NYSDOT Projects: Requirements for Precast Concrete Materials and Installation, Schemes and Mind Maps of Construction

Download NYSDOT Projects: Requirements for Precast Concrete Materials and Installation and more Schemes and Mind Maps Construction in PDF only on Docsity! NEW YORK STATE DEPARTMENT OF TRANSPORTATION OFFICE OF STRUCTURES PRESTRESSED CONCRETE CONSTRUCTION MANUAL APRIL 2017 Revised January 2019 i April, 2017 New York State Department of Transportation Prestressed Concrete Construction Manual Table of Contents TABLE OF CONTENTS ................................................................................................... i FOREWORD ................................................................................................................. xiv SECTION 1 INTRODUCTION .................................................................................... 1-1 1.1 PURPOSE .............................................................................................. 1-1 1.2 APPLICABILITY ...................................................................................... 1-1 1.2.1 Locally Administered Federal Aid Projects ................................... 1-2 1.2.2 Design-Build Projects ................................................................... 1-2 SECTION 2 DRAWINGS ............................................................................................ 2-1 2.1 CONTRACT DRAWINGS ....................................................................... 2-1 2.1.1 Definition ...................................................................................... 2-1 2.1.2 Requests for Clarification ............................................................. 2-1 2.1.3 Dimensions .................................................................................. 2-1 2.1.4 Errors ........................................................................................... 2-1 2.1.5 Principal Controlling Dimensions and Material Properties ............ 2-2 2.1.6 Fabricating Dimensions ................................................................ 2-2 2.2 SHOP DRAWINGS ................................................................................. 2-2 2.2.1 Preparation .................................................................................. 2-2 2.2.2 Drawing Size and Type ................................................................ 2-3 2.2.2.1 Standard Size .................................................................. 2-3 2.2.2.2 Neatness and Clarity ....................................................... 2-3 ii April, 2017 2.2.2.3 Title Block ........................................................................ 2-3 2.2.3 Returned Without Examination..................................................... 2-4 2.2.4 Electronic Format ........................................................................ 2-4 2.2.5 Information Required in Shop Drawings Submissions ................. 2-4 2.2.5.1 Production Notes ........................................................... 2-4 2.2.5.2 Additional Information Required in the Production Notes for Pretensioned Units. ......................................... 2-5 2.2.5.3 Layout Details ................................................................. 2-6 2.2.5.4 Precast Unit Details ........................................................ 2-6 2.2.5.5 Additional Information Required for Precast Units which will be Installed Using Segmental Construction (Non-Match Cast Joints). .................................................................... 2-8 2.2.5.6 Additional Information Required for Precast Units with Post-Tensioning (Match Cast and Non-Match Cast Joints). . .......................................................................... 2-8 2.2.5.7 Additional Information Required for Precast Units which will be Installed Using Segmental Construction (Match Cast Joints). ............................................................................ 2-9 2.2.5.7.1 Geometry Control ........................................... 2-9 2.2.5.7.2 Casting Curves ............................................... 2-9 2.2.5.8 Forms for Precast Units with Match Cast Joints ........... 2-10 2.3 INSTALLATION DRAWINGS ............................................................... 2-11 2.3.1 Installation Notes ........................................................................ 2-12 2.3.2 Installation Details ...................................................................... 2-12 2.3.3 Additional Information Required for Precast Post-Tensioned Units .......................................................................................... 2-12 2.3.3.1 Calculations of Theoretical Elevations and Alignment .... 2-14 iii April, 2017 2.3.4 Additional Information Required for Precast Units Connected Together with Field Cast Joints or Closure Pours ..................... 2-14 2.3.5 Temporary Structures and Equipment ...................................... 2-15 2.3.6 Checks and Modifications of Permanent Structural Components for Construction Loads ............................................................... 2-15 2.3.7 Revised Installation Drawings ................................................... 2-16 2.4 SUBMISSION OF SHOP DRAWINGS AND INSTALLATION DRAWINGS ......................................................................................... 2-16 2.4.1 Check Prints ............................................................................... 2-16 2.5 EXAMINATION OF SHOP DRAWINGS AND INSTALLATION DRAWINGS .......................................................................................... 2-17 2.5.1 Examination Time ................................................................... 2-17 2.5.2 Special Circumstances ............................................................... 2-17 2.5.2.1 Large Sets of Drawings ................................................. 2-17 2.5.2.2 Design Calculations ...................................................... 