714PRECAST CONCRETE PRODUCTS

714.1GENERAL REQUIREMENTS—As shown on the Standard Drawings, as indicated and as follows:

manufacturer listed in Bulletin 15.

Standard Drawings without submitting shop drawings to the BoB for acceptance, unless otherwise indicated. For deviations or modifications of the standards, submit shop drawings for acceptance.

714.2PRECAST CONCRETE UNITS—Plants may be approved for any of the following items:

• Concrete barrier: median barrier, single face, temporary, permanent, structure mounted, etc.

• Manholes

• Inlet Boxes

• Concrete Top Units for Inlet Boxes

• Junction boxes

• Endwalls

• Sound barrier posts and panels.

• Non-structural precast architectural products such as balustrade, rails, pylons, etc.

• Other precast products, as approved by the CSME.

714.3MATERIAL—

• Storage of Material. Section 106.05

• Cement Concrete. Section 704, except Sections 704.1(d) 4, (d)5, (d)6, and (d)7. Requirements for remediation of a potential alkali-silica reaction do not apply for cement concrete used in the fabrication of precast concrete barrier that is to be used in temporary installations only, as specified in Section 627 and Section 714.6(d).

• Coarse Aggregate, Type A, No. 8, No. 57, or No. 67. Section 703.2

• Fine Aggregate, Type A. Section 703.1

• Concrete Curing Material. Sections 711.1 and 711.2(a)

• Reinforcement Steel. Section 709. Epoxy coated or galvanized reinforcement bars or epoxy coated or galvanized welded wire fabric are not required for the fabrication of precast concrete barrier that is to be used in temporary installations only, as specified in Section 627 and Section 714.6(d).

• Steel Anchor Bolts. Section 1105.02(c)

• Metal Units. Sections 605.2(a) and (b)

• Manhole Steps. Section 605.2(c)

• Penetrating Sealers. Section 1019 or Section 1045, where specified

• Aesthetic Coating. Section 1044

714.4PLANT ACCEPTANCE—

a permanent building offered for the Department's acceptance. All casting operations must occur inside the permanent building, unless authorized by the CSME. Material, equipment, test procedures, methods of fabrication, handling, storage, and transportation are subject to inspection. Precast facilities fabricating solely non-structural precast architectural products need only to be certified under Architectural Precast Association (APA) plant certification program. Register and certify the plant under either the PCI or National Precast Concrete Association (NPCA) plant certification program. Submit an annual endorsed copy to the CSME for continued qualification.

Plan and mix design (s) to the CSME, BoB, Structural Materials Division, 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 required by the CSME, because of changes in processes, materials, or personnel.

facilities, QC, sampling and testing, and fabrication of the product, and who will ensure items are fabricated as shown on the Standard Drawings. 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 they successfully completed certification requirements for an ACI Grade I Field Technician Certification or have approval from the CSME as a technician -in-training. A written training plan must be provided with the request for a technician -in-training. Technicians-in-training may not perform acceptance testing of concrete. Do not proceed with production until qualified personnel are present and approved.

714.5PLANTS AND PLANT SITES—

Provide a drainage system as needed for the removal of rainfall and curing water. Provide a stabilized area for product storage. Furnish necessary facilities for the inspection of material and work. Allow Inspectors employed by the Department unrestricted access to the premises during plant working hours. The necessary facilities for inspection include a plant office conforming to the following minimum requirements:

Number of Each Requirements 150 Floor space: square feet Yes Air-conditioned/heated 1 Desk and chair 1 Plan rack 1 Work table

1 Two-drawer fire resistant (D-label) metal file cabinet Adequate number Chair and stools 1 Individual Access Phone line 1 Internet Service: a wired broadband Internet service, for exclusive use by Department personnel for official business purposes only. Choose a service that provides the fastest available highspeed broadband internet access, with a minimum connection of 5 Mbps per inspector, to the account by means of a Cable or Digital Subscriber Line (DSL). Provide a wireless broadband router, with a minimum-security setting of WPA2, to connect to the provided wired broadband. Based on the specific type of high-speed connection provided, furnish a compatible modem with built-in hardware firewall protection. If such high-speed wired broadband connection is not attainable at the Inspector Office desk area alternate internet connectivity options must be submitted to the CSME for review and acceptance. Demonstrate connectivity with the Internet Service Provider once the service is initiated. To ensure reliability and continued access, audits of this connection may be done at any time by a qualified PennDOT/OA IT Personnel. 1 Telephone (business and emergency calls only) and answering machine or voice-mail 1 Sanitary electric water cooler 1 Fire extinguisher Adequate number Cupboards, closets, lockers 1 First-aid kit (OSHA 1926.50(d) and 1926.50 Appendix A compliant)

