540PRECAST CONCRETE

540

5-249SECTIO N 540 – PRECAS T CONCRETE

540.0 1 DESCRIPTION . This work shall consist of manufacturing, transporting, and erecting precast concrete structure components. 540.0 2 MATERIALS . Materials shall meet the requirements of the following subsections: Portland Cement ................................ ................................ ................................ ......... 701.02 High Early -Strength Portland Cement ................................ ................................ .......701.0 3 Portland -Pozzolan Cement ................................ ................................ ......................... 701.0 4 Portland -Limestone Cement ................................ ................................ ...................... 701.0 5 Portland Blast -Furnace Slag Cement ................................ ................................ ......... 701.0 6 Ternary Blended Cement ................................ ................................ ........................... 701.0 7 Fine Aggregate for Concrete ................................ ................................ ...................... 704.01 Coarse Aggregate for Concrete ................................ ................................ .................. 704.02 Lightweight Fine Aggregate for Concrete ................................ ................................ .704.19 Mortar, Type IV ................................ ................................ ................................ ......... 707.0 1(e) Preformed Joint Filler, Cork, and Asphalt -Treated Felt ................................ ............ 707.0 6 Polyvinyl Chloride (PVC) Waterstop ................................ ................................ ........ 707.08 Bar Reinforcement ................................ ................................ ................................ .....713.01 Mechanical Splices for Bar Reinforcement ................................ ............................... 713.02 Welded Wire Reinforcement ................................ ................................ ..................... 713.0 3 Prestressing Strand and Post -Tensioning Strand ................................ ....................... 713.0 4 Structural Steel ................................ ................................ ................................ ........... 714.02 High -Strength Low -Alloy Structural Steel ................................ ................................ 714.03 Carbon Steel Bolts, Nuts , and Washers ................................ ................................ .....714.04 High -Strength Structural Bolts and Assemblies, 120 ksi ................................ ........... 714.05 Concrete Curing Materials ................................ ................................ ......................... 725.01 Air-Entraining Admixtures ................................ ................................ ........................ 725.02(b) Retarding Admixtures ................................ ................................ ................................ 725.02(c) Water -Reducing Admixtures ................................ ................................ ..................... 725.02(e) Water -Reducing and Retarding Admixtures ................................ .............................. 725.02(f) Water -Reducing, High Range Admixtures ................................ ................................ 725.02(g) Water -Reducing, High Range, and Retarding Admixtures ................................ .......725.02(h) Accelerating Admixtures ................................ ................................ ........................... 725.02(i) Water -Reducing and Accelerating Admixtures ................................ ......................... 725.02(j) Specific Performance Admixtures ................................ ................................ ............. 725.02(k) Mineral Admixtures ................................ ................................ ................................ ...725.0 3 Waterproofing Membrane System, Type III ................................ .............................. 726.08(c) Polystyrene Insulation Board ................................ ................................ ..................... 735.01

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5-250Blanket Insulation Material ................................ ................................ ........................ 735.02

Pipe Insulation ................................ ................................ ................................ ........... 740.0 6 Water ................................ ................................ ................................ .......................... 745.01 Concrete Repair Material , Type I ................................ ................................ .............. 780.0 1(a) Concrete Repair Material, Type II ................................ ................................ ............. 780.01(b) Bearing pads for structures shall meet the requirements of Section 731 . 540.0 3 GENERA L FABRICATIO N REQUIREMENTS .

116 and PCI MNL -135, except as modified in this section , or with the NPC A Quality Control Manual for Precast Plants.

PCI under its plant certification program for precast concrete or by the NPCA plant certification program. Precast concrete shall be manufactured in a plant that maintains a quality control laborat ory that meets the requirements of the Agency’s Qualified Laboratory Program . As a minimum, the laborat ory shall be equipped with a compression testing machine, curing room or chamber, apparatuses for measuring slump/flow and air entrainment, and a complete set of aggregate sieves. The compression testing machine shall be calibrated yearly by an independent laborat ory using equipment that is certified by the National Institute of Standards and Technology. The tes ting machine shall be power operated and capable of applying the load continuously rather than intermittently, and without shock.

