THREE-SIDED REINFORCED CONCRETE BRIDGE/CULVERT 620.1-DESCRIPTION: This work shall consist of furnishing the design, construction plans, materials, and construction of single piece precast or cast -in-place reinforced concrete three -sided flat-topped bridge/culverts or single piece precast reinforced concrete three-sided arch-topped bridge/culverts or a two -piece precast reinforced concrete continuous arch bridge/culverts, with headwalls and wingwalls, in accordance with these specifications and in reaso nably close conformity with the lines, grades, design, and dimensions shown in the plans. 620.2-GENERAL: The bridge/culvert design and detail plans for construction shall be submitted t o the Engineer for approval. The time required for preparation and review of these submittals shall be charged to the allowable contract time. Delays caused by untimely submittals or insufficient data will not be considered justification for time extensions. No additional compensation will be made for any additional material, equipment, or other items found necessary to comply with the project specifications as a result of the Engineer's review. The proposed bridge/culvert design shall be compatible with the Contractor's proposed method of construction, and shall be compatible with any method of construction shown in the plans. The Division does not assume nor warrant any bridge/culvert system's compatibility with any particular construction methods. 620.3-DESIGN CRITERIA: 620.3.1-General: The following data will be provided on the contract plans:
box in addition to the bearing capacity and roadway profile. The size of all structural elements shall be determined such that the design load stresses do not exceed the allowable stresses found in the AASHTO LRFD Bridge Design Specifications, latest editio n. The structural design of the two -piece precast reinforced concrete arch bridge/culverts shall provide for a structurally reinforced section at the crown/closure section such that the completed arch bridge/culvert is structurally continuous. If parapets are used on any portion of the headwalls and wingwalls as shown in the plans, they shall be designed to resist traffic loads in accordance with the AASHTO LRFD Bridge Design Specifications, latest edition. The load shall be a HL-93 (HS25) test level 3. The length and height of the wingwalls and headwalls must be designed to accommodate the specified fill slope without fill encroaching on the underlying streambed, waterway or edge 468 of roadway template. Wingwalls with a tapered bottom surface shall not be used due to compaction difficulties beneath the wingwall. Wingwall options other than cast-in-place shall only be systems that have been evaluated by HITEC. Except those on roads with a design year ADT less than 500 and where the product of the design year percent trucks times the ADT is less than 100, all flat -topped structures with less than two feet of cover shall have approach slabs per the Divisions Structural Design Manual. 620.3.2-Precast Three -Sided Bridge/Culvert: The bridge/culvert unit dimension and reinforcement details shall be as prescribed in the plan and the shop drawings provided by the manufacturer. The minimum concrete compressive strength shall be 4000 psi. The minimum steel yield strength shall be 60 ksi. The minimum require d strength for form removal and handling shall be 70% of Design Strength unless otherwise specified by the Designer. The precast three-sided bridge/culvert unit shall also conform to MP 604.02.40. The top exterior surface shall ha ve positive drainage with a minimum slope of 2% from the centerline of the span to the exterior corner of the structure. Unless noted otherwise on the shop drawings and designed accordingly, a minimum of one foot of cover above the crown of the bridge/culvert unit is required in the installed condition. 620.3.2.1-Placement of Reinforcement: The cover of concrete over the outside reinforcement shall be two (2) inches minimum. The cover of concrete over the inside reinforcement shall be 1 -1/2 inches minimum. The clear distance of the end shall not be less than one (1) inch nor more than two (2) inches from the ends of the bridge/culvert unit. Reinforcement shall be assembled utilizing single or multiple layers of welded wire fabric, or utilizing a sin gle layer of deformed billet -steel bars. The welded wire fabric shall be composed of circumferential and longitudinal wires meeting the spacing requirements of 620.3.2.3 and shall contain sufficient longitudinal wires extending through the unit to maintain the shape and position of the reinforcement. Longitudinal distribution reinforcement may be welded wire fabric or deformed billet -steel bars and shall meet the spacing requirements of subsection 620.3.2.3. The ends of the longitudinal distribution reinforcement shall be not more than three (3) inches from the ends of the unit. 620.3.2.2-Bending of Reinforcement: The outside and inside circumferential reinforcing steel for the corners of the bridge/culvert unit shall be bent to such an angle that is approximately equal to the configuration of the unit's outside corner. 