PRECAST SUBSTRUCTURE ELEMENTS
PART 1 GENERAL
1.1SECTION INCLUDES
A.Precast substructure elements for bridges such as foundations, columns,
bent caps, abutment stems, and wall stems.
1.2RELATED 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
1.3REFERENCES
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
ChlorideIon Penetration
Precast Substructure Elements
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
1.4DEFINITIONS
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.
1.5SUBMITTALS
A.Working Drawings
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.
Precast Substructure Elements
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 anchors 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 rods which may displace due to pressure from the grout in vertical grout joints.
g.Methods for curing cementitious materials.
B.Materials
1.Structural Non-Shrink Grout or Mortar
a.Certified test report for review
Precast Substructure Elements
b.Warranty letter for information stating that Contractor
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 Schedules
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
2.1MATERIALS
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
B.Reinforcing Steel
1.Coated reinforcing steel. Refer to Section 03211.
Precast Substructure Elements
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 productable 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 No cracking exhibited in 4 Restrained Shrinkage C 1581 days <1700 C measured at 28 Permeability C 1202 days, min
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.
Precast Substructure Elements
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.
2.2FABRICATION
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 surfaces 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.
2.3QUALITY CONTROL
A.Precast Substructure Elements
1.Document test results. The quality control file will contain at least
the following information:
a.Element identification
Precast Substructure Elements
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
3.1GENERAL PROCEDURE FOR INSTALLATION OF ELEMENTS
A.Follow the authorized erection drawings.
1.Resubmit the drawings for review if 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 spliced 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.
Precast Substructure Elements
3.2FOUNDATIONS
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 this 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.
3.3BENT 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.
Precast Substructure Elements
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.
3.4BENT 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.
3.5WALL PANELS
A.Wall panels include:
1.Cantilever Abutment Stems
2.Wingwall stems
3.Integral abutment pile cap stems
4.Abutment backwalls and cheekwalls
B.Wall panels supported on precast concrete elements (foundation 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. Precast Substructure Elements
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 the
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 temporary 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.
Precast Substructure Elements
3.6PRECAST 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.
END OF SECTION
Precast Substructure Elements
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Source: Utah Standard Specifications for Road and Bridge Construction, 2026 Edition. Pages 994–1004 of 1,331.
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