Part 1 — General
1.1 Section Includes
A.Precast substructure elements for bridges such as foundations, columns, bent caps, abutment stems, and wall stems.
1.2 Related Sections
A.Section 03055: Portland Cement Concrete
B.Section 03056: Self -Consolidating Concrete (SCC)
C.Section 03211: Reinforcing Steel and Welded Wire
D.Section 03310: Structural Concrete
E.Section 03390: Concrete Curing
F.Section 03575: Flowable Fill
1.3 References
A.AASHTO M 31: Deformed and Plain Carbon and Low -Alloy Steel Bars for Concrete Reinforcement
B.AASHTO M 36: Corrugated Steel Pipe, Metallic -Coated, for Sewers and Drains
C.AASHTO M 111: Zinc (Hot -Dip Galvanized) Coatings on Iron and Steel Products
D.ASTM A 706: Deformed and Plain Low -Allow Steel Bars for Concrete Reinforcement.
E.ASTM C 666: Resistance of Concrete to Rapid Freezing and Thawing
F.ASTM C 1202: Electrical Indication of Concrete’s Ability to Resist Chloride Ion Penetration
G.ASTM C 1581: Determining Age at Cracking and Induced Tensile Stress Characteristics of mortar and Concrete under Restrained Shrinkage
H.ASTM C 1583: Tensile Strength of Concrete Surfaces and the Bond Strength or Tensile Strength of Concrete Repair and Overlay Materials by Direct Tension (Pull -off Method)
I.ASTM D 2240: Rubber Property – Durometer Hardness
J.ASTM D 5249: Backer Material for Use with Cold- and Hot -Applied Joint Sealants in Portland- Cement Concrete and Asphalt Joints
K.National Precast Concrete Association (NPCA)
L.Precast /Prestressed Concrete Institute ( PCI) Design Handbook
1.4 Definitions
A.Working Points – Identifiable points of reference between elements to be connected .
B.Working Lines – Reference lines connecting working points .
1.Typically oriented along the length of elements to be connected .
2.Provide a basis for aligning elements located along the working line.
3.Provide a reference for the verification of length between working points.
1.5 Submittals
A.Working D rawings
1.Detailed shop drawings of fabricated materials for review .
a.Include at least the following: 1) Geometry of precast elements including projections, recesses, notches, openings, blockouts, grout ports and other pertinent details. 2) Location, type, and size of post -tensioning hardware, anchorage assembly, ducts, duct supports, blockouts, grout tubes, vents, drains, and local zone reinforcement. 3) Weight of precast elements and load distribution to lifting devices 4) Locations and details of lifting inserts, hardware, and devices . 5) Type and amount of additional reinforcing required for lifting. 6) Minimum compressive strength required before handling the precast elements. 7) Details of vertical adjusting hardware.
b.Include supporting engineering calculations.
2.Erection Drawings for precast concrete members for review , including at least the following:
a.A work area plan showing: 1) Utilities overhead and below the work area 2) Drainage inlet structures 3) Protective measures as required
b.Lifting equipment including cranes, excavators, lifting slings, sling hooks, cables and jacks 1) Include crane information including charts, crane and pick locations, and operation radii
c.Precast element erection and assembly sequence including: 1) Equipment that will be used for the assembly of the substructure 2) Methods of providing temporary support of the elements 3) Procedures for controlling both horizontal and vertical tolerances including details of alignment jigs with bi- level templates for reinforcing anchor s 4) Estimated timeframe of strength gain for concrete and grouted connections 5) Weather limitations for the assembly of work
d.Methods for placement of flowable bedding concrete for spread footings. 1) Detail grout ports in the footings to facilitate the bedding process if required.
e.Method, sequence, and equipment for forming grout voids and installing the structural non- shrink grout.
f.Methods of forming vertical joints or closure pours between elements . 1) Provide additional forming to retain backer rod s which may displace due to pressure from the grout in vertical grout joints .
g.Methods for curing cementitious materials .
B.Material s
1.Structural Non- Shrink Grout or Mortar
a.Certified test report for review
b.Warranty letter for information stating that C ontractor guarantees the structural non- shrink grout against material and installation defects such as bonding, cracking, and spalling failures incurred during normal traffic for a period of two years . 1) The warranty period starts on the date of Substantial Completion . 2) Include in the letter a) State Project Designation b) State Project Name c) State Structure Numbers d) Contractor, Provider, and product Name 3) The warranty covers 100 percent of the Structural Non-Shrink Grout or Mortar materials and installation costs.
C.Casting and Shipping S chedules
1.A casting schedule for information at least 14 calendar days in advance to make inspection and testing arrangements.
2.A shipping schedule for information at least 14 calendar days before shipping precast substructure elements to the job site.
D.Repair Procedure
1.Written procedure for defects and breakage of precast elements for review .
Part 2 — Products
2.1 Materials
A.Concrete
1.Precast elements a. Class AA(AE) concrete . Refer to Section 03055 .
b.Self-Consolidating Concrete (SCC) may be used at the contractor’s option. Refer to Section 03056.