620.3.2.3-Laps, Welds, and Spacing: Tension splices in the circumferential reinforcement shall be made by lapping. Laps may be tack welded together for assembly purposes. For smooth welded wire fabric, the overlap shall meet the requirements of ACI 12.8 and 12.19. For deformed welded wire fabric, the overlap shall meet the requirements of ACI 12.7 and 12.18. For deformed billet -steel bars, the overlap shall meet the requirements of ACI 12.2. For splices other than tension splices, the overlap shall be a minimum of twelve (12) inches for welded wire fabric or deformed billet -steel bars. The spacing center-to-center of the circumferential wires in a wire fabric sheet shall be not less than two (2) inches nor more than four (4) inches. For the wire fabric, the spacing center - to-center of the longitudinal wires shall not be more than eight (8) inches. The spacing center-to-center of the longitudinal distribution steel for either line of reinforcing in the top slab shall be not more than sixteen (16) inches. 469 620.3.3-Cast-In-Place Three -Sided Bridge/Culvert: Cast-in-place structures shall be constructed per section 601. 620.4-SUBMITTALS: 620.4.1-General: The Contractor shall submit complete design calculations, explanatory notes, and detail plans for the proposed bridge/culvert system. The detail plans shall include all details, dimensions, quantities, and cross sections necessary to construct the bridge/culvert and shall include but not be limited to the following items:
edition, to determine the headwater elevation and velocity of flow for the proposed culvert, plus all supporting hydraulic calculations on separate sheets.
requirements.
with bar size, length, and spacing indicated. Footing plan and section views shall be provided. The soil bearing pressure used in the design shall be noted on the footing detail sheets.
reinforcing steel and anchorage details. Wingwall plan, elevation, and section views shall be provided.
details. Headwall elevation and section views shall be provided.
At the time the detail plans are submitted for review, they shall be accompanied by design calculations and explanatory notes. These do cuments shall be legible and shall demonstrate that the design criteria have been met. The plans shall be prepared on reproducible sheets eleven (11) x seventeen (17) inches including borders. Each sheet shall have a title block in the lower right hand corner. The title block shall include the sheet number of the drawing, name or designation of the structural unit detailed on the sheet, the state and federal project designation, project name, fabricator and Contractor name. Design calculations and notes shall be prepared on sheets 8½ x 11 inches, and shall contain the project designation, structural unit designation, date of preparation, initials of designer and checker, and page number at the top of the page. The Detail Plans, Design Calculations, and E xplanatory Notes shall be signed and stamped by a Professional Engineer registered in West Virginia and knowledgeable in the proposed bridge/culvert system. The initial submission shall include three sets of the detail plans, calculations, and notes. One set of notes and plans will be returned to the Contractor with any indicated corrections. When the plans and notes are stamped approved by the Engineer, the Contractor shall furnish the Engineer with the requested number of sets of prints and a Mylarse t of the plans for distribution by the Division. The Contractor shall perform no work or ordering of materials for the structures until the Engineer has approved the submittal. 470 620.4.2-Precast Three-Sided Bridge/Culvert: The details and material specifications for the bridge/culvert system elements and incidental accessories shall be included with the detail plans for approval by the Engineer. 620.4.3-Cast-in-Place Three Sided Bridge/Culvert: The plans for the cast -in-place bridge/culvert shall contain a complete reinforcing bar schedule showing all bending details and bar marks. The plans shall also show the location of all construction joints, expansion joints, or other joints in the bridge/culvert. 620.5-MATERIALS: 620.5.1-Concrete: The concrete for the bridge/culvert units shall be air -entrained composed of Portland cement, fine and coarse aggregates, admixtures and water. Concrete shall contain 7 ± 2 percent (7±2%) air. The air entraining admixture shall conform to section 707.1. 620.5.1.1-Portland Cement: Shall conform to the requirements of sections 701.1 and 701.3. 620.5.1.2-Coarse Aggregate: Shall consist of stone having a maximum size of one