2-17 2.5.2.3 Contract Changes ......................................................... 2-18 2.5.2.4 Contract Award ............................................................. 2-18 2.5.3 Concrete Mix Designs ................................................................ 2-18 2.5.4 Approved as Noted .................................................................... 2-18 2.5.5 Returned with Comments ........................................................... 2-18 2.5.6 Final Approval ............................................................................ 2-19 2.5.7 Distribution of Approved Shop Drawings and Installation Drawings .................................................................................... 2-19 2.6 ERECTION DRAWINGS ....................................................................... 2-19 2.6.1 General .................................................................................... 2-19 2.6.2 Required Information ................................................................. 2-20 vi April, 2017 5.5 EMBEDDED STEEL ............................................................................... 5-3 5.5.1 Reinforcing and Prestressing Steel .............................................. 5-3 5.5.2 Welded Wire Fabric ..................................................................... 5-3 5.5.3 Inserts .......................................................................................... 5-4 5.6 STRESSING REQUIREMENTS FOR PRETENSIONING ...................... 5-4 5.6.1 General ........................................................................................ 5-4 5.6.2 Tensioning of Tendons ................................................................. 5-4 5.6.3 Methods of Force Measurement .................................................. 5-5 5.6.3.1 Initial Tensioning ............................................................. 5-5 5.6.3.2 Final Tensioning .............................................................. 5-5 5.6.3.3 Gauging System .............................................................. 5-5 5.6.4 Prestressing Strands .................................................................... 5-6 5.6.5 Control of Jacking Force .............................................................. 5-6 5.6.6 Wire Failure in Tendons ............................................................... 5-6 5.6.7 Time Allowed Between Tendon Tensioning and Concrete Placement .................................................................................... 5-6 5.6.8 Detensioning of Tendons ............................................................. 5-6 5.7 MATCH CAST SEGMENTS ................................................................... 5-7 5.8 CONCRETE MIX DESIGN AND PROPORTIONING ............................. 5-8 5.9 PLACING CONCRETE ........................................................................... 5-8 5.9.1 Preparation .................................................................................. 5-8 5.9.2 Cold Weather ............................................................................... 5-8 5.9.3 Hot Weather ................................................................................. 5-8 5.9.4 Mass Placement ........................................................................... 5-9 5.9.5 No Segregation ............................................................................ 5-9 5.9.6 Placing ......................................................................................... 5-9 5.9.7 Consolidation ............................................................................... 5-9 vii April, 2017 5.10 CONCRETE SURFACES .................................................................... 5-10 5.10.1 Surfaces .................................................................................... 5-10 5.10.2 Top Surfaces............................................................................. 5-10 5.10.3 Exposed Surfaces ..................................................................... 5-10 5.10.4 Keyway Surfaces ...................................................................... 5-10 5.11 CURING ................................................................................................ 5-10 5.11.1 General ..................................................................................... 5-10 5.11.2 Natural Cure ............................................................................. 5-11 5.11.3 Steam Curing ............................................................................ 5-11 5.11.4 Record of Curing Time and Temperature ............................... 5-12 5.11.5 Transfer of Prestress .............................................................. 5-13 5.12 REMOVAL OF FORMS ........................................................................ 5-13 5.13 PRODUCTION TESTING OF CONCRETE ......................................... 5-13 5.13.1 Testing Cylinders For Strength ................................................. 5-13 5.13.1.1 Casting Test Cylinders .............................................. 5-13 5.13.1.2 Curing Test Cylinders ................................................ 5-14 5.13.1.3 Testing for Concrete Strength .................................. 5-14 5.13.2 Testing Slump ........................................................................... 5-14 5.13.3 Testing Air Content ................................................................... 5-14 5.13.4 Temperature ............................................................................. 5-14 5.13.5 Water/Cementitious Materials Ratio .......................................... 5-15 5.13.6 Unit Weight ............................................................................... 5-15 5.13.7 Additional Tests for Self-Consolidating Concrete (SCC) ........... 5-15 5.13.7.1 General ..................................................................... 5-15 5.13.7.2 Slump Flow ............................................................... 