714.6FABRICATION—

approval to produce a new product type. Plants must produce test sections and conduct a prefabrication meeting as specified in Section 1085.3(g) for products containing an architectural finish or requiring staining or both. Use only qualified welders for all welding operations , including tack welds. Submit a weld procedure specification (WPS) for review and approval to the CSME for welding of reinforcement or steel embedded in concrete.

as indicated, within specified tolerances. Secure reinforcing in beds and forms using chairs or blocking so the reinforcing maintains its position during placement and vibration of concrete. Bars may be fabri cated into cages by tying and tack welding. Do not tack weld epoxy coated ; galvanized; uncoated, corrosion - resistant; stainless steel; or Grade 60 reinforcement bars. Use acceptable chairs or ties for support. If bar spacing is greater than or equal to 12 inches, tie all intersections with annealed iron wire or metal clips. If bar spacing is less than 12 inches, either tie all intersections or tie alternate intersections with annealed iron wire or metal clips in each direction to provide a staggered tie layout prohibiting movement of reinforcement bars during manufacturing. For epoxy-coated reinforcement or galvanized reinforcement, provide plastic -coated tie wire, epoxy -coated tie wire, metal clips, or plastic clips. When using tie wire, secure reinforcing steel with tie wire of the same type/coating.

for the manufacture of products within tolerances, according to approved drawings and specifications. Clean forms after each use to prevent accumulation of coatings. Wooden forms must be adequately coated and sealed to prevent leakage. Wooden form surfaces must be coated to eliminate transfer of wood grain to the finish product.

end of each precast unit as soon as possible after stripping using a permanent marking system. For inlets, manholes, and junction boxes, also provide the type identification. Identify barrier meeting NCHRP 350 by indenting the top section of each barrier section with minimum 2-inch block lettering as follows: “T 350” for temporary barrier and “P 350” for permanent barrier. Identify barrier meeting MASH by indenting the top section of each barrier section with minimum 2-inch block lettering as follows: “T-M-XX” for temporary barrier and “P -M-XX” for permanent barrier. The “XX” characters indicate the MASH compliance year (e.g., “09” for 2009, “16” for 2016, etc.). Use temporary barrier conforming to the manufacturing and crash testing requirements as specified in Section 627.2.

precast concrete deck panels as shown on the Standard Drawings and as specified in Section 1107.01(b). Conduct welding and testing of assembly as specified in Section 1105 and according to the applicable AASHTO and AWS codes. Alternate vertical adjustment devices may be used if the structure can be produced within the specified erection tolerances.

714.7CONCRETE—

in Section 704, for each lot. If the test results of the acceptance cylinders fail to meet the required 28 -day minimum compressive strength, the disposition of the products will be resolved as specified in Section

110.13. Perform plastic concrete slump, air, and temperature testing at the frequencies established in

Section 704 and Publication 145. Perform slump, air content, and temperature tests according to Section 704. For self-consolidating concrete mixtures (SCC) p erform slump flow tests according to ASTM C1611/C1611M, perform J-Ring tests according to ASTM C1621/C1621M.

a workable mix for the precast concrete units. Maintain the cement concrete consistency within 1 1/2 inches on either side of the selected value. At no time is the slump upper limit to exceed 5 inches for mixes without water-reducing admixtures, 6 1/2 inches for mixes with water-reducing admixtures, and 8 inches for mixes with high range water-reducing admixtures (superplasticizers). If the upper limit is exceeded on any slump test, the plant’s technician must reject the cement concrete.

C1611/C1611M. Evaluate the visual stability index (VSI) of the mixture when the slump flow is measured during testing. Reject mixtures with a VSI>1. Conduct J -Ring testing according to ASTM C1621/C1621M, whenever the slump flow test is performed. Establish a slump flow target for production of not less than 20 inches nor more than 30 inches and maintain the slump flow within a range of ± 3 inches of the target. Reject the concrete if the upper specification limit is exceeded. If the slump flow test result is less than the lower production range limit or the difference between the slump flow test result and J -Ring test result is greater than 2.0 inches reject the concrete mixture unless the mixture has been approved for vibration and is subsequently vibrated. Take immediate corrective action whenever the slump flow limits, or action points are exceeded and test succeeding batches until material control has been reestablished.

and as specified in Section 704. For SCC mixes, furnish concrete meeting the Class indicated and as specified in Section 704 except provide concrete with a plastic air content of 7% ± 2%. In addition, perform the following additional qualification tests at mix qualification before beginning production:

• Column Segregation Test, ASTM C1610/C1610M: 12% maximum

• Freeze Thaw Resistance, ASTM C666/C666M, Procedure A or B: minimum durability factor of 80.