620.5.1.3-Water Reducing Admixture: The manufacturer may submit for approval by the Engineer, a water -reducing admixture, per section 707.3, for the purpose of increasing workability and reducing the water requirement for the concrete. 620.5.1.4-Calcium Chloride: The addition to the mix of calcium chloride or admixtures containing calcium chloride will not be permitted. 620.5.1.5-Fine Aggregates: Shall conform to section 702.1. Only siliceous sand shall be used when the top of the structure is to be the driving surface. 620.5.1.6-Mixing Water: Shall conform to section 715.7. 620.5.1.7-Water Reducers / Retarding Admixtures: Shall conform to section 707.2. 620.5.1.8-Joint Material: Shall conform to Section 708.7. 620.5.1.9-Supplementary Cementitious Materials (SCMs): Shall conform to 620.5.2-Reinforcing Steel: All reinforcing steel for the bridge/culvert units shall be fabricated and placed in accordance with the detailed shop drawings submitted by the manufacturer. Reinforcement shall be grade 60 or as specified in the plans, and shall comply with sections 709.1, 709.4 or 709.6. Longitudinal distribution reinforcement may consist of welded wire fabric or deformed billet-steel bars. 471 Steel reinforcing shall be epoxy coated per AASHTO M -284 or galvanized per AASHTO M-111 for structures installed at an elevation such that the top or crown of the structure is above the bottom of the subgrade in the pavement section. 620.5.3-Permissible Variations: 620.5.3.1-Internal Dimensions: The internal dimensions shall not vary from the design dimensions by more tha n 1 percent (1%) or 1-1/2 inches, whichever is less. The haunch dimensions shall vary not more than 3/4 inch from the design dimension. 620.5.3.2-Slab and Wall Thickness: The slab and wall thickness not be less than that shown in the design by more th an 1/4 inch. A thickness more than that required in the design shall not be cause for rejection. 620.5.3.3-Length of Opposite Surfaces: Variations in laying lengths of the two opposite surfaces of the culvert shall not be more than 5/8 inch in any bridge/culvert unit, except where beveled ends for laying of curves are specified by the purchaser. 620.5.3.4-Length of Unit: The underrun in length of a unit shall not be more than 1/2 inch in any unit. 620.5.3.5-Position of Reinforcement: The maximum variation in position of the reinforcement shall be + 1/2 inch. In no case shall the cover over the reinforcement be less than 1-1/2 inch for the outside circumferential steel or be less than one (1) inch for the inside circumferential steel as measured to the external or internal surface of the bridge/culvert unit. These tolerances or cover requirements do not apply to mating surfaces of the joints. 620.5.3.6-Area of Reinforcement: The areas of steel reinforcement shall be the design steel areas as shown in the manufacturer's shop drawings. Steel areas greater than those required shall not be cause for rejection. The permissible variation in diameter of any reinforcement shall conform to the tolerances prescribed in the ASTM Specification for that type of reinforcement. 620.5.4-Curing: All Bridge/Culvert units shall be cured in accordance with Section
601.12except that curing may be discontinued once 70% of the design Strength is achieved
620.5.5-Testing and Inspection: 620.5.5.1-Precast Three-Sided Bridge/Culvert Units: 620.5.5.1.1-Type of Test Specimen: Concrete compressive strength shall be determined from compression te sts made on cylinders or cores. For cylinder testing a minimum of 5 cylinders shall be fabricated during each production day. For core testing, one core shall be cut from a unit selected at random from each group of 15 units or less of a particular size and production run. For each continuous production run, each group of 15 units of a single size or fraction thereof shall be considered separately for the purpose of testing and acceptance. A production run shall be considered continuous if not interrupted for more than 3 consecutive days. 472 620.5.5.1.2-Compression Testing: Cylinders shall be made and tested as prescribed by the AASHTO T 22 and R 100 Specifications. Cores shall be obtaine d and tested for compressive strength in accordance with the provisions of the AASHTO T 280. 