2.Bedding Concrete
a.Flowable Fill. Refer to Section 03575.
b.Class B(AE) concrete . Refer to Section 03055.
3.Pile connections and closure pours
a.Class AA(ES) concrete unless shown otherwise. Refer to Section 03055.
B.Reinforcing Steel
1.Coated reinforcing steel . Refer to Section 03211.
2.Use reinforcing steel according to ASTM A 706 for vertical reinforcing in the bent columns, transverse reinforcing in the bent columns, and bar passing from the columns into the foundation or bent cap.
3.Use reinforcing steel according to AASHTO M 31 for other substructure elements.
C.Miscellaneous Steel Items
1.Galvanize steel items permanently cast into structural concrete elements according to AASHTO M 111.
D.Structural Non-Shrink Grout or Mortar
1.Use gray, cementitious grout or mortar, containing no calcium chloride or admixture containing calcium chloride.
2.Use a pre- packaged commercial product satisfying the requirements shown in Table 1.
a.Provide a product able to be mixed to a flowable or fluid consistency according to the manufacturer’s technical information. Table 1 Structural Non -Shrink Grout or Mortar Properties Requirements ASTM Durability Factor 95, min. C 666 Compressive Strength 5,000 psi @ 24 hours, min. C 109 Direct Bond Strength 200 psi min. C 1583 Restrained Shrinkage No cracking exhibited in 4 days C 1581 Permeability <1700 C measured at 28 days, min C 1202
E.Grouted Splice Couplers . Refer to Section 03211.
F.Continuous Butt Welded Hoops . Refer to Section 03211.
G.Corrugated Steel Pipe. Refer to AASHTO M 36 .
H.Leveling Devices
1.Use fabricated steel leveling devices as shown.
a.Alternate devices may be used provided the devices can support the anticipated loads.
I.Vertical Joint Seals
1.Use natural rubber or neoprene sheet with a durometer of 50- 60 according to ASTM D 2240.
J.Backer Rod
1.Size the diameter of the backer rod to be 25 percent to 50 percent larger than the opening at time of installation. For Example:
a.0.5 inch backer rod for 3/8 inch opening
b.0.625 inch backer rod for ½ inch opening
c.1 inch backer rod for ¾ inch opening
d.1.25 inch backer rod for 1 inch opening
2.Use a closed cell, polyethylene- foam rod joint filler.
a.Meet the requirements of ASTM D 5249 Type 1 or Type 3.
K.Lifting Devices
1.Use lifting devices that can support the required vertical and horizontal forces with the applicable factors of safety according to the Component Handling and Erection Bracing requirements in the PCI Design Handbook .
2.2 Fabrication
A.Use a Department pre-qualified supplier. .
B.Do not place concrete into forms until materials have been inspected and verified by the Department .
C.Construct precast elements to the tolerances specified by PCI or National Precast Concrete Association ( NPCA ) and as shown.
D.Finish the precast elements according to Section 03310.
1.Trowel finish the exposed surface s of precast concrete elements.
E.Permanently mark each precast element with date of casting and supplier identification.
1.Stamp markings in fresh concrete.
F.Cure concrete according to Section 03390 .
2.3 Quality Control
A.Precast Substructure Elements
1.Document test results. The quality control file will contain at least the following information:
a.Element identification
b.Date and time of cast
c.Concrete cylinder test results
d.Quantity of used concrete and the batch printout
e.Form stripping date and repairs if applicable
f.Location/number of blockouts and lifting inserts
g.Temperature and moisture of curing period
h.Lifting device details, requirements , and inserts
2.Provide documentation upon request.
B.Dry fit adjacent precast elements in the shop.
Part 3 — Execution
3.1 General Procedure for Installation of Elements
A.Follow the authorized erection drawings .
1.Resubmit the drawings for review i f changes are warranted due to varying site conditions.
B.Establish working points, working lines, and benchmark elevations before placing elements.
C.Check the condition of the receiving bonding surface before connecting elements
1.Remove items such as dust, rust, and debris .
2.Bring concrete surfaces to a Saturated Surface Dry (SSD) condition.
3.Prepare grouted splice couplers according to the recommendations of the grouted splice coupler manufacturer .
E.Mix structural non- shrink grout or mortar just before its use according to the manufacturer's instructions.
F.Allow the grout in the grouted splice couplers to cure until the grouted splice coupler can resist 100 percent of the specified minimum yield strength of the bar before removing temporary bracing and proceeding with installation of components above the s pliced elements.
1.The required grout strength is based on the grouted splice coupler submittal required in Section 03211.
G.Grinding for bridge girder bearing areas.
1.Refer to Section 03310.
2.Grinding is permitted up to a depth of 3/8 inch.
3.2 Foundations
A.Set foundation in the proper horizontal and vertical location.
1.Check for proper alignment within tolerances as described.
B.Adjust vertical leveling devices before full release of the element from the crane to facilitate the vertical adjustment process .
1.Check for proper grade within tolerances as described .