Fully automated batch systems using in -mixer moisture probes may be utilized, at the Fabricator’s request and approval by the CSME. Fully automated batch systems must be operated according to Publication 145.

material derived from quarried stone, for use as an ingredient in hydraulic cementitious mixtures and meeting specified chemical and physical requirements conforming to ASTM C1797. AMF is to be used to replace a small percentage of fine aggregate to enhance the optimization of concrete mixes.

Material Specification

Gradation

Sieve Percent Passing

#10 100 % passing (maximum #200 35% passing (maximum)

Methylene blue value (mg/g) < 5.0% Total Organic Carbon Content % by mass < 0.5% Moisture Content (%) by mass < 1.0%

Limits on Use

The percentage of AMF must not exceed 15% (by mass) of the total cementitious factor.

part of the form. Methods of placement are subject to acceptance. Do not work or flow concrete along the forms from the point of deposit. Work concrete under and around reinforcement. Place concrete batches in form within one half hour of each other. Consolidate the plastic concrete by internal vibration or external vibration or both. Do not consolidate SCC mixtures without approval and unless the mixture was qualified within 2.0 inches of the upper production slump flow limit during the trial batching and evaluation phase. Air temperatures within the work area must remain above 40F for production.

lot cast. Mold additional test cylinders for Department acceptance testing, if directed. Mold cylinders according to PTM No. 631 . Cure cylinders the same as the product. Test cylinders according to PTM No. 604. Match-mark test cylinders with the lot represented. Record test results and give records to the Representative.

areas, depressions, or projections. Do not add water to the concrete to facilitate finishing.

Use patching material listed in Bulletin 15 or as approved by the CSME. Submit repairs beyond the scope of Publication 145 to the CSME for evaluation and disposition.

714.8CURING AND PROTECTIVE COATING—

to ACI 308. Maintain products in their forms, maintaining primary cure, until 70% of the 28-day strength is obtained. Set stripping time based on the inherent characteristics of the product. Where stripping strengths are not indicated on the drawings, s ubmit reduced stripping time/strength calculations with a QC Plan addendum

to the CSME for review and approval prepared and sealed by a Professional Engineer registered in the Commonwealth of Pennsylvania. Accomplish secondary curing by approved methods. Maintain precast concrete units, after stripping and during secondary curing, in a minimum 50F environment until they have reached a compressive strength of 8 0% of the 28 -day minimum compres sive strength for the product as indicated on the shop drawing. Do not place uni ts in an environment of less tha n 32F after the secondary cure unless the differential between the units and the air temperature is less than 30F. Store units until the 28-day minimum compressive strength is obtained.

Use boiled linseed oil or a penetrating sealer and apply as specified in Section 1019 . Penetrating sealer must not discolor the concrete. If curing compound is used for secondary curing, wait 14 days before applying the protective coating. Barriers for temporary use need not receive a protective coating.

714.9TOLERANCES—As shown on the Standard Drawings, according to Publication 145, or according

to PCI MNL 135, except as follows:

Length of Member—1/8 inch per 10 feet with a minimum of 1/4 inch and a maximum of 3/4 inch

Cross-Sectional Dimensions— ≤ 36-inch… ± 1/4-inch > 36-inch… ± 3/8-inch

714.10HANDLING AND STORAGE —Handle and move products to the storage yard when they have

gained adequate strength to be moved without causing damage. Maintain adequate support when handling and storing the product. Store the product, until shipment, in areas accessible for inspection .

714.11TRANSPORTATION—Provide 24-hour advance notice of loading and shipping schedule. Do not

ship unapproved items. Include Form CS-4171 with each shipment . Observe hauling restrictions. Ensure that supports, bracing, and shipping methods dampen vibration. Provide adequate padding material between the tie chains or cables to prevent concrete chipping.

714.12DISPUTES—In matters of disputes over products, the CSME, BoB, SMD, or the designated on-site

representative have the final word on acceptability of the product.

714.13CERTIFICATION—Section 106.03(b)3, and as further directed by the CSME, BoB, SMD