PRESTRESSED CONCRETE
PART 1 GENERAL
1.1SECTION INCLUDES
A.Pre-tensioning, fabricating, curing, storing, transporting, and erecting
precast, prestressed concrete members.
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 05120: Structural Steel
G.Section 05822: Bearings
1.3REFERENCES
A.AASHTO M 111: Zinc (Hot-dip Galvanized) Coatings on Iron and Steel
Products
B.AASHTO M 169: Steel Bars, Carbon, and Alloy, Cold-Finished
C.AASHTO M 203: Steel Strand, Uncoated Seven-Wire for Prestressed
Concrete
D.AASHTO M 270: Structural Steel for Bridges
E.AASHTO/AWS D1.5: Bridge Welding Code
F.ASTM A 153: Zinc Coating (Hot-Dip) on Iron and Steel Hardware
Prestressed Concrete
G.ASTM A 307: Carbon Steel Bolts, Studs, and Threaded Rods 60000 PSI
Tensile Strength
H.ASTM A 563: Carbon and Alloy Steel Nuts
I.ASTM F 3125: High Strength Structural Bolts, Steel and Alloy Steel, Heat
Treated, 120 ksi (830 MPa) and 150 ksi (1040 MPa) Minimum Tensile Strength, Inch and Metric Dimensions
J.ASTM F 436: Hardened Steel Washers
K.ASTM F 959: Compressible-Washer-Type Direct Tension Indicators for
Use with Structural Fasteners
L.American Institute of Steel Construction (AISC)
M.Precast/Prestressed Concrete Institute (PCI) Manual for Quality Control
for Plants and Production of Structural Precast Concrete Products (MNL-116)
N.Precast/Prestressed Concrete Institute (PCI) Tolerance Manual for
Precast and Prestressed Concrete Construction (MNL-135)
O.US Military Specifications
P.UDOT Quality Management Plan
1.4DEFINITIONS
A.Working Force – The force remaining in the prestressing steel after
prestressing losses have either taken place or been provided for. These losses include concrete creep and shrinkage, concrete elastic compression, steel creep, and anchorage take ups.
B.Working Stress – The stress remaining in the prestressing steel after
prestressing losses have either taken place or been provided for. These losses include concrete creep and shrinkage, concrete elastic compression, steel creep, and anchorage take ups.
Prestressed Concrete
1.5SUBMITTALS
A.Working Drawings
1.Detailed shop drawings of fabricated materials for review.
a.Include the following:
1) Details and calculations of the method, materials, and equipment to be used in the prestressing operations, including additions or rearrangement of reinforcing steel and revision in concrete dimensions from that shown. 2) Method and sequence of stressing.
a.Specifications and details of the prestressing
steel, working stresses, and other data pertaining to the prestressing operation.
b.Proposed arrangement of the prestressing
steel in the members.
c.Cutting or release pattern. Include location and
detail of hold-down devices and debonded strands. 3) Location, descriptions, and details for embedment items including plates, inserts, sleeves, lifting devices, and other items used for temporary and permanent attachments.
2.Erection drawings for precast, prestressed concrete members for
review.
a.Illustrate the proposed method of erection. Provide details of
the process including but not limited to the following: 1) Temporary supports, bracing, guys, dead-men, lifting devices, connection details, and attachments to bridge members. 2) Details for anticipated phases and conditions during erection. 3) The erection schedule and sequence, crane location, crane capacities, location of lifting points on the bridge members, member weights, and other assumed loads during progressive stages of construction. 4) Minimum number and arrangement of items such as primary members, secondary members, and connections that must be installed, braced, and properly connected to provide structural integrity and stability. 5) Incorporate into the plan the requirements from this Section, Article 3.1. Prestressed Concrete
B.Material Submittals
1.Certifications
a.Certification stating the manufacturer’s minimum guaranteed
ultimate tensile strength for each sample of prestressing steel.
b.Documentation of AISC Bridge Component QMS (CPT)
Certification for information.
c.The certified calibration chart required by this Section,
Article 2.7, paragraph B.
1.6ACCEPTANCE
A.Girders may be accepted at a reduced price when the average
compressive strength, based on field cured cylinders, is at least 94 percent of the specified 28-day minimum compressive strength.
1.Price reduction factor is as follows:
f ' c − AVG Price Reduction Factor = 1.00-0.30 0.06 f ' c Where: f’c = specified 28-day minimum compressive strength in psi. AVG = average compressive strength of 3 cylinder breaks in psi.
2.Department will calculate the amount paid by multiplying the
contract unit price for the girder by the price reduction factor.
3.The Department will reject girders if the average compressive
strength of field cured cylinders is less than 94 percent of the specified 28-day minimum compressive strength.
a.Core tests are not permitted for compressive strength tests.