Agency as to its a bility and commitment to produce precast concrete to the requirements of this section . A satisfactory program of quality control shall include gradation and moisture determinations of the aggregates, as well as slump, air content, and strength determinatio ns of the concrete. These tests shall be performed at regular and suitable intervals as specified in the Materials Sampling Manual and actively used to maintain the quality of the concrete within the specified requirements. The fabricator shall have a plan t specific quality control plan approved by the Agency prior to the beginning of any fabrication activities.

540 5-251 540.0 4 SUBMITTALS . As soon as practical after award of the Contract, all required information shall be prepared and submitted. A complete copy of the structural design calculations for the precast concrete shall be submitted as construction drawings in accordance with the requirements of Subsection 105.06 . The design calculations shall substantiate that the proposed precast concrete satisfies the design parameters of the Contract. The design calculations shall include a load rating for superstructures with a span length greater than or equal to twenty feet, measured along the roadway centerline. For all other superstructures, the design vehicle shall be clearly noted in the calculations. Where applicable, superstructures shall be load rated for all the vehicle configurations noted in the load rating section of the VTrans Structures Design Manual . The design calculations shall also include any general or construction notes required for the fabrication and construction of the precast concrete. The applicable design code will be the AASHTO LRFD Bridge Design Specifications unless otherwise indicated in the Contract. Fabrication drawings , also referred to in the precast industry as production drawings or shop drawings , for the precast concrete shall be submitted in accordance with the requirements of Subsection 105.06 , with an additional copy provided to the Structural Concrete Engineer. Fabrication drawings shall include such detail as needed to fully describe the inte nded as -built condition of the precast elements including any connections between precast elements or existing structures and materials. In addition to the requirements for fabrication drawings in Subsection 105.06 , the following shall be included:

components:

minimum for absorption and specific gravity per the requirements of AASHTO T 84 and AASHTO T 85 and unit weight per the requirements of AASHTO T 19 .

540 5-252 (6) Lab data that shall include, but not be limited to, the following items:

during production, including water contributed to hydration by all admixtures when the cumulative total exceeds 1 gallon per cubic yard . All mix qualification test results shall be generated with concrete from batches that are produced at this maximum W/CM ratio.

concrete shall be classified and tested as self-consolidating concrete (SCC) if the minimum spread is at least 18 inches. When the concrete is tested as a SCC mix, the difference between the J -ring test (ASTM C1621 ), and the spread test (ASTM C1611 ), shall be two inches or less for the minimum and maximum spread. Concrete that fails to meet the 18 inches minimum spread threshold will be classified and tested as conventional concrete. The visual stability index (VSI) determination will be included for the minimum and maximum values and shall not be greater than 1. T he concrete shall not demonstrate segregation at the minimum or maximum slump/spread.

AASHTO T 22 for early breaks, design strength, and the 28 -day standard cure as defined in AASHTO R 100 . The type of cure shall be listed for each age of break.

requirements of AASHTO T 358 . Results shall be categorized as Low, Very Low, or Negligible in accordance with AASHTO T 358, Table 1. The surface resistivity may be accepted p rior to 56 days if the results meet these requirements. The 56 day test results shall be completed and submitted regardless of the results of earlier tests. Testing shall be performed by an independent AASHTO re:source qualified laboratory. Test results that are suspected to have been adversely affected due to the presence of polymeric admixtures in the proposed mix may be retested with the polymeric admixture omitted.

540 5-253 g. The alkali -silica reactivity (ASR) of each ty pe of aggregate shall be measured separately based on the requirements of AASHTO T 303 . If one or more of the aggregates exceeds 0.10% expansion, then the aggregate shall be tested again according to the requirements of ASTM C1567 . .

