PRECAST APPROACH SLABS
PART 1 GENERAL
1.1SECTION INCLUDES
A.Precast concrete approach slabs
B.Precast sleeper slabs
1.2RELATED SECTIONS
A.Section 02755: Concrete Slab Jacking
B.Section 02982: Bridge Concrete Grinding
C.Section 03055: Portland Cement Concrete
D.Section 03056: Self-Consolidating Concrete (SCC)
E.Section 03211: Reinforcing Steel and Welded Wire
F.Section 03310: Structural Concrete
G.Section 03390: Concrete Curing
H.Section 03575: Flowable Fill
1.3REFERENCES
A.AASHTO M 111: Zinc (Hot-Dip Galvanized) Coatings on Iron and Steel
Products
B.AASHTO M 153: Preformed Sponge Rubber, Cork, and Recycled Rubber
Expansion Joint Fillers for Concrete Paving and Structural Construction
C.AASHTO M 213: Preformed Expansion Joint Fillers for Concrete Paving
and Structural Construction (Nonextruding and Resilient Bituminous Types)
D.ASTM C 578: Rigid, Cellular Polystyrene Thermal Insulation
Precast Approach Slabs
E.ASTM C 928: Packaged, Dry, Rapid-Hardening Cementitious Materials
for Concrete Repairs
F.ASTM D 4635: Plastic Films Made from Low-Density Polyethylene and
Linear Low- Density Polyethylene for General Use and Packaging Applications
G.National Precast Concrete Association (NPCA)
H.Precast/Precast 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.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) Weight of precast elements and load distribution to lifting devices 3) Locations and details of lifting inserts, hardware, or devices. 4) Type and amount of additional reinforcing required for lifting 5) Locations and details of vertical adjusting hardware 6) Minimum compressive strength required before handling the precast elements
b.Provide the seal of a Professional Engineer (PE) or
Professional Structural Engineer (SE) licensed in the State of Utah on plans and calculations.
c.Include supporting engineering calculations.
Precast Approach Slabs
2.Erection Drawings for precast concrete approach slabs and sleeper
slabs for review. Include at least the following:
a.A work area 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.Approach slab and sleeper slab erection and sequence
including: 1) Equipment necessary for final positioning 2) At least two target elevations at working points at the top of each precast sleeper slab element to verify elevations and slopes. 3) Target elevations at working points near the corners of each precast approach slab element to verify elevations and slopes 4) Methods to adjust in-place elevations of precast approach slab and sleeper slab elements as applicable
d.Approach slab mortar and foam placement method
including: 1) Containment for mortar to the abutment support area. 2) Placement of mortar to ensure adequate filling of the void.
a.Modify if required after the mock-up pre-test.
Refer to this Section, Paragraph 3.3 C1. 3) Placement of foam under the approach slab 4) Verification of foam filling the entire void.
e.Grinding areas and depths to accommodate final structural
profile.
f.Include supporting engineering calculations.
B.Manufacturer’s product data sheets for the following products, for review:
1.Rapid Setting Flowable Repair Mortar
2.Bond Breaker Material
3.Rigid Plastic Foam
4.Premolded Joint Fillers
5.Include recommended installation instructions for information
C.Casting and Shipping Schedules
1.A casting schedule for information at least 14 calendar days in
advance to make inspection and testing arrangements.
Precast Approach Slabs
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 approach slab
a.Class AA(LS) concrete. Refer to Section 03055.
b.Self-consolidating concrete (SCC) may be used at the
contractor’s option. Refer to Section 03056.
2.Precast sleeper slab and other precast elements
a.Class AA(AE) concrete. Refer to Section 03055.
1) Class AA(LS) concrete may be used at the contractor’s option.
b.Self-consolidating concrete (SCC) may be used at the
contractor’s option. Refer to Section 03056.
3.Bedding Concrete under Sleeper Slabs
a.Flowable Fill. Refer to Section 03575.
b.Class B(AE) concrete. Refer to Section 03055.
4.Closure Pours
a.Class AA(ES) concrete unless shown otherwise. Refer to
B.Coated Reinforcing Steel. Refer to Section 03211.
C.Miscellaneous Steel Items
1.Galvanize steel items according to AASHTO M 111.
D.Rapid Setting Flowable Repair Mortar
1.Meeting the requirements of ASTM C 928, R3.
2.Provide materials free of magnesium phosphate.
3.Provide a productable to be mixed to a flowable or fluid
consistency according to the manufacturer’s technical information.
