• 11.2 Slab and Wall Thickness. Do not allow slab and wall thickness to vary from design dimensions by more than plus 1/2 inch or minus 3/16 inch.

• 11.3 Length of Opposite Surface (square segments only ). Do not allow laying length of any opposite or opposing surfaces of the box segment to vary more than 1/8 inch/foot of the internal span, with a maximum of 5/8 inch.

• 11.5 Position of Reinforcement . Do not allow the position of the reinforcement to vary from the approved shop drawings by more than 1/2 inch in any direction. Place reinforcement so the indicated cover clearance does not deviate more than ± 1/4 inch. Provide 1 1/2 inch minimum cover at t he mating surface, as measured to the end of the joint.

Certify as specified in Section 106.03(b)3.

stencil, or otherwise affix this code to each pad at intervals of not more than 24 inches and in letters and numerals of not less than 1/4-inch height. Additional information such as lot or batch numbers, date, plant and place of manufacture, trademark, or name of manufacturer may also be added. Certify as specified in Section 106.03(b)3.

neoprene and may be composed of laminations. Use material conforming to the following:

• ASTM D1056, Type 2, Class C, Grades 2, 3, 4, and 5, including the requirements of suffixes B3 and F1

• ASTM D1171, Quality Retention Rating of 100% after 6 weeks exposure

1085.3CONSTRUCTION—Construct as indicated and according to Article 12.11 of the AASHTO LRFD

Specifications.

Part 4.

Show segment length on drawing. Provide segments of maximum length compatible with hauling equipment to minimize the number of joints. Provide shop drawings as specified in Section 105.02(d). Provide shop drawings clearly showing all items incorporated into the box culvert including all reinforcing. List items such as chairs and inserts by source, type, and supplier.

The necessary facilities for inspection include a plant office as specified in Section 714.5(a).

Plan and mix design(s) to the Structural Materials Engineer, BoB, SMD, for review and approval. Include with the QC Plan a company organizational chart indicating a separate chain of command from the QC Manager to the Owner/Plant Manager, independent of the Production Manager. Resubmit the QC Plan, mix design, and organizational chart if processes, materials, or personnel change.

facilities, QC, sampling and testing, and fabrication of the product, and who will ensure that items are fabricated as designed and as specified. QC Managers are required to maintain an active ACI Grade I Field Technician Certification.

responsible for QC and sampling and testing during the complete fabrication process, storage, and shipment. Technicians responsible for concrete sampling and testing are required to provide written evidence that they successfully completed the certification requirements for an ACI Grade I, Field Technician or have approval from the Structural Materials Engineer as a technician -in-training. Do not proceed with production until qualified personnel are present and approved.

Precast Concrete Association (NPCA), American Concrete Pipe Association (ACPA) box culvert or Prestressed Concrete Institute (PCI), box culvert plant certification program. Sub mit an annual endorsed copy to the Chief Structural Materials Engineer for continued qualification.

damage will not occur to the concrete or reinforcing steel. Provide suitable lifting devices for handling and installing precast reinforced concrete box culvert segments. Galvanize metal devices as specified in Section

1105.02(s). Before shipping, verify gasket material is sufficiently adhered to the joint. Verify gaps are not

present between strips of adjacent gasket material. If gaps are present, a minimum of 6 inches must be replaced to assure material is tight.

storing, handling, transporting, or erection . Minor damage may be repaired in the field according to Publication 145. Submit major repair procedures beyond the scope of Publication 145 to the Chief Structural Materials Engineer for evaluation and acceptance. Replace any segment that cannot be repaired to the satisfaction of the Representative. The Representative will inspect the segments at the site for possible damage and cracking during shipment and for tolerances and other dimensions required for acceptance. Do not ship segments until the 28-day minimum compressive strength is attained. Provide 24-hour advance notice of loading and shipping schedule. Have the Representative verify Form CS-4171 and properly tag segments before shipping. Do not ship unapproved items. Before shipping, patch lifting or handling devices that were temporarily used by the fabricator. Repair with Bulletin 15 approved patching material. If temporary lifting or handling devices are deemed necessary to be used during shipping and/or handling at the project site, provide details on the shop drawings for review and acceptance. Repair temporary lifting or handling devices with Bulletin 15 approved patching material.

Fabricator’s location to verify shop drawing, catalog cuts, staining materials, and fabrication information.

acceptance of the shop drawings and catalog cuts for the architectural treatment. Fabricate samples using the same process and materials that will be used for production. Erect samples at place of manufacture and store outdoors to allow for proper lighting for comparisons during manufacturing and inspection. Apply penetrating stain, where specified, to one half of sample, to show the final finish after the sample wall is constructed. Once test sections are fabricated, notify the Department, at least seven days before normal fabrication, so the appropriate Representatives may be present to determine acceptability of the test sections. Representatives may include the Environmental Manager, Project Manager, Design Staff, Construction Staff, Structural Materials Section representative and any other project team member designated by the Department. Use test sections to determine the acceptability of the various surface treatments based on quality and overall appearance. Provide surfaces uniform in color and free of surface blemishes. View architectural treatments for the sample and subsequent production pieces for acceptance at a distance of 30 feet, unless otherwise specified. Produce additional samples until an acceptable product is produced if initial test sections are found to be unacceptable. Accepted test samples will be used for comparative purposes for accepting production pieces. Additional test sections may be required if test sections are needed at the project site location. Acceptable samples fabricated to the accepted shop drawings are allowed to be incorporated into the project in the final stage of construction, after all production has been completed and accepted.