620.5.5.1.3-Acceptability of Cylinder Tests: Each compressive strength test used for acceptance shall consist of the average strength of a minimum of two compressive strength test cylinders fabricated from a single rando mly selected batch of concrete as it is being placed in the forms. Failure of any of the individual 28 day test cylinders to meet 90 percent (90%) of the minimum compressive strength requirement can be cause for rejection. The average of all cylinders comprising a strength test must meet or exceed the design strength. 620.5.5.1.4-Acceptability of Core Tests: The compressive strength of the concrete in each group of units as defined in subsection 620.5.4.1.1 is acceptable when the core test strength is equal to or greater than the design concrete strength. When the compressive strength of the core tested is less than the design concrete strength, the unit from which that core was taken may be recored. When the compressive strength of the recore is equal to or greater than the design concrete strength, the compressive strength of the concrete in that group of units is acceptable. When the compressive strength of any recore is less than the design concrete strength, the unit from which that core was taken shall be rejected. Two units from the remainder of the group shall be selected at random and one core shal l be taken from each. If the compressive strength of both cores is equal to or greater than the design concrete strength, the compressive strength of the remainder of that group of units is acceptable. If the compressive strength of either of the two cores tested is less than the design concrete strength, the remainder of the group of units shall be rejected or, at the option of the manufacturer, each culvert of the remainder of the group shall be cored and accepted individually, and any of these units that have cores with less than the design concrete strength shall be rejected. Plugging Core Holes-The core holes shall be plugged and sealed by the manufacturer in a manner such that the unit will meet all of the test requirements of this specification. Units so sealed shall be considered satisfactory for use. Test Equipment -Every manufacturer furnishing unit under this specification shall furnish all facilities and personnel necessary to carry out the test required. 620.5.5.2-Cast-In-Place Three -Sided inspection shall be per section 601. Bridge/Culvert: Cast-in-place testing and 620.5.6-Joints: 620.5.6.1-Precast Three-Sided Arch-Topped Bridge/Culvert Units: The bridge/culvert units shall be produced with flat bu tt ends. The ends of the unit shall be such that when the sections are laid together they will make a continuous line of units with a smooth interior free of appreciable irregularities, all compatible with the permissible variations in subsection 620.5.3. The joint width shall not exceed 3/4 inches. The outside edges of the ends of each bridge/culvert unit shall be chamfered. The butt joint made by two adjoining units shall be covered with a piece of preformed bituminous joint sealant and a minimum of a nine (9) inch wide joint wrap. 473 620.5.6.2–Precast Three-Sided Flat-Topped Bridge/Culvert Units: The bridge/culvert units for flat-topped culverts shall be produced with a minimum four (4) inches deep by 1-1/2 inches wide keyway joint. Shear key grout in accordance with Section 715.5 shall be placed in the keyway joint. Field Testing of shear key grout shall be performed by the Contractor in accordance with ASTM C109, as modified by ASTM C1107. Compressive strength of the grout as determined by the average result of three test specimens shall meet the requirements specified in the Contract Plans. 620.5.7-Workmanship and Finish: The bridge/culvert units shall be substantially free of fractures. The ends of the units shall be normal to the walls and centerline of the unit section, within the limits of the variations given in subsection 620.5.3, except where beveled ends are specified. The inside and outside surfaces of the units shall be a smooth steel form finish. 620.5.8-Repairs: All repairs are to be performed in accordance with subsection 620.10.2. 620.5.9-Inspection: The quality of materials, the process of manufacture, and the finished bridge/culvert units shall be subject to inspection by the engineer. 620.5.10-Rejection: Bridge/culvert units shall be subject to rejection on account of any of the specification requirements. Individual units may be rejected beca use of any of the following:
exceed one half the thickness of the wall.
Section 5.
than ½” diameter and over 1” deep occur.
satisfactory joint. For butt type joints, damaged surfaces greater than 12” long and over 2” deep will be cause for rejection of the units.
