FULL-DEPTH PRECAST CONCRETE DECK PANELS
PART 1 GENERAL
1.1SECTION INCLUDES
A.Production, installation and finishing of full-depth precast concrete deck
panels for bridge decks on new and existing girders.
1.2RELATED SECTIONS
A.Section 02982: Bridge Concrete Grinding
B.Section 03055: Portland Cement Concrete
C.Section 03056: Self-Consolidating Concrete (SCC)
D.Section 03211: Reinforcing Steel and Welded Wire
E.Section 03251: Post-Tensioning Concrete
F.Section 03310: Structural Concrete
G.Section 03390: Concrete Curing
H.Section 03412: Prestressed Concrete
1.3REFERENCES
A.AASHTO M 111: Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel
Products
B.AASHTO M 270: Structural Steel for Bridges
C.AASHTO/AWS D1.5: Bridge Welding Code
D.ASTM A 108: Steel Bars, Carbon and Alloy, Cold-Finished
E.ASTM A 500: Cold-Formed Welded and Seamless Carbon Steel
Structural Tubing in Rounds and Shapes
Full-Depth Precast Concrete Deck Panels
F.ASTM C 109: Compressive Strength of Hydraulic Cement Mortars (Using
50 mm [2 in.] Cube Specimens)
G.ASTM C 666: Resistance of Concrete to Rapid Freezing and Thawing
H.ASTM C 1202: Electrical Indication of Concrete’s Ability to Resist
ChlorideIon Penetration
I.ASTM C 1581: Determining Age at Cracking and Induced Tensile Stress
Characteristics of Mortar and Concrete under Restrained Shrinkage
J.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)
K.ASTM D 5249: Backer Material for Use with Cold- and Hot-Applied Joint
Sealants in Portland Cement Concrete and Asphalt Joints
L.PCI Design Handbook
1.4DEFINITIONS Not Used
1.5SUBMITTALS
A.Working Drawings
1.Shop drawings of fabricated materials for review.
a.Include at least the following:
1) Geometry of precast concrete deck panels including projections, recesses, notches, openings, blockouts, and other pertinent details. 2) Locations and details of lifting inserts, hardware, or devices.
a.Provide at least 4 lifting insets, hardware, or
devices per panel. 3) Weight of precast elements and load distribution to lifting devices. 4) Type and amount of additional reinforcing required for lifting. 5) Locations and details of vertical adjusting hardware such as leveling bolts. 6) Location, type, and size of post-tensioning hardware, anchorage assembly, ducts, duct supports, blockouts, grout tubes, vents, drains, and local zone reinforcement. 7) Minimum compressive strength to be attained before handling the precast elements. Full-Depth Precast Concrete Deck Panels
8) Additional Calculations.
a.Design local zone reinforcing for post-
tensioning assembly.
b.Show that tensile stresses on both faces do not
exceed the 67 percent of the modulus of rupture during the handling, fabrication, shipping, and erection of the panel.
b.Include supporting engineering calculations.
c.Provide the seal of a Professional Engineer (PE) or
Professional Structural Engineer (SE) licensed in the State of Utah on drawings and calculations.
2.Erection Drawings for precast concrete deck panels for review,
including at least the following.
a.Work plan showing:
1) Utilities overhead and below 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) Provide crane information including charts, crane and pick locations, and operating radii.
c.Panel erection and sequence
1) Equipment necessary for final positioning 2) Methods to adjust in-place lateral position and elevation as applicable
d.Haunch and closure pour forming and placement
1) Method, equipment, and sequence for forming the haunch and installing the structural non-shrink grout or mortar. 2) Method, equipment, and sequence for forming the shear keys at joints between precast panels and installing the rapid setting flowable repair mortar.
e.Include supporting engineering calculations.