The Contractor may elect to go directly to ASTM C1567 testing if they suspect that

the aggregate may exceed the 0.10% expansion if tested by AASHTO T 303. Testing

shall be performed by an independent AASHTO re:source qualified laboratory

accredited in the specific test method.

performed by an independent AASHTO re:source qualified laboratory accredited

in testing in accordance with the requirements of AASHTO T 160. The maximum

free shrinkage test result shall not exceed 0.06%. The cross-section of the prism

shall be 4 inches × 4 inches. The requirements of AASHTO T 160, Section 11.1.2

shall be followed for storage and measurements.

be allowed re-approval if the following conditions are satisfied:

approved mix design.

volumes adjusted accordingly. The properties to be tested shall include, but not be

limited to, specific gravity, unit weight, and absorption.

Aggregate property values will be valid for 14 months from the date tested.

test mix data and any applicable updated test information.

New mix designs and mix designs that were approved more than 36 months ago

shall have new testing completed to be submitted for approval.

The proposed concrete mix design, including performance history and all requests

for variance from the material requirements of these specifications, shall be

submitted for approval. The Structural Concrete Engineer may require a minimum

of 8 weeks for testing, review, and approval of new mix designs.

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and inserts.

requirements of Subsection 540.08.

concrete strength to allow lifting, with calculations stamped by a professional engineer.

Lifting attachments are not required to be permanently installed in the work and may be removed

or left in place at the Contractor’s convenience, provided that the minimum clear cover is met.

All design details shall be in accordance with the VTrans Structures Design Manual and the AASHTO

LRFD Bridge Design Specifications. A professional engineer shall stamp any design calculations included

in the submittals.

540.05CONCRETE

subsections of Section 501 listed in Table 540.05A.

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TABLE 540.05A – BATCH PLANT OPERATION SUBSECTIONS AND TOPICS

Subsection Topic

Subsection 501.04(a) General Requirements

Subsection 501.04(d) Testing Laboratory

Subsection 501.04(e) Bins and Scales

Subsection 501.04(f) Production Tolerances for Batching

Subsection 501.04(g) Storage and Proportioning of Materials

Subsection 501.05 Mixing and Delivery

Paragraphs 1 and 3 only.

For plants not located in Vermont, the Agency has the option

of waiving the requirements of Subsection 501.05(a)(6) in

their entirety and Subsection 501.05(c), paragraph 1 only.

curing, and testing requirements. Specimens shall be tested either at the Agency’s Materials

Testing and Certification Section Central Laboratory, or at the fabricator’s plant laboratory. An

Agency representative shall witness all tests.

Concrete for precast concrete shall conform to the following requirements:

design compressive strength shown on the Plans. When a 28-day test result is below the

specified design strength, all concrete represented by that test shall be unacceptable for the

requirements of this section. The Engineer reserves the right to reject all members that were

manufactured from this concrete.

water contributed to cement hydration by all admixtures when the cumulative total exceeds

1 gallon per cubic yard. If total cementitious material content exceeds 900 pounds per cubic

yard, then water batched shall not exceed 300 pounds per cubic yard. The maximum W/CM

ratio in production shall not exceed the maximum W/CM ratio determined in Subsection

540.04(a)(6)a

152.

as tested in accordance with the requirements of AASHTO T 309.

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the minimum/maximum slump or spread submitted in the mix design, the load may be

rejected. The visual stability index (VSI) shall be less than or equal to 1.

be cured with the piece they represent through the complete curing period. These cylinders

shall meet the testing requirements of AASHTO T 277 and AASHTO T 358 and shall be

kept with the piece they represent until collected by the Agency.

Any admixture containing calcium chloride shall not be used. Only the cementitious

combinations and sources from the approved mix design shall be used in the precast units

required for any one structure, unless otherwise authorized by the Structural Concrete

Engineer.

540.06INSPECTION. Materials furnished and the work performed under Section 540 shall be inspected

by the Agency. The inspector shall have the authority to reject any material or work that does not meet

the requirements of these specifications. Any work performed that has not been inspected may be rejected,

unless waived in writing by the Engineer.