5-15 5.13.7.3 Visual Stability Index ................................................ 5-16 5.14 GEOMETRY CONTROL OF MATCH CAST SEGMENTS .................... 5-16 5.14.1 General ..................................................................................... 5-16 5.14.2 Geometry Control Method ......................................................... 5-16 viii April, 2017 5.14.3 Reference Points and Bench Marks .......................................... 5-16 5.15 POST-TENSIONING............................................................................. 5-16 SECTION 6 HANDLING, FINISHING AND ACCEPTANCE ............................. 6-1 6.1 HANDLING ............................................................................................. 6-1 6.2 FINISHING .............................................................................................. 6-1 6.2.1 Surface Cleaning .......................................................................... 6-1 6.2.2 Exposed Steel .............................................................................. 6-1 6.2.3 Sealing of Concrete Units ............................................................ 6-1 6.2.3.1 Weather Limitations ........................................................ 6-2 6.2.3.2 Sealer Application ........................................................... 6-2 6.2.4 Finishing Surfaces ........................................................................ 6-2 6.2.5 Cleaning, Sealing, and Finishing .................................................. 6-3 6.3 ACCEPTANCE OF UNITS ...................................................................... 6-3 6.3.1 Strength Requirement .................................................................. 6-3 6.3.2 Performance Criteria .................................................................... 6-3 6.3.3 Durability ...................................................................................... 6-3 6.3.4 Injurious Materials ........................................................................ 6-3 6.3.5 Tolerances ................................................................................... 6-4 6.4 DEFECTIVE UNITS ................................................................................ 6-4 6.4.1 Non-Structural Defects ................................................................. 6-4 6.4.2 Structural Defects ......................................................................... 6-4 6.4.3 Repairs of Structural Defects ....................................................... 6-5 6.4.3.1 Documentation of Defects ............................................... 6-5 6.4.3.2 Description of Repairs ..................................................... 6-5 6.4.3.3 Supporting Material ......................................................... 6-5 6.4.3.4 Engineering Calculations................................................. 6-5 6.5 STORAGE .............................................................................................. 6-6 6.6 SHIPPING OF UNITS ............................................................................. 6-6 xi April, 2017 8.4.5.4 Placement of Cement Based Grout Material for Shear Keys .................................................................... 8-3 8.4.5.5 Tensioning of Transverse Ties ...................................... 8-4 8.4.5.6 UHPC ............................................................................ 8-5 8.4.6 Field Cast Joints and Closure Pours for NEXT Type D Beams, Deck Bulb Tee Beams, Precast Concrete Abutment or Pier Units, Precast Concrete Bridge Deck Panels and Approach Slab Panels .......................................................................................... 8-5 8.4.6.1 Field Cast Joints and Closure Pours Using UHPC ......... 8-5 8.5 POST-TENSIONING............................................................................... 8-6 8.5.1 Post-Tensioning System Requirements ....................................... 8-6 8.5.2 Protection of Prestressing Steel .................................................. 8-6 8.5.2.1 Packaging ...................................................................... 8-7 8.5.2.2 Storage............................................................................ 8-7 8.5.2.3 Installation ....................................................................... 8-7 8.5.2.4 Protection After Installation ............................................. 8-8 8.5.3 Post-Tensioning Operations ......................................................... 8-8 8.5.3.1 Geometry Control ............................................................ 8-8 8.5.3.2 Tensioning ....................................................................... 8-9 8.5.3.3 Friction ............................................................................ 8-9 8.5.3.4 Stressing Jacks ............................................................. 8-10 8.5.3.5 Calibration ..................................................................... 8-10 8.5.3.6 Recalibration ................................................................. 8-10 8.5.3.7 Stressing of Tendons ................................................... 8-10 8.5.3.8 Duct Field Pressure Test ............................................... 8-11 8.5.3.9 In Place Friction Test ................................................... 8-12 8.6 GROUTING OF DUCTS ....................................................................... 8-12 8.6.1 Batching Equipment ................................................................. 8-13 xii April, 2017 8.6.2 Mixer .......................................................................................... 8-13 8.6.3 Screen ........................................................................................ 8-13 8.6.4 Grout Pump ................................................................................ 8-13 8.6.5 Pressure Gauge ......................................................................... 