B.Materials
1.Structural Non-Shrink Grout or Mortar
a.Certified test report for review
b.Manufacturer’s technical data sheet and installation
instructions for information
2.Prestressing Steel
a.Certification for information stating the manufacturer’s
minimum ultimate tensile strength for each sample of prestressing steel
3.Backer Rod
a.Manufacturer’s product data sheets for information
Full-Depth Precast Concrete Deck Panels
C.Repair Procedure
1.Written repair procedures for defects and breakage of precast
elements for review
PART 2 PRODUCTS
2.1MATERIALS
A.Concrete
1.Class AA(LS) concrete according to Section 03055.
a.Self-consolidating concrete (SCC) may be used at the
Contractor’s option. Refer to Section 03056.
B.Coated Reinforcing Steel
1.Refer to Section 03211.
C.Vertical Adjusting Hardware
1.Provide fabricated steel vertical adjusting hardware as shown.
D.Embedded Blind Pocket Blockouts
1.Use cold formed rectangular steel tubing according to ASTM A 500
Grade B.
2.Use a steel top plate according to AASHTO M 270 Grade 36.
Higher strength grades of steel may be substituted with approval.
3.Galvanize the steel assembly after fabrication according to
AASHTO M 111.
4.Use plastic pipe for grout ports and vents.
E.Lifting Devices
1.Use devices that provide support for 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.Use a device that will have 2¾ inch top cover and 1 inch bottom
cover after installation.
a.Partial removal of the device after installation may be
required.
F.Structural Non-Shrink Grout or Mortar
1.Use for girder haunches, shear stud blockouts, shear key
blockouts, and other blockouts shown.
a.Use gray, cementitious grout or mortar, containing no
calcium chloride or admixture containing calcium chloride
Full-Depth Precast Concrete Deck Panels
b.Use a pre-packaged commercial product satisfying the
requirements shown in Table 1. 1) 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 Restrained Shrinkage No cracking exhibited in 4 C 1581 days Permeability <1,700 C measured at 28 C 1202 days, min
G.Prestressing Steel
1.Refer to Section 03412.
H.Post-Tensioning Hardware
1.Refer to Section 03251.
I.Post-Tensioning Grout
1.Refer to Section 03251.
J.Shear Studs
1.Use headed anchor studs according to dimensions shown.
2.Use steel according to ASTM A 108.
K.T-Headed Bars
1.Refer to Section 03211.
L.Post-Installed Adhesive Anchors
1.Refer to Section 03211.
M.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
Full-Depth Precast Concrete Deck Panels
2.Use a closed cell, polyethylene-foam rod joint filler.
a.Meet the requirements of ASTM D 5249 Type 1 or Type 3.
N.Miscellaneous Steel Items
1.Galvanize miscellaneous steel items permanently cast into
structural concrete elements according to AASHTO M 111.
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 panels to tolerances specified by the Precast/Prestressed
Concrete Institute (PCI) or National Precast Concrete Association (NPCA) and as shown.
D.Perform prestressing according to Section 03412.
E.Finish the precast concrete deck panels according to Section 03310.
1.Texture the top surface of the elements according to the
requirements of Section 03310 for final texturing of bridge decks.
F.Permanently mark each precast unit with date of casting and supplier
identification.
1.Stamp markings in fresh concrete.
G.Cure according to Section 03390.
H.Maintain a quality control file for precast deck panels
1.The quality control file must 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.
Full-Depth Precast Concrete Deck Panels
PART 3 EXECUTION
3.1INSTALL SHEAR STUDS
A.Install shear studs at the locations shown.
B.Weld shear studs to steel girders or plates embedded in precast concrete
girders according to AASHTO/AWS D1.5.
1.Adjust studs as necessary to provide clearance for bolts in existing
bolted splices.
2.Use method and equipment recommended by the manufacturer of
the studs.
3.Field weld studs using automatic end welding.
4.Use equipment with adequate capacity for the size of stud welded.
3.2INSTALL POST-INSTALLED ADHESIVE ANCHORS
A.Field drill holes in the top flange of existing concrete and precast concrete
girders as shown.
1.Locate girder reinforcing steel before drilling holes.
2.Avoid drilling through reinforcing steel.
B.Refer to Section 03211.