deeper than the shear key may be cause for rejection. 620.5.11-Marking: Each culvert shall be clearly marked by waterproof paint. The following shall be shown on the inside of the vertical leg of the culvert section: Bridge/Culvert Unit Span X Bridge/Culvert Unit Rise Date of Manufacture Name of the manufacturer WV State and Federal Project Number Project Contract Number 620.5.12-Backfill: Backfill material shall be select material for backfilling in accordance with 626.5.3. Backfilling shall be according to subsection 626.6.1.3. The backfill material is to be placed in a zone with a minimum width that extends to a point located four (4) feet outside the base of each leg and with a height being equal to the outside height of the structure plus two feet or the minimum cover, whichever is less. This material is also to be placed to a depth of at least four (4) feet behind each wingwall. 474 Additional granular material requirements are the responsibility of the contractor and the bridge/culvert supplier. 620.6-CONSTRUCTION METHODS: 620.6.1-Precast Three-Sided Bridge/Culvert: 620.6.1.1-Footings: The bridge/culvert units shall be installed on cast -in-place concrete footings. The elevation of the bottom of the footing shall be equal to or lower than the elevation as shown on the plans. A keyway for grouting with a minimum depth of three (3) inches shall be formed in the top surface of the footing and the keyway shall extend to where three (3) inches clear of the inside and outside faces of the bridge/culvert unit, unless specified otherwise on the plans or by the bridge/culvert system supplier. The footings shall be given a rough float finish and shall reach a compressive strength of 2,000 psi before placement of the bridge/culvert units. The completed footing surface shall be constructed in accordance with grades shown on the plans. When tested with a 10 foot straight edge, the top surface of the footings shall not vary more than ¼ inch in ten (10) feet. The foundation is to be constructed in accordance with the approved shop drawings. 620.6.1.2-Placement of the Bridge/Culvert Units: A representative of the manufacturer shall be present during the first three days the structure is being placed. The units shall be placed as shown on the Engineer’s plan drawings. Special care shall be taken in setting the units to the true line and grade. The units shall be set on masonite or steel shims at least five (5) inches square, or on a concrete leveling pad cast inside the keyway. When set on shims a minimum of a ½ inch gap shall be provided between the footing and the base of the unit leg. Prior to grouting three sided structures with legs that have a curved exterior surface, the legs shall be supported horizontally using hardwood wedges driven between the outside of the structure leg and the wall of the keyway. The requirements for the grout will conform to subsection 715.5 and testing of the grout shall be performed by the Contractor in accordance with ASTM C109, as modified by ASTM C1107. Compressive strength of the grout shall be at least XXXX psi at X days as determined by the average result of three test specimens. Wedges shall be spaced no more than two (2) feet apart along both sides of the structure. 620.6.1.3-External Waterproofing: When specified on the plans and the limits of application are shown, a waterproofing membrane as described below shall be applied to the top and the sides of the structure unless the top of the structure is to be the driving surface. The material should be installed per the waterproofer manufacturer’s instructions. Property Value 1 Test Method Strip Tensile 50 lbs./in. ASTM D8822 Puncture Resistance 200 lbs. ASTM E154 Permeance 0.10 perms (max.) ASTM E96, Method B Pliability No cracks in fabric or rubberized asphalt ASTM D1463 1 Minimum average roll values unless otherwise noted 2 Using 12 in/min test speed and 1” initial distance between grips. 3 Using 180° bend on ¼ inch mandrel at -25°F 475 The surface shall be free of dirt before applying the waterproofing material. A primer compatible with the waterproofing membrane to be used shall be applied before the membrane is installed. The structure should be covered continuously from the bottom of one bridge/culvert unit leg, across the top of the structure and to the bottom of the opposite bridge/culvert unit leg. The joint between the end unit and the headwall shall also be sealed by carrying the membrane up the headwall at least four (4) inches. If precast wingwalls are used, the joint between the wingwall and the end units should be covered in a similar fashion, or, at the discretion of the engineer, filter fabric can be substituted. 620.6.1.4-Backfill Placement: Backfill shall be considered as all replaced excavation and new embankment adjacent to the precast bridge/culvert units and wingwalls. The project construction and material specifications, which include the specifications for excavation for structures and roadway excavation and emban kment construction, shall apply except as modified in this section. No backfill shall be placed against any structural elements until they have been approved by the Engineer. No backfill shall be placed against the structure until the grout has cured for a minimum of 12 hours. On three sided structures with legs that have a curved exterior surface the grout shall be cured for a minimum of 72 hours before placing backfill against the structure. Backfill against the waterproofing membrane when specified on the plans shall be placed carefully