C.Check the spacing of dowels or grouted splice couplers between adjacent foundations that are to support common elements in future stages of construction.
1.Use bi-level templates and jigs.
2.Adjust the location of the foundation if required.
D.Pump bedding concrete through the ports for spread footings .
1.Start from the center of the footing and proceed toward the outside edges.
2.Verify that bedding concrete is filling the entire void between the footing and the subgrade.
E.Place concrete in voids around pile tops as shown for foundations supported on drilled shafts or piles .
1.Allow t his concrete to flow partially under the pile cap .
2.The entire underside of the cap need not be filled with concrete.
F.Do not remove temporary supports or proceed with the installation of elements above the foundation until the compressive test result of the cylinders for bedding concrete or pile connection concrete has reached the specified 28 day minimum compressive strength .
3.3 Bent Columns
A.Survey the elevation of the element directly below the column.
1.Use leveling devices or shims to bring the bottom of the column to the required elevation.
2.Measure the elevation of the top of the leveling device or shim stack and the top of the projecting dowels.
3.Verify that the elevations and dowel extensions are within tolerances as described.
B.Check the dowel spacing or grouted splice coupler spacing at top of adjacent columns that will support common elements in future stages of construction.
1.Use bi-level templates and jigs.
2.Maintain vertical alignment of columns within tolerances as described.
3.Adjust the location of the foundation if required.
C.Set the column in the proper horizontal location.
1.Check for proper horizontal and vertical alignment within tolerances as described.
2.Adjust the leveling devices or shims and reset the column if the column is not within tolerance.
D.Install the grouted splice couplers according to Section 03211 once the connection geometry is established and checked.
3.4 Bent Caps
A.Survey the elevation of the column directly below the cap.
1.Use leveling devices or shims to bring the bottom of the cap to the required elevation.
2.Measure the elevation at the top of the leveling device or shim stack and the top of the projecting dowels.
3.Verify that the elevations and dowel extensions are within tolerances as described.
B.Set the cap in the proper horizontal and vertical location.
1.Check for proper horizontal and vertical alignment within tolerances as described.
C.Install the grouted splice couplers according to Section 03211 once the connection geometry is established and checked.
3.5 Wall Panels
A.Wall panels include :
1.Cantilever Abutment Stems
2.Wingwall stems
3.Integral abutment pile cap stems
4.Abutment backwalls and c heekwalls
B.Wall panels supported on precast concrete elements (f oundation or stem) .
1.Survey the elevation of the base directly below the panel.
a.Use leveling devices or shims to bring the bottom of the panel to the required elevation.
b.Measure the elevation of the top of the leveling device or shim stack and the top of the projecting dowels.
c.Verify that the elevations and dowel extensions are within tolerances as described.
2.Set the panel in the proper horizontal and vertical location.
a.Check for proper horizontal and vertical alignment within tolerances as described.
b.Adjust the leveling devices or shims and reset the panel if the panel is not within tolerance.
3.Install the grouted splice couplers according to Section 03211 once the connection geometry is established and checked.
4.Install backer rod and vertical joint seals as shown.
5.Place concrete inside the blockouts and cure if the panels contain corrugated pipe blockouts .
6.Place structural non- shrink grout or mortar in joints between precast abutment and backwall segments after leveling jacks and temporary supports are removed.
a.Do not apply additional dead loads or live loads to t he precast backwall segments for at least 3 hours after placement .
C.Wall panels supported on piles or drilled shafts (integral abutments) .
1.Set the panel in the proper horizontal and vertical location.
a.Check for proper alignment within tolerances as described.
b.Adjust the leveling devices before full release from the crane if vertical leveling devices are used.
c.Check for proper grade within tolerances as described .
2.Check the spacing of dowels or grouted splice couplers between adjacent panels that will support common elements in future stages of construction.
a.Use bi -level templates and jigs .
b.Adjust the location of the panel if required.
3.Place concrete around pile tops as shown.
a.Allow concrete to flow partially under the panel .
b.The entire underside of the panel need not be filled with concrete.
4.Do not remove t emporary supports , or proceed with the installation of elements above the panel until the compressive test result of the cylinders for the pile connection concrete has reached the specified 28 day minimum compressive strength .
5.Install backer rod and vertical joint seals as shown.
6.Place structural non- shrink grout or mortar in joints between precast abutment and backwall segments after leveling jacks and temporary supports are removed.
a.Do not apply additional dead loads or live loads to the precast abutment segments for at least 3 hours after placement .
3.6 Precast Beam Seats
A.Set beam seat in the proper horizontal location.
1.Check for proper alignment within tolerances as described.
B.Adjust vertical leveling devices or shims .
1.Check for proper grade within tolerances as described .
C.Pump structural non- shrink grout or mortar through the blockouts in the seat.
1.Start from the center of the seat and proceed toward the outside edges.
2.Verify that grout is filling the entire void between the seat and the substructure element below .
Source: Utah Standard Specifications for Road and Bridge Construction, 2026 Edition. Pages 994–1004 of 1,331.