E.Bond Breaker Material
1.Low density polyethylene sheet according to ASTM D 4635 that will
allow sliding of the structural concrete after placement.
a.Use ⅛ inch thick sheets.
b.Use two layers at each interface.
Precast Approach Slabs
F.Rigid Plastic Foam
1.Preformed, extruded, cellular polystyrene thermal insulation
material according to ASTM C 578.
G.Leveling Devices
1.Use fabricated steel leveling devices as shown.
a.Alternate devices may be used provided the devices can
support the anticipated loads.
H.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.Use devices that provide 2¾ inch top clear cover and 1 inch bottom
clear cover after installation. This may require partial removal of the device after installation.
I.Foam under Approach Slabs
1.High Density Polyurethane according to Section 02755.
J.Premolded Joint Fillers
1.Refer to AASHTO M 153 and AASHTO M 213.
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 approach slab and sleeper slab 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.Texture the top surface of the elements according to the
requirements of Section 03310 for final texturing of approach slabs.
E.Permanently mark each precast element with the date of casting and
supplier identification.
1.Stamp markings in fresh concrete.
F.Cure concrete according to Section 03390.
Precast Approach Slabs
2.3QUALITY CONTROL
A.Precast Approach Slab and Sleeper Slab Elements
1.Document test results. The quality control file will contain at least
the following information:
a.Element identification
b.Date and time of casting
c.Concrete cylinder test results
d.Quantity of the 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.
PART 3 EXECUTION
3.1GENERAL
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 and remove items such as dust, rust, and debris to provide the satisfactory bonding required.
D.Perform rapid setting flowable repair mortar pre-test before installation of
approach slab. Refer to this Section Article 3.3 C1.
3.2INSTALLATION OF SLEEPER SLAB
A.Set sleeper slab in the proper horizontal and vertical position.
1.Check for proper alignment and grade within tolerances as
described.
2.Adjust leveling devices or shims before full release of the sleeper
slabs from the crane.
B.Pump bedding concrete through the ports when shown.
1.Install forms around edges of the sleeper slab to contain bedding
concrete
Precast Approach Slabs
2.Start from the center of the sleeper slab and proceed toward the
outside edges.
3.Remove forms and verify that bedding concrete is filling the entire
void between the sleeper slab and the subgrade.
4.Do not remove the installation bolts or proceed with the installation
of the approach slab until the compressive test result of the cylinders for bedding concrete has reached at least:
a.70 percent of the trial batch strength for flowable fill
b.0.7 f’c for Class B(AE) concrete
3.3INSTALLATION OF APPROACH SLABS
A.Install bond breaker materials on sleeper slab in two layers as shown.
1.Seal the edges and joints to prevent concrete or mortar from
penetrating the interface between the two sheets.
a.Duct tape is acceptable for this purpose.
B.Set approach slab in the proper horizontal and vertical position.
1.Check for proper alignment and grade within tolerances as
described.
a.Survey the top elevation of the approach slab.
2.Adjust vertical leveling devices before full release of the approach
slab from the crane.
3.Prevent shifting of the precast approach slab panels after the
proper grade is achieved.
C.Place rapid setting flowable repair mortar
1.Pre-test rapid setting flowable repair mortar installation under field
conditions in a similar void mock-up before construction of the approach slab to determine mortar flowability.
a.Include in the mock-up at least two fill ports that are of the
same configuration as the actual bridge.
b.The Engineer may determine modifications to the grouting
process.
2.Saturate Surface Dry (SSD) surfaces receiving mortar.
3.Prepare and place mortar following the manufacturer’s
recommendations.
4.Fill blockouts and leveling device voids.
5.Texture top surface of grouted blockouts according to Section
03310 for approach slabs.
6.Do not apply vehicular construction loads to the precast approach
slabs for at least 3 hours after placement of the rapid setting flowable repair mortar.
7.Cure mortar according to manufacturer’s recommendations.
Precast Approach Slabs
D.Place Foam
1.Pump high density polyurethane foam under the end of the
approach slab as shown.
a.Start from the center of the approach slab and proceed
toward the outside edges or start from one end and proceed continuously to the other end.
b.Check that high density polyurethane foam is filling the entire
void between the approach slab and the sleeper slab.
E.Joint Extrusions
1.Set prefabricated joint extrusions as shown.
3.4GRINDING
A.Profile grind the approach slab according to Section 02982 after precast
approach slabs are in place, grouting is complete, closure pours are complete, and the specified minimum 28 day compressive strength is achieved.
END OF SECTION
Precast Approach Slabs
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Source: Utah Standard Specifications for Road and Bridge Construction, 2026 Edition. Pages 1014–1021 of 1,331.
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