The inspector shall be provided with a minimum office space of 100 square feet with a least dimension of

6 feet. A desk surface with a minimum of two drawers, as well as dedicated private telephone and internet

services, shall be provided to the laboratory. The phone and internet service shall be provided in

accordance with Subsection 631.02(a)(4), except that selection of the service by the Engineer is not

required. Any variances shall be approved by the Structural Concrete Engineer. This office space shall be

located on the premises as close to the production area as practicable.

The Engineer reserves the right to reject inadequate office facilities and require suitable alternatives.

540.07FABRICATION

of 14 calendar days prior to beginning concrete placement, unless the Engineer deems, in writing,

that a pre-production meeting is unnecessary. The meeting shall be held a minimum of 5 calendar

days prior to beginning concrete placement unless otherwise approved by the Structural Concrete

Engineer.

At a minimum, the pre-production meeting shall be attended by the crew supervisor, plant

manager, inspector or inspector’s supervisor, a representative from the Agency’s Materials Testing

and Certification Section Structural Concrete Unit, and the Project Manager or designer.

Additionally, the fabricator shall have available at the pre-production meeting the approved

fabrication drawings and a complete anticipated production schedule for all components included

in the fabrication drawings.

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for rejection. Holes or cutouts for anchoring devices, diaphragm connections, openings for

connection rods, recesses for grout holes for guardrail bolts, and any other related details shown

on the Plans shall be provided for in the members.

encased in an approved conduit. Unless otherwise shown on the Plans, the ratio of cross-sectional

area of the post tensioning strand to be encased to the interior cross-sectional area of the conduit

shall not exceed 0.4, except when a steel bar is used as a tendon, the inside diameter of the conduit

shall be at least 3/8 inch greater than the diameter of the bar. Conduit that has been crushed or has

opened seams shall not be used.

The conduit shall be rigidly constructed, completely sealed, accurately placed, and securely

fastened to maintain the desired profile during concreting. No conduit shall be located more than

1/4 inch from the position shown on the Plans. Bundling of conduits will not be permitted.

reinforcement shall be furnished and installed in conformance with the requirements of Section

507. The chairs or spacers used to support or locate the reinforcement that bears on the faces of

the forms shall be made of, or be coated with, a non-corrosive material so that no discoloration

will show on the faces of the precast concrete units.

approved placement of the reinforcement, conduits, and anchorages. The concrete shall be vibrated

internally, externally, or a combination thereof to the required consolidation. When a vibrator is

used with rebar with special coatings or made of non-metallic material or a material that could be

susceptible to damage, the vibrator head shall be non-metallic or rubber-coated.

SCC concrete should not be vibrated. If there is a need to vibrate SCC concrete, it shall only be

vibrated for the minimum time necessary so as to avoid segregation. The vibrating shall be done

with care and in such a manner to ensure that the following conditions are met:

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and PCI MNL-135, or with the NPCA Quality Control Manual for Precast Concrete, unless

otherwise noted in the Contract or as approved by the Engineer.

manufacturing site.

Minor defects are defined as the intermittent presence of holes, honeycombing, chips, or spalls,

which are 6 inches or less in the longest dimension, and that do not penetrate deeper than 1 inch

into the concrete. Minor defects may be repaired using an approved standard repair procedure as

detailed in Subsection 540.07(g)(3). Surface voids or bug holes that are less than 5/8 inch in

diameter and less than 1/4 inch deep need not be repaired. Minor defects that recur with any

identifiable regularity or pattern may be required to be addressed through a non-conformance

report, at the discretion of the Structural Concrete Engineer.

Major defects are anything beyond the scope of minor as described above. It is at the sole discretion

of the Structural Concrete Engineer to determine into which category any defect is categorized.

Structural Concrete Engineer. Cracks equal to or greater than 0.01 inch in width may be

cause for rejection based on their width, length, location, and frequency.