8-14 8.6.6 Pipes and Other Fittings ............................................................. 8-14 8.6.7 Mixing Grout ............................................................................... 8-14 8.6.8 Cleaning and Flushing Tendons ............................................... 8-15 8.6.9 Placing Grout ........................................................................... 8-15 8.6.9.1 Pressure ........................................................................ 8-15 8.6.9.2 Temperature ................................................................. 8-16 8.6.10 Protection of Prestress Anchorages .......................................... 8-16 8.6.11 Post-Grouting Operations and Inspections ............................... 8-17 8.6.12 Grouting Report ........................................................................ 8-18 8.7 INSTALLATION OF SEGMENTAL BOX GIRDERS ............................. 8-19 8.7.1 Installation Tolerances ............................................................... 8-19 8.8 INSTALLATION OF REINFORCED CONCRETE SPAN UNITS (THREE- SIDED STRUCTURES) ........................................................................ 8-19 SECTION 9 CONTRACTOR’S DESIGN CALCULATIONS ........................................ 9-1 9.1 COVER SHEET ...................................................................................... 9-2 9.2 DESIGN / ANALYSIS SUMMARY .......................................................... 9-2 9.3 CALCULATION SHEETS ....................................................................... 9-3 9.4 DESIGN SKETCHES .............................................................................. 9-3 9.5 USE OF COMPUTER PROGRAMS ....................................................... 9-4 9.6 OFFICE OF STRUCTURES’ REVIEW OF COMPUTER PROGRAMS .. 9-4 9.7 VERIFICATION OF THE COMPUTER PROGRAMS ............................. 9-5 9.8 ACCEPTANCE OF COMPUTER PROGRAMS ...................................... 9-5 APPENDIX A DEFINITIONS .............................................................................. A-1 xiii April, 2017 APPENDIX B SAMPLE INSPECTION REPORT ................................................ B-1 APPENDIX C REPORT OF ACCEPTANCE /SHIPPING OF STRUCTURAL CONCRETE ............................................................................... C-1 APPENDEX D NOTICE OF DEFECT ................................................................. D-1 APPENDEX E NYSDOT STERSSING REPORT ................................................. E-1 April 2017 1-2 1.2.1 Locally Administered Federal Aid Projects For all locally administered Federal Aid Projects on the State or National Highway System that include structural precast or prestressed concrete items, all provisions of this manual shall apply. For all locally administered Federal Aid Projects off of the State or National Highway System (including highways that are signed as US or NY touring routes but are not State owned) that include structural precast or prestressed concrete items, all provisions of this manual shall apply except that the Local Authority shall be responsible for providing Quality Assurance (QA) for the fabrication of the units. This includes the review and approval of shop drawing submittals as well as providing inspection and material testing at the precast facility. NYSDOT may choose to provide QA for the fabrication of precast units in a locally administered Federal Aid Projects off of the State or National Highway System if it involves an innovative or nontraditional structure as documented in the Design Approval Document. 1.2.2 Design-Build Projects For Design-Build Projects in New York State, all provisions of this manual shall apply except as modified by NYSDOT’s Design-Build Procedure Manual or in the Request for Proposals (RFP) for the specific project. April 2017 2-1 SECTION 2 DRAWINGS 2.1 CONTRACT DRAWINGS 2.1.1 Definition The drawings that are part of the contract documents are hereinafter referred to as the “plans.” The plans are not intended to be used as “shop drawings,” "installation drawings" or “erection drawings.” 2.1.2 Requests for Clarification Requests for clarification of the contract requirements for items covered by this specification should be directed to the Concrete Engineering Unit, with informational copies sent to the Engineer-In-Charge (EIC). The Concrete Engineering Unit will furnish the clarification to the Contractor. 2.1.3 Dimensions In case of a difference on the plans between scaled dimensions and numbers, the numbers shall be followed. 2.1.4 Errors The Contractor shall verify and be responsible for the correctness of all dimensions other than the principal controlling dimensions shown on the plans, and shall call to the attention of the Concrete Engineering Unit any errors or discrepancies that may be discovered. The Contractor shall have no claim for damages that may result from following an error, except for an error in the principal controlling dimensions or material properties shown on the plans or listed in the specifications. On bridge rehabilitation projects, the Contractor shall be responsible for field verifying all principal controlling dimensions prior to fabrication. Shop drawings for all primary April 2017 2-2 components on bridge rehabilitation projects shall include a note indicating the date that the dimensions were field verified. 2.1.5 Principal Controlling Dimensions and Material Properties The following shall be considered principal controlling dimensions and material properties. Any change requires pre-authorization by the DCES. • Length of span (i.e., the horizontal distance between bearing centerlines, or other points of support). • Length of the precast or prestressed concrete unit. • Width of the precast or prestressed concrete unit. • Depth of the precast or prestressed concrete unit. • Thickness of flanges and webs. • Elevations of pedestals, bridge seats, and other supports for precast and prestressed concrete units. • Jacking force. • Ultimate strength of prestressing steel. • Yield strength or grade of reinforcing bars. • Compressive strength of concrete. 