Wisconsin WisDOT Standard Specifications (within FDM) — Section 504

Effective with the December 2018 Letting 239 2019 Standard Spec ifications Section 504 Culverts, Retaining Walls, and Endwalls

504.1Description

(1)This section describes providi ng culverts whether defined as a culvert or bridge under 101.3 , retaining

walls, and endwalls. This work does not include providing pipe culverts.

504.2Materials

(1)Furnish steel reinforcement conforming to 505 .

Revise 504.2 to specify different concrete material requirements for cast in place vs precast structures.

(2)For cast in place structures, furnish grade A, A-FA, A-S, A-T , A-IS, A-IP, or A-IT air-entra ined concrete

conforming to 501 as modified in part 7 . Where the contract specifies or the engineer allows, the contractor may use high earlys trength concrete. Provide QMP fo r concrete as follows: - For culverts and retaining walls as specified in 715 for class I structure concrete. - For endwalls as specified in 716 for class III ancillary concrete.

(3)For precast structures, conform to ASTM C1577 . Manufacture in a plant lis ted under precast concrete

fabricators on the department's APL. Conform to the specified ASTM ma terials requirements for the structure specified except as follows: - Use concrete with 565 pounds or m ore cementitious material per cubic yard. - The contractor may use cement conforming to 501.2.1 or may substitute for portl and cement a t the time of batching conforming to 501.2.6 for fly ash, 501.2.7 for slag, or 501.2.8 for other pozzolans. In either case the maximum total supplementary cementitious content is limited to 30 percent of the to tal cementitious content by weight. - For wet cast use air-entrained concrete with 7.0 percent +/- 1.5 percent air content.

504.3Construction

504.3.1 General

(1)Construct culverts, retaining walls, and endwalls conforming to 502.3 .

504.3.2 Placing Concrete

(1)For constructing concrete box c ulverts, unless specified other wise, place the curtain walls, base slab,

and the barrel sidewalls as a single unit to an approximate hei ght of 6 inches and allow to set before constructing the remaining culvert. If constructing the sidewal ls and top slab of box culverts as a monolith, allow not less than one hour or more than 3 hours to elapse between completing placement of the sidewalls and beginning placement of the top slab. 504.3.3 Removing Falsework and Applying Load

(1)For culvert spans less than 12 feet, the engineer may allow fa lsework removal based on one of the

following: - Absent compressive strength in formation, the mi nimum equivalent days specified in 502.3.10.1 . - With compressive strength information, a strength of 2000 psi or greater.

(2)For culvert spans of 12 feet and greater, the engineer may all ow falsework removal after 7 equivalent

days as defined in 502.3.10.1 .

(3)The contractor may backfill culverts, retaining walls, and end walls that have attained the specified

compressive strength or upon expiration of the minimum times as specified in 206.3.13 . Do not apply additional loads on culverts until attaining a compressive stre ngth of 3500 psi or, absent compressive strength information, for at least 21 days. 504.3.4 Name Plates

(1)Install nameplates on culverts and retaining walls conforming to 506.2.4 at the locations the plans

show. Embed in concrete as specified in 502.3.11 . 504.3.5 Curing

(1)Cure concrete in culverts, ret aining walls, and end walls by any of the methods specified in 502.3.8 .

(2)Cure retaining wall parapets with pigmented cure and seal conf orming to 502.2.11 . If applying

architectural or other surface treatments, use a curing method compatible with those treatments.

504.4Measurement

(1)The department will measure the several bid items that constit ute the completed and accepted

structure according to the prov isions of the contract for those bid items and in the units the contract specifies. All work i ncluded within the sc ope of this contract but not listed as bid items in the proposal is incidental to the work.

Effective with the December 2018 Letting 240 2019 Standard Spec ifications (2) The department will measure the Concrete Masonry Culverts and the Concrete Masonry Retaining Walls bid items by the cubic yard acceptably completed. The dep artment will not measure work or material for forms, falsework, co fferdams, unless specified oth erwise. The department will not measure pumping, bracing, or ot her incidentals necessary to com plete the work.

(3)The department will measure Concre te Masonry Endwalls by the c ubic yard acceptably completed.

504.5Payment

504.5.1 General

(1)The department will pay for measured quantities at the contrac t unit price under the following bid

items: ITEM NUMBER DESCRIPTION UNIT

504.0100 Concrete Masonry Culverts CY

504.0200 Concrete Masonry Culverts HES CY

504.0500 Concrete Masonry Retaining Walls CY

504.0600 Concrete Masonry Retaining Walls HES CY

504.0900 Concrete Masonry Endwalls CY

(2)Perform miscellaneous work the plans show, or the contract oth erwise specifies but does not list as a

bid item, as a part of and incidental to other contract bid ite ms.