At the Structural Concrete Engineer’s discretion, cracked members shall be repaired or

replaced at the Contractor’s expense. Members with crack widths of 0.05 inch and greater

will be rejected.

the Agency’s Approved Products List. Any unsound concrete shall be carefully chipped

out and the perimeter saw-cut to a minimum depth of 1/4 inch or deeper if recommended

by the repair material manufacturer. The prepared surface profile shall be as specified by

the repair material manufacturer. If not specified, the prepared surface profile shall

conform to, at a minimum, the International Concrete Repair Institute’s CSP 6 (Medium

Scarification) surface profile. The repair material shall be cured as specified by the

manufacturer.

prescribed procedure for repairing minor defects at the fabricator’s facility. At a minimum

the SRP shall detail the scope of defects for which that procedure is intended to be used,

detailed narrative including every step of the repair procedure, and the product

documentation for the specific repair materials that will be used. The SRP shall include

example pictures of defects for which the procedure could be used, detailed example

pictures of every step of the repair procedure, and pictures of an example completed repair.

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Approval to use an SRP for any given defect is at the sole discretion of the Structural

Concrete Engineer, and all SRPs shall be approved by them prior to their use. SRPs shall

be submitted to the Structural Concrete Engineer at least 14 calendar days in advance of

the repair work. The Agency’s consent to use an SRP for the repair of a defect does not

constitute acceptance of that repair.

minor above, shall be documented with a non-conformance report (NCR). At a minimum,

the NCR shall detail what the defect is, including adequate pictures of the piece and defect,

what caused it, the proposed repair, the procedure for carrying out the proposed repair, and

a plan of action to prevent additional similar defects from occurring. Any approved repairs

shall be documented and photographed during the repair work and after completion of the

repair.

NCRs shall be submitted within 2 working days of the discovery of the defect.

conditions when the ambient air temperature is expected to be below freezing at any point in time

or below 40°F for an 8-hour continuous period. The requirements of Subsection 501.07(b) shall

apply in addition to the requirements of Subsection 540.08.

marked on each individual piece of precast concrete. The mark shall be in a location that will not

be visible in the finished product.

required and approved in Subsection 540.04(f) is achieved as specified in the Materials Sampling

Manual.

540.08CURING

Concrete Engineer’s approval. The fabricator shall submit with the fabrication drawings complete

details of the proposed methods for approval.

The curing period for precast concrete is defined as a minimum of 72 hours of wet curing to begin

immediately following completion of placing and finishing of the concrete. The following

requirements shall apply:

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Except where modified herein, precast concrete structure components shall be cured by

either water curing, wetted burlap covered with white polyethylene sheeting, or white

burlap-polyethylene sheeting (burlene) as specified in Subsection 501.15.

within the enclosure shall exceed 90% throughout the duration of the curing period. A

curing enclosure is considered any means of moisture retention that allows air to contact

the surface of the piece.

they represent, or by specimens match-cured in an approved match-curing system. Wet

curing shall be continued until 80% of the 28-day design strength is achieved, but shall be

no less than 72 hours in duration.

not ambient temperatures of the curing area unless specifically stated as such.

the first 12 hours of the curing period, and shall be maintained at or above 68°F for the

remainder of the curing period.

thermocouples placed as near as practicable to the center of mass of the finished piece. In

addition, the temperature within the curing enclosure shall be monitored using temperature

sensors placed carefully within the curing enclosure in such a way that temperatures being

measured accurately represent the curing conditions.

The requirement for temperature monitoring may be waived by the Structural Concrete

Engineer if the concrete is not subject to accelerated curing and ambient temperatures are

expected to be well above 40°F throughout the duration of production.

procedure described in Subsection 540.08(a), in accordance with the requirements of PCI

MNL-116, Section 4.19 and the following conditions:

540

takes fresh concrete to reach a compressive strength of 500 psi.

Testing to determine the time of set shall be done when the temperature is within

± 5°F of the anticipated concrete placement temperature.

Alternately, time of set may be found by taking a minimum of three different

concrete temperatures at intervals of approximately 10°F, entering that data on a

graph, and then drawing a best-fit smooth curve line through the three data points.