1.7HANDLING, STORAGE, AND DELIVERY
A.Prevent cracking or damaging precast units during handling, storage, and
delivery.
B.Take appropriate measures to prevent member camber from exceeding
the tolerances in this Section, Article 2.7 until deck is placed.
C.Store units with adequate dunnage and bracing.
1.Secure and protect units from movement.
2.Prevent cracking, distortion, warping, contact with soil, staining, and
other physical damage.
Prestressed Concrete
3.Store units with dunnage across full width of each bearing point
unless otherwise specified.
4.Place stored units so identification marks are clearly visible and
units can be inspected.
D.Do not ship prestressed concrete members until tests on concrete
cylinders manufactured from the same concrete and cured under similar conditions as the girders, indicate the concrete has attained an average compressive strength equal to or greater than the specified 28-day minimum compressive strength or for seven days after concrete placement, whichever is longer.
E.Transport precast members in an upright position.
1.Support the members during transportation in approximately the
same points they will be supported when installed.
F.Remove portions of lifting devices protruding above the top of the
member, when no longer needed.
PART 2 PRODUCTS
2.1CONCRETE
A.Class AAA(AE) concrete according to Section 03055.
1.The minimum compressive strength for transfer of prestressing
force is as shown, but not less than 4,000 psi.
2.Pay factor for reduced strength in girders is as defined in this
Section, Article 1.6.
B.Self-Consolidating Concrete (SCC) may be used at the Contractor’s
option. Refer to Section 03056.
2.2PRESTRESSING STEEL
A.Refer to AASHTO M 203. Use 0.5 or 0.6 inch diameter, Grade 270.
2.3REINFORCING STEEL
A.Use coated reinforcing steel according to Section 03211.
2.4ELASTOMERIC BEARING PADS
A.Refer to Section 05822.
Prestressed Concrete
2.5ZINC RICH PAINT
A.Refer to US Military Specification MIL-P-24441/20.
2.6MISCELLANEOUS STEEL ITEMS
A.Headed Studs – Use steel according to AASHTO M 169.
1.Automatic end welded.
B.Embedded Plates – Use AASHTO M 270, Grade 36 steel.
1.Galvanize according to AASHTO M 111 after fabrication.
C.Tapered Sole Plates – Use AASHTO M 270, Grade 50 steel.
D.Graffiti Cover
1.Plates – Use AASHTO M 270, Grade 36 steel.
2.Bolts – Use ASTM A 307, Grade A steel.
3.Nuts – Use ASTM A 563 steel.
4.Washers – Use ASTM F 436 steel.
5.Galvanize plates according to AASHTO M 111 after fabrication.
6.Galvanize bolts, nuts, and washers according to ASTM A 153,
Class C.
E.Intermediate Diaphragms
1.Connection angles and Plates
a.Use AASHTO M 270, Grade 36 steel.
2.Bolts
a.Use ASTM F 3125, Grade A325, Type 1 for steel to steel
connections.
b.Use ASTM A 307, Grade A for steel to concrete connections.
3.Nuts
a.Use ASTM A 563
4.Washers
a.Use ASTM F 959 washers for steel to steel connections.
b.Use ASTM F 436 washers for concrete to steel connections.
5.Galvanize connection angles and plates according to AASHTO
M 111.
6.Galvanize bolts, nuts, and washers according to ASTM A 153,
Class C.
F.Threaded Rods – Refer to AASHTO M 270, Grade 36.
G.Welding – Refer to AASHTO/AWS D1.5.
Prestressed Concrete
H.Galvanize structural steel items permanently cast into concrete according
to AASHTO M 111.
2.7FABRICATION
A.General
1.Use a Department prequalified supplier of precast concrete
products according to the UDOT Quality Management Plan 505: Precast/Prestressed Concrete Structures.
2.Comply with camber and dimensional tolerances of PCI MNL-135.
3.Fabricate structural steel according to Section 05120.
a.Structural steel for prestressed concrete members requires
AISC Bridge Component QMS (CPT) Certification unless otherwise specified.
B.Preparation
1.Equipment used to stress tendons must be accurate including
jacks, pressure gauges, and load cells.
a.Furnish a certified calibration chart.
b.Calibrate each jack and its gauge as a unit with the cylinder
extension in the final jacking force position.
2.Calibrate the load cell and provide an indicator to determine the
prestressing force in the tendon.
a.The range of the load cell must be so that the lower 10
percent of the manufacturer’s rated capacity is not used in determining the jacking stress.
3.The prestressing force may be tested by the Engineer.
4.Provide sufficient labor, equipment, and material to install and
support testing equipment at the prestressing tendons and to remove the equipment when testing is completed.