capacities, crane operator’s license for the operator performing the crane work, setting devices, rigging, and communication system to be employed during beam setting operations in the ere ction plan. Maintain an accepted copy of the erection plan onsite during erection operations. Erect culvert according to the accepted erection plan and accepted shop drawings. Have a Professional Engineer registered in the State sign and seal the erection plan. At the project site, the culvert will be inspected for tolerances, dimensions, and damage during shipment. Replace culvert segments damaged by improper storing, handling, transporting, or erecting at no additional cost to the Department. Before setting the culvert, conduct a pre-erection meeting a minimum of 14 calendar days before erection with the Professional Engineer of record for the erection plan, prime contractor, superintendent in charge of culvert setting operation, crane operators or crane company

representative, signal personnel, Structure Control Engineer, and onsite Representative to discuss the accepted erection plan. Conduct safety talk with crane operator as specified in Section 108.05(c)6.

Provide uniform bedding material within 1/4 inch of the elevations shown on the plans. Use templates, screeds, and/or string lines to grade bedding within tolerance. If unsuitable foundation material or rock is encountered, remove all unsuitable material at least 12 inches or rock at least 24 inches below bottom of box culvert and backfill with No. 2A or AASHTO No. 8 Coarse Aggregate, as shown on the Standard Drawings, graded in close conformity with the stream bed grade to provide proper bedding conditions. Accurately shape bedding material with a template to provide uniform contact (90% of bearing).

sealed and hardware is installed.

Prevent aggregate from entering box culvert segment joints during placement. Place box culvert segments by matching the interior floor, haunches, and wall lines from segment to segment.

trench as specified in Section 601.3(f).

equipment until after cover or fill has been placed, unless cover exceeds 5 feet. Do not use vibratory rollers to compact cover or fill over, or directly adjacent to, box culverts.

Drawings. Submit a plan to the Department to correct exterior joints that exceed 1/2-inch difference across two adjacent box segments. Ensure waterproofing membrane will have full support and contact across the joint after correction and before membrane installation.

For fill heights greater than 24 inches at post locations, provide type 31 strong post guide rail as shown on the Standard Drawings. For fill heights 24 inches or less at post locations, provide bridge barrier as shown on the Standard Drawings and furnish a Class A cement concrete headwall.

deep Class A cement concrete, or less if directed, and install upstream and downstream. If indicated, install alternate cut off wall with grouted rock.

on the Standard Drawings.

coating the contact surfaces with concrete bonding compound.

of SSPC-PS 16-82, to the top of the box and exposed end faces and to the entire height of the outside walls.

curing, in a minimum 50F environment until they have reached a compressive strength of 70% of the required 28-day minimum concrete design strength shown on the approved shop drawings.

and as specified in Section 1108 and as described below:

of box culver t segments. Skewed segments may require tensioning of corners before internal post - tensioning locations. Determine post-tensioning sequence, staging, etc. based on the weight of segments being tensioned. Deviating from the established post-tensioning sequence, due to field adjustments, must be approved by the District Bridge Engineer, or their designee.

Remediate joints that are not sealed, to the satisfaction of the Representative.

are stressed, then within 4 hours after stressing, protect the tendons and grout ducts against corrosion and debris by temporarily sealing all openings and vents, cleaning rust and other debris from all metal surfaces to be covered by the grout cap; and placing the grout cap, including a seal, over the anchor plate until the tendon is grouted. Grout ducts within 3 calendar days after tensioning. Failure to grout the ducts within 3 calendar days after tensioning will require the contractor to demonstrate the ducts are unobstructed to achieve complete grouting. If obstruction(s) are present, clean ducts to remove obstructions and re-inspect before grouting.

1085.4MEASUREMENT AND PAYMENT—

The price includes the following component items:

• Cement Concrete. Section 1001.4(a)

• Deformed Welded Wire Fabric. Section 1001.4(b)3

• Precast Reinforced Concrete Box Culvert Segments. Linear Foot The unit price includes post-tensioning, if indicated.

• Precast Reinforced Concrete Box Culvert End Segments, Aprons, and Wing Walls. Each The unit price includes post-tensioning, mechanical straps, and other incidental hardware.

• Reinforcement Bars. Section 1002.4

• Membrane Waterproofing. Section 680.4

• Selected Borrow Excavation - Structure Backfill. Section 1001.4(g)

• Rock Protection. Section 850.4(a)

• Protective Coating (Coal Tar Epoxy). Square Yard

The Department will pay as specified in Section 110.03.