to avoid damage to the waterproofing material. Mechanical tampers or approved compacting equipment shall be used to compact all backfill and embankment immediately adjacent to each side of the bridge/culvert and over the top of the bridge/culvert until it is covered to a minimum depth of one (1) foot. The backfill within four (4) feet of each side of the bridge/culvert shall be placed in lifts of eight (8) inches or less (loose depth). Heavy compaction equi pment shall not be operated in this area or over the bridge/culvert until it is covered to a depth of 1 foot. Lightweight dozers and graders may be operated over culverts having one (1) foot of compacted cover, but heavy earth moving equipment (larger than a D-4 Dozer weighing in excess of twelve ( 12) tons and having track pressures of eight (8) psi or greater) shall require two (2) feet of cover unless the design cover is less than two (2) feet. In no case shall equipment operating in excess of the design load be permitted over the bridge/culvert unless approved by the Engineer. Any additional fill and subsequent excavation required to provide this minimum cover shall be made at no additional cost to the project. When placing backfill at no time shall the difference between the heights of fill on opposite sides of the bridge/culvert exceed 18”. Backfill in front of wingwalls shall be carried to ground lines shown in the plans. 620.6.2-Cast-in-Place Reinforced Concrete: Except as otherwise shown in the plans or herein, construction methods for cast -in-place three -sided structures shall comply with the Specifications. When specified on the plans, a waterproofing membrane per section 620.6.1.3 shall be applied to the exterior top and the sides of the structure. Construction methods for the following shall be per the indicated section of the Specifications: 476 ITEM SECTION Unclassified Borrow Excavation 211 Structure Excavation 212 Rock Excavation 212 Wet Excavation 212 Select Material for Backfilling 613.5.11 Concrete 601 Reinforcing Steel 602 620.7-METHOD OF MEASUREMENT: Excluding headwalls and wingwalls, three-sided bridge/culverts shall be measured by the linear foot, the measurement being along the centerline of the bridge/culvert and extending from the exposed face to exposed face of the headwalls. Wingwalls shall be measured by the unit. A wingwall is the entire end section for the three- sided structure including but not limited to headwalls, aprons, foundations for the wingwall, cut - off walls and appurtenances. There shall be no measurement and payment for headwalls. Headwalls shall be incidental to and included in the unit bid price of the wingwalls. There shall be no separate measurement and payment for the excavation required for installing the bridge/culvert, including any undercut to establish an adequate foundation. Excavation, whether unclassified, stru cture, rock or wet excavation shall be incidental to and included in the unit bid price for the bridge/culvert and wingwalls. There shall be no separate measurement and payment for backfill below an elevation two feet above the top or crown of the outside of the bridge/culvert whether such backfill is unclassified borrow, select rock fill, select backfill or salvaged existing streambed material. All such backfill shall be incidental to and included in the unit bid price for the bridge/culvert and wingwalls. There shall be no separate measurement and payment for waterproofing membrane if the waterproofing membrane is specified on the plans and the limits of application are shown. Concrete and backfill shall be placed under dry conditions. Should cofferd ams, pumping or other methods be necessary to maintain dry conditions, the cost of these methods shall be incidental to and included in the unit bid price for the bridge/culvert and wingwalls. If the maintenance of traffic scheme necessitates the use of sheet piling or bulkheads during the installation of the bridge/culvert, the cost of piling and bulkheads shall be incidental to and included in the unit bid price for the bridge/culvert and wingwalls. If the design necessitates undercutting the foundation and backfilling to the footing elevation with select rock fill, the select rock fill shall be separated from soils with fabric for separation per subsection 715.11.8. The cost of the fabric shall be incidental to the unit bid price for the bridge/culvert and wingwalls. The cost of the construction layout work shall be incidental to and included in the unit bid price for the bridge/culvert and wingwalls. Additional work arising from changed conditions found during the construction from those shown on the approved drawings shall be paid in accordance with subsection 109.4. 620.8-BASIS OF PAYMENT: The quantities, determined as provided above, will be paid for at the contract price per unit of measurement, respectively, for each pay item listed below and shown in the bid schedule, which prices and payment will be full compensation for the work prescribed in this section. 477 620.9-PAY ITEMS: ITEM DESCRIPTION UNIT 620001-* Precast Reinforced Concrete Arch-Topped Bridge/Culvert, “vendor name” Linear Foot 620002-* Precast Reinforced Concrete Flat-Topped Bridge/Culvert, “vendor name” Linear Foot 620003-* Cast-In-Place Reinforced Concrete Culvert Linear Foot 620004-* Wingwall for Concrete Culvert Each 620005-* Two-Piece Precast Reinforced Concrete Arch Bridge/Culvert Linear Foot * Sequence number SECTION 621 THROUGH SECTION 622-BLANK 478
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