C.Prestressing Steel
1.Clearly mark the shipping package or form with handling
instructions and information about the corrosion inhibitor including date, place, safety orders, and instructions for use.
2.Protect against physical damage and corrosion during handling,
storing, and shipping.
3.Replace prestressing steel that has damage, loose rust, pitting, or
serious corrosion.
a.Slight rusting is acceptable if it does not cause visible pits.
4.Do not oil or grease prestressing strand.
Prestressed Concrete
D.Pre-tensioning
1.Tension prestressing steel with hydraulic jacks so that the force in
the prestressing steel is not less than the value shown
2.Do not allow the stress before transfer to exceed 75 percent of the
specified minimum ultimate tensile strength.
3.Maximum temporary tensile stress (jacking stress) in prestressing
steel must not exceed 80 percent of the specified minimum ultimate tensile strength.
4.Anchor the prestressing steel at stresses that result in the ultimate
retention of working forces not less than those shown.
5.The stress loss in pretensioned, prestressing steel due to concrete
creep and shrinkage, steel creep, and concrete elastic compression is as shown.
6.Check prestressing steel strands in pretensioned members for loss
of prestress not more than 12 hours before placing concrete for the members if tensioned individually.
a.Use methods and equipment acceptable to Engineer.
7.Re-tension strands that show a loss of prestress in excess of three
percent.
8.Make tensioning corrections as required by PCI MNL-116.
a.Adjust the tensioning and calculated prestressing steel
elongation in pretensioned members when the following conditions are present: 1) Strands are anchored to abutments that are independent from the form 2) The temperature of the steel at the time of tensioning differs by more than 25 degrees F from the time the concrete begins to set 3) The net force differential is greater than 2.5 percent
b.Do not exceed the maximum temporary tensile stress in the
prestressing steel.
9.Do not cut or release prestressing steel in pretensioned members
until the concrete in the member has attained the minimum compressive strength specified in this Section, Article 2.1.
10.Maintain a minimum lateral eccentricity of prestress when cutting
and releasing prestressing steel in pretensioned members.
a.Follow the cutting and release pattern in the authorized shop
drawings.
Prestressed Concrete
11.Cut off pretensioned, prestressing steel flush with the end of the
member except when otherwise shown. Clean and paint the exposed strand ends and a 1 inch strip of adjoining concrete with zinc rich paint. Alternatively, cut the strands at least 1 inch back from the girder end, fill the recess with grout, and finish flush with the girder ends.
a.Use a wire brush or abrasive blast cleaning to remove dirt
and residue not firmly bonded to the metal or concrete surfaces.
b.Cover the surfaces with a thick application of zinc rich paint.
1) Work paint into voids in the strands.
c.Apply two applications of zinc rich paint to surfaces that are
not covered by concrete or mortar.
E.Place Concrete
1.Do not place concrete into forms until the reinforcement, embedded
elements and prestressing steel has been inspected and the Engineer has given permission to proceed.
a.Securely tie or support reinforcing and embedded elements
before concrete placement.
2.Clean the inside surface of forms of dirt, mortar, and foreign
material before concrete placement.
3.Vibrate the concrete internally, externally, or both.
a.Do not vibrate SCC.
4.Do not displace reinforcing steel, embedded elements or strands.
F.Finishing
1.Finish top surfaces of precast girders, against which cast-in-place
concrete will be placed, to a coarse texture of approximately ¼ inch amplitude.
a.Clean surfaces of laitance or other foreign material before
shipping.
2.Finish sides and bottom surfaces of precast girders to an ordinary
surface finish according to Section 03310.
a.Patch surface voids or “bug holes” that are larger than ½
inch in diameter or 3/8 inch deep.
b.Fill air holes larger than ¼ inch in diameter that occur in high
concentrations (more than one per two square inches).
G.Cure
1.Cure according to Section 03390.
Prestressed Concrete
PART 3 EXECUTION
3.1ERECTION
A.Erect prestressed concrete members according to the authorized erection
drawings.
B.Clean bearing surfaces and surfaces that will be in permanent contact
before the members are erected.
C.Use lifting devices in a manner that will not cause bending or torsional
forces.
D.Accurately assemble parts as described and according to the contract
documents or authorized erection drawings. Follow match-marks.
E.Temporarily support, anchor, and brace erected superstructure members
as necessary for stability and to resist wind or other loads until they are permanently secured to the structure.
1.Support, anchor, and brace superstructure members as detailed in
the authorized erection drawings before allowing traffic under the bridge.
F.Do not open traffic under a partially erected bridge superstructure unless
allowed in the erection drawings or authorized by the Engineer and approved by the Professional Engineer responsible for signing and sealing the erection drawings.
END OF SECTION
Prestressed Concrete
Prestressed Concrete in other states
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 1074–1083 of 1,331.
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