This graph will be used to determine the time of set for the anticipated concrete

placement temperature, rounded up to the nearest half hour.

component, an enclosure that is suitable for containing live low-pressure steam or heat

shall be placed over the forms. The fabricator shall make these enclosures available for

inspection prior to casting.

shall be taken to prevent the live steam from being directed on the concrete or forms in

such a way as to cause damage from localized high temperatures.

covered with plastic sheeting. Radiant heat may be applied by means of circulation pipes

containing steam, hot oil, or hot water, or by electric heating elements.

increased at a maximum rate of 10°F per hour. However, the temperature within the

concrete shall not be more than 40°F higher than the initial concrete placement temperature

or more than 104°F, whichever is less.

Following initial set, the internal concrete temperature shall increase at a rate not exceeding

40°F per hour until the desired curing temperature is reached. The maximum internal

concrete temperature shall not exceed 160°F. The maximum differential between the

curing enclosure temperature and internal concrete temperature shall not exceed 40°F. The

selected curing enclosure temperature range shall be as approved on the fabrication

drawings.

The accelerated curing cycle shall be considered complete when the method of supplying

heat is stopped or the concrete temperature drops below 120°F. Two cylinders shall be

tested immediately upon completion of the accelerated cure cycle.

540

The maximum cooling rate from the sustained accelerated curing temperature shall be 50°F

per hour. Cooling at this rate shall continue until the concrete temperature is 40°F or less

above the ambient temperature outside the curing enclosure.

additionally wet cured until this strength threshold is met. If the precast concrete has

attained 80% of the 28-day strength during the accelerated curing cycle, no further curing

will be required.

then be exposed to cold weather conditions as defined in Subsection 540.07(i) shall be allowed 24

hours to cool and dry in an environment of at least 40°F prior to exposure to cold weather

conditions. For pieces cast outdoors in cold weather ambient conditions, all requirements of

Subsection 501.07(b) shall apply.

recorder per contiguous form group and common heat source, per day. The Structural Concrete

Engineer may require that additional temperature recorders be installed if it is determined that one

per day of production does not adequately monitor the curing conditions.

The recorder shall record, at intervals not to exceed 15 minutes, the temperature of the air

surrounding the piece as well as the internal concrete temperature. Temperature recording shall

continue until completion of the chosen curing method.

Each recorder’s data log shall indicate the casting bed, date of casting, time of start and finish of

record, and the mark number of the precast concrete structure component being cured. At the

completion of the temperature recording, the data logs shall be given to the Agency representative.

Temperatures recorded on the data logs shall be used to determine whether the precast concrete

structure components have been cured in accordance with the specifications and the approved

fabrication drawings.

Recorder accuracy shall be certified at least once every 12 months, and the certificate displayed

with the recorder. Calibration and certification shall be performed by either the manufacturer, the

supplier, or an independent laboratory. Random temperature checks of each recorder may be made

by an Agency representative.

540.09HANDLING, STORAGE, AND SHIPPING. All precast concrete shall be handled, stored, and

shipped in such a manner as to minimize chipping, cracks, fractures, discoloration, and excessive bending

stresses. Units damaged by handling, storage, or shipping shall be replaced at the Contractor’s expense.

Prior to shipment of any members, all NCRs shall be resolved. In addition, all required testing shall

demonstrate the design requirements have been met.

540

540.10INSTALLATION

concrete structure erection shall be of adequate design and capacity to safely erect, align, and

secure all members and components in their final positions without damage. The Contractor is

solely responsible for the methods and equipment employed for the erection of the precast concrete

structure components.

Construction drawings for precast concrete structure component erection shall be submitted in

accordance with the requirements of Subsection 105.06. The erection plan shall include the

necessary computations to indicate the magnitude of stress in the units during erection and to

demonstrate that all of the erection equipment has adequate capacity for the work to be performed,

and provisions for all stages of construction, including temporary stoppages. When the fabricator-

designed lifting hooks will be used by the Contractor, computations indicating the magnitude of

stress in the segments during erection are not required, unless otherwise ordered by the Engineer.