2.1.6 Fabricating Dimensions The Contractor or the Contractor’s designee shall be responsible for modifying the dimensions of precast units to compensate for elastic shortening, shrinkage, grade correction, and other phenomena that make in-process fabricating dimensions different from those shown on the plans. 2.2 SHOP DRAWINGS 2.2.1 Preparation Complete and accurate drawings shall be made by the Contractor or the Contractor’s designee, showing how each concrete unit is to be fabricated. These drawings shall be made as soon as possible after the contract award and shall be designated as shop April 2017 2-5 the shop drawings have been approved shall be subject to the approval of the DCES. If the Fabricator intends to use a Self-Consolidating Concrete (SCC) mix, it shall be clearly stated in the Production Notes. If high performance concrete meeting the requirement of §718-06 High Performance Concrete for Precast and Prestressed Bridge Beams of the NYSDOT Standard Specifications, Construction and Materials, is being used, a table showing the pre-production testing results and a strength gain curve shall be shown. • All quality control tests and procedures, including anticipated test results. • Unit and cylinder curing procedures, as required by Section 5.11 CURING. • Required compressive strength for each phase of fabrication, including transfer of prestressing force, removal of forms, lifting, discontinuation of cure, and shipping. • Proposed method of handling and transporting precast concrete units, including appropriate details. • Cold weather or hot weather concreting procedures, if need is anticipated. • Material and manner of applying penetrating sealer, including application rate in ft² per gal, as required by Section 6.2.3 Sealing of Concrete Units. • Finishing procedures. • Tolerances. • Unit Summary Table showing the number of units and the unit piece marks. • A complete bill of materials. • Index of drawings. 2.2.5.2 Additional Information Required in the Production Notes for Pretensioned Units • The date the high performance concrete mix design was approved by the DCES. • The name of the NYSDOT approved manufacturer of the prestressing steel, including any alternate source. • Calculations of strand elongation for each unique casting length (grip to grip). Actual data shall be used in this calculation whenever available. April 2017 2-6 • Tensioning force (initial and final). • Transfer of prestressing force procedure for all unit types to be fabricated. • Strand cutting method, sequence and material as well as the manner of protecting the exposed portions of the prestressing steel. • The assumed camber due to the prestressing force and beam dead load at transfer of prestressing force (without growth) as shown on the plans. If this anticipated camber value is not shown on the plans, the Contractor shall notify the Concrete Engineering Unit. • The assumed camber due to the prestressing force and beam dead load at shipping (with growth) as shown on the plans. This is the camber value that the designer assumes when determining pedestal/bridge seat elevations. If this anticipated camber value is not shown on the plans, the Contractor shall notify the Concrete Engineering Unit. 2.2.5.3 Layout Details • North arrow. • Plan layout of structure. • General cross section views looking “up station.” • Piece mark and its location on each unit. • Bridge begin, end, and pier stations as needed. • Center to center of bearing dimensions, for all spans. • Necessary section details. 2.2.5.4 Precast Unit Details • Unit plan dimensions. • Unit elevation. • Unit cross section dimensions. • Reinforcing layout, including plan, elevation and cross section views. • Details of reinforcing steel shall clearly show the size, spacing, cover, and April 2017 2-7 location of bars, including any special reinforcing required but not shown on the contract plans. • The top reinforcing mat for buried bridge structures with less than 2 feet of fill shall be one of the following: o Epoxy-coated bar reinforcement meeting the requirements of §709-04. o Galvanized bar reinforcement meeting the requirements of §709-11. o Stainless steel bar reinforcement meeting the requirements of §709-13. o Any other non-corrosive bar reinforcement approved by the DCES. This requirement is in addition to the corrosion inhibitor requirement in Section 4.1.1 Materials for Concrete. • Bar list including bar sizes, bend dimensions (conforming to CRSI standards), etc. shall be shown on the same drawing on which reinforcing details are shown. • Locations of any prestressing strands as well as any strand debonding or draping details. • Railing anchorage layout and details. • Miscellaneous details, including diaphragms, required daps, special beam end requirements, and special surface finishes. • Details and locations of all other items to be embedded in the units, such as inserts, post-tensioning hardware, etc. shall be clearly detailed. • Fully and accurately dimensioned views of precast units shall show clearly the three-dimensional relationship of all embedded items. These views shall show all projections, recesses, shear keys, notches, openings, blockouts, and other pertinent details. • Type and location of lifting device for all concrete units to be fabricated. • Details showing how the units will be lifted and/or rotated, how they will be stored in the precastor’s yard, and all relevant transportation details, including how they will be placed on the truck. • For drainage purposes, buried bridge structure units shall show a positive top slope that will produce a minimum 1% final installed slope. April 2017 2-10 schedule, loads, and material properties proposed by the Contractor. Casting curves shall be sufficiently accurate to allow the determination of control point settings for accurately