3.3PLACE PRECAST CONCRETE DECK PANELS
A.Fully brace concrete girders or steel girders before placing panels.
B.Place the precast concrete deck panels as shown.
C.Survey the top elevation of the deck panels after deck panels are placed.
1.Check the grade before post-tensioning of the deck panels, if
applicable.
D.Provide vertical adjustment in the sequence defined in the erection plan to
bring panels to the elevations shown.
E.Prevent shifting of the precast concrete deck panels during the joining of
the deck panels after the proper grade is achieved.
3.4LONGITUDINAL POST-TENSIONING
A.Clean and remove debris from blockouts.
B.Place backer rods and seal duct connections.
Full-Depth Precast Concrete Deck Panels
C.Grout shear key between panels.
1.Saturate the concrete surfaces in the shear keys with potable water
before placing grout.
2.Take extra care to prevent grout from entering post-tensioning
ducts or leaking below the panels.
D.Do not begin stressing operations until the concrete reaches the strength
and age designated on the plans and the structural non-shrink grout or mortar in shear keys has cured for at least 24 hours.
E.Install and tension strands, and grout ducts according to Section 03251.
3.5INSTALLATION OF HEADED T BARS AND ANCHORS
A.Install according to Section 03211.
3.6PREPARATION AND INSTALLATION OF STRUCTURAL NON-SHRINK
GROUT OR MORTAR IN HAUNCHES AND BLOCKOUTS
A.Do not place structural non-shrink grout or mortar in haunches and
blockouts until post-tensioning operations have been completed
B.Clean and remove debris from the haunches and blockouts before placing
the structural non-shrink grout or mortar.
C.Keep bonding surfaces free from laitance, dirt, dust, paint, grease, oil,
rust, or contaminant other than water.
D.Form the girder haunches as shown after installing shear studs at the
locations shown.
E.Pre-test grout or mortar material installation under field conditions in a
grout pocket and haunch mock-up to determine flowability and whether subsequent cracking will occur. Include in the mock-up at least two shear stud pockets and a haunch that is the same configuration as the actual bridge.
1.The Engineer may determine modifications to the grouting process.
2.Proceed with grouting process as modified by the Engineer.
F.Saturate surface dry (SSD) surfaces receiving structural non-shrink grout
or mortar.
Full-Depth Precast Concrete Deck Panels
G.Mix and place structural non-shrink grout or mortar following
manufacturer’s recommendations for preparation and installation.
1.Mix structural non-shrink grout or mortar just before use according
to the manufacturer’s instructions.
H.Grout the girder haunches using structural non-shrink grout or mortar.
1.Place structural non-shrink grout or mortar in the girder haunch in a
continuous operation within a panel.
I.Grout the shear stud blockouts using structural non-shrink grout or mortar.
1.Structural non-shrink grout or mortar in the blockouts can be placed
as part of the placement of the structural non-shrink grout or mortar in the girder haunches.
J.Do not allow voids in the grout for the girder haunches and shear stud
blockouts.
K.Do not apply construction loads to the precast concrete deck panels until
the structural non-shrink grout or mortar in the shear stud blockouts and the girder haunches has cured for at least 3 hours.
L.Fill surface voids with non-shrink grout or mortar including lifting device
blockouts, vertical adjusting hardware blockouts and grout ports.
M.Texture top surface of grouted blockouts and voids according to Section
03310 for bridge decks.
N.Cure structural non-shrink grout or mortar according to manufacturer’s
recommendation.
O.Finish grout ⅛ inch above adjacent panels.
3.7DECK GRINDING
A.Profile grind the deck according to Section 02982 after panels are in
place, grouting and closure pours are complete, and the specified minimum 28 day compressive strength is achieved.
END OF SECTION
Full-Depth Precast Concrete Deck Panels
Utah revises spec sections through supplementals and new editions. We check this one every week and email you the day it changes. Free, no account.
Source: Utah Standard Specifications for Road and Bridge Construction, 2026 Edition. Pages 1005–1013 of 1,331.
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