Submittal of the erection plan is for documentation purposes only and shall in no way be construed

as approval of the proposed method of erection. The Contractor shall follow the erection plan as

submitted.

sheet membrane shall be placed over the joints of precast concrete units in accordance with the

Contract. All work performed shall be in accordance with the manufacturer’s recommendations.

Membrane material shall meet the requirements of Subsection 726.08(c).

Waterproofing shall not be performed in wet weather or when the temperature is below 40°F,

without the authorization of the Engineer.

The concrete surfaces that are to be waterproofed shall be reasonably smooth and free from

projections or holes and shall be cleaned of dust and loose material. The surfaces shall be visibly

dry prior to and during application of the membrane system.

540.11GROUT

roughened in accordance with the Plans. The surface to be grouted shall be thoroughly wetted, yet

free of all standing water. Shear keys shall be saturated surface dry prior to grouting.

540

level screw voids, and for fairing joints as detailed in the Contract or as ordered by the Engineer.

Grout shall be Type IV mortar in accordance with Subsection 707.01(e)(1). Additional aggregates

shall not be added to the material during field mixing. Ready mixed mortar in accordance with

Subsection 707.01(e)(2) may be substituted with written permission of the Engineer. Placement of

ready mixed mortar shall be complete within 90 minutes of the time of batching.

The Contractor shall submit a proposed grouting procedure to the Engineer for their review and

approval. The proposed grouting procedure shall include the required equipment, workforce,

manufacturer’s product data sheet for prepackaged mortar or the approved mix design of the ready

mixed mortar when approved, placement rate, batch size, and all necessary details to explain how

the grouted element will be placed in accordance with specification and manufacturer

recommendations as applicable without air voids or cold joints.

Post-tensioning may occur when a field cured sample demonstrates conformance with post-

tensioning strength requirements specified in the Contract, as determined in accordance with

ASTM C109. Three cubes shall constitute a single sample.

recommendations and shall be readily pourable so that it completely fills the shape of the shear

keys or holes, depending on the product being installed. The placement of the grout shall be

continuous. The grouting of each shear key shall be completed in its entirety within a single

working day.

Grout shall be placed between precast concrete structure components as required for fairing out

any unevenness between adjacent components. Type IV mortar shall be used. The mortar shall be

placed to the thickness necessary to eliminate unevenness, forming a smooth surface from the

higher edges to the lower surface. The finished surface shall be feathered smoothly and be free of

depressions or sharp edges.

cured for not less than three days by the wetted burlap method in accordance with the requirements

of Section 501. Curing shall commence as soon as practical after grout placement.

540.12POST-TENSIONING. Post-tensioning strands shall not be bonded to the concrete and shall be

protected against corrosion as specified in the Contract.

Post-tensioning of strands shall not commence until a minimum compressive strength of 1,500 psi has

been attained in the grout, when tested in accordance with the requirements of Subsection 540.11(b). If

the design strength is met prior to completion of the required curing, the grout cure shall be maintained

during the post-tensioning operation.

540

Strands shall be stressed in the following sequence:

tension. Stressing shall begin by pulling the inner-most strands first, then proceeding

symmetrically towards the member’s ends.

In the case where the Plans call for top and bottom strands, the sequence shall be followed using an initial

pull of 15.0 kips, top and bottom, followed by a sequence using the final design tension.

No loading of elements shall be allowed until post-tensioning is completed.

540.13METHOD OF MEASUREMENT. The quantity of Precast Concrete Structure of the type and size

specified to be measured for payment will be on a lump sum basis in the complete and accepted work.

The lump sum will include all of the precast concrete structure components for each location specified in

the Contract.

The quantity of Precast Concrete Deck Panels to be measured for payment will be the number of square

feet of precast concrete deck panels used in the complete and accepted work.

540.14BASIS OF PAYMENT. The accepted quantity of Precast Concrete Structure of the type and size

specified will be paid for at the Contract lump sum price. The accepted quantity of Precast Concrete Deck

Panels will be paid for at the Contract unit price per square foot. Payment will be full compensation for

designing, detailing, fabricating, repairing, transporting, handling, and erecting the materials specified, for

furnishing and implementing the erection plan, and for furnishing all labor, tools, equipment, and

incidentals necessary to complete the work. The Engineer may authorize partial payments in the following

manner:

been approved by the Agency.

elements have met the requirements of Section 540.09 for shipping.

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Furnishing and placing preformed sheet membrane waterproofing, including primer, mastic, polyurethane

membrane sealant, and surface preparation, will be considered incidental to Precast Concrete Structure.

Any grouting work, such as fairing out unevenness between adjacent precast concrete structure

components and filling leveling screw holes, shear keys, transverse anchor recesses, and dowel holes, will

be considered incidental to the work for Precast Concrete Structure.

Payment will be made under:

Pay Item Pay Unit

00 Precast Concrete Structure ........................................................................Lump Sum

540.2000 Precast Concrete Deck Panels ...................................................................Square Foot

541

5-267SECTION 541 – STRUCTURAL CONCRETE

541.01DESCRIPTION . This work shall consist of furnishing and placing Portland cement concrete for

structures and incidental construction. The Portland cement concrete may consist of a homogeneous mixture of Portland cement, fine aggregate, coarse aggregate, water, admixtures, and pozzolans, proportioned and mixed according to these specifications.

541.02MATERIALS . Materials shall meet the requirements of the following subsections:

Portland Cement ................................ ................................ ................................ ......... 701.02 Portland -Pozzolan Cement ................................ ................................ ......................... 701.04 Portland -Limestone Cement ................................ ................................ ...................... 701.05 Portland Blast -Furnace Slag Cement ................................ ................................ ......... 701.06 Ternary Blended Cement ................................ ................................ ........................... 701.07 Fine Aggregate for Concrete ................................ ................................ ...................... 704.01 Coarse Aggrega te for Concrete ................................ ................................ .................. 704.02 Lightweight Coarse Aggregate for Concrete ................................ ............................. 704.14 Lightweight Fine Aggregate for Concrete ................................ ................................ .704.19 Mortar, Type I ................................ ................................ ................................ ............ 707.01 (b) Mortar, Type IV ................................ ................................ ................................ ......... 707.0 1(e) Preformed Joint Filler, Cork, and Asphalt -Treated Felt ................................ ............ 707.0 6 Polyvinyl Chloride (PVC) Waterstop ................................ ................................ ........ 707.08 Concrete Bonding Systems ................................ ................................ ........................ 707.1 4 Steel for Corrugated Metal Forms ................................ ................................ ............. 715.03 Epoxy Bonding Systems ................................ ................................ ............................ 719.01 Concrete Curing Materials ................................ ................................ ......................... 725.01 Air-Entraining Admixtures ................................ ................................ ........................ 725.02(b) Retarding Admixtures ................................ ................................ ................................ 725.02(c) Water -Reducing Admixtures ................................ ................................ ..................... 725.02(e) Water -Reducing and Retarding Admixtures ................................ .............................. 725.02(f) Water -Reducing, High Range Admixtures ................................ ................................ 725.02(g) Water -Reducing, High Range, and Retarding Admixtures ................................ .......725.02(h) Accelerating Admixtures ................................ ................................ ........................... 725.02(i) Water -Reducing and Accele rating Admixtures ................................ ......................... 725.02(j) Specific Performance Admixtures ................................ ................................ ............. 725.02(k) Anti-Washout Admixtures ................................ ................................ ......................... 725.02(l) Pozzolans ................................ ................................ ................................ ................... 725.03(a) Silica Fume ................................ ................................ ................................ ................ 725.03(b) Ground Granulated Blast -Furnace Slag (GGBFS) ................................ .................... 725.03(c)