(3)Payment for the Concrete Masonry Culverts and the Concrete Mas onry Retaining Walls bid items is

full compensation for materials , forms, falsework, placing, fin ishing, curing, protecting, and heating; and for providing nameplates.

(4)Payment for Concrete Masonry E ndwalls is full compensation for excavating; materials, including

reinforcement; forms; placing, i ncluding reinforcement; finishing, curing, protecting and heating.

Effective with the December 2018 Letting 241 2019 Standard Spec ifications Section 505 Steel Reinforcement

505.1Description

(1)This section describes furnishing and placing bar steel, high- strength bar steel or coated high-strength

bar steel.

505.2Materials

505.2.1 General

(1)Use deformed reinforcing bars unless the contract specifies ot herwise.

(2)Unless the plans show otherwise or the special provisions spec ify otherwise, use the deformed type

for all bar steel, all high-str ength bar steel, and all coated high-strength bar st eel reinforcement. If plain, round steel reinforcement is specified, conform to ASTM A675, grade 80.

(3)Use fabrication tolerances for straight and bent bars specifie d in Subsection 4.3, Tolerances, of the

American Concrete Institute Committee 315, in the American Concrete Institute Detailing Manual.

(4)Unless the contract specifies otherwise, submit a manufacturer 's certified report of test or analysis

showing the reinforcement confor ms to the specifications to the engineer before incorporating the reinforcement into the work. 505.2.2 Bar Steel Reinforcement

(1)Conform to AASHTO M31.

505.2.3 High-Strength Bar Steel Reinforcement

(1)Conform to AASHTO M31, grade 60.

505.2.4 Coated High-Strength Bar Steel Reinforcement 505.2.4.1 General

(1)Conform to AASHTO M31, grade 60. E nsure that the coating is ap plied in a CRSI certified epoxy

coating plant. Bend bars that require bending before coating, u nless the fabricator can bend the bar without damaging the coating.

(2)Do not weld epoxy-coated reinfo rcement except as the plans sho w.

505.2.4.2 Coating Material

(1)Coat reinforcement according to ASTM A775 with a fusion-bonded powder from the department's

APL. Provide written certification from the resin manufacturer that the coating material is the same formulation and quality as subm itted to the department for preq ualification testing.

(2)Furnish a two-part epoxy resin that meets ASTM A775 for field repairs and patching.

505.2.4.3 Surface Preparation

(1)Ensure the bar surface is cle an and free from rust, scale, oil , grease, and similar surface

contamination, and slivers, scabs and other surface defects det rimental to proper coating.

(2)Blast the surface to a near white No. 10 finish according to S SPC-SP 10. Provide an anchor pattern

with blast profile maximum roughness depth readings within the range of 1.6 mils to 4.0 mils. Determine the readings according to NACE RP-287, using replica tape.

(3)Remove all traces of grit and dust from the blasting before co ating.

(4)Apply the coating to the cleaned surface as soon as possible a fter cleaning and before visible

oxidation of the surface occurs . The contractor shall not wait to apply the coating more than 8 hours after cleaning, unless the e ngineer directs otherwise. 505.2.4.4 Coating Process

(1)Apply the coating as an electros tatically charged dry powders prayed onto the grounded steel bars

using an electrostatic spray gun. The contractor may apply the powder to either a hot or a cold bar. Give the coated bar the thermal treatment the epoxy resin manuf acturer recommends to provide a fully cured finished coating.

(2)Cure, post-cure, or cure and post-cure the coating film to a f ully cured condition. The coating

applicator shall check a represent ative proportion of each prod uction lot, using the method it finds most effective for measuring cure, to ensure the entire production lot of coating is fully cured. 505.2.4.5 Test Bar Conditioning

(1)Condition bars being tested for coating thickness, holidays (p inholes not visually discernible), coating

adhesion, and abrasion resistance at a temperature range of 68 F to 86 F. If disputed, conduct tests at 73 F +/- 4 F and 50 +/ - 5 percent relative humidity according to ASTM D3451 section 3.1.

Source: Wisconsin Standard Specifications for Highway and Structure Construction, 2019 Edition. Pages 248–249 of 601.

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503 Prestressed Concrete Members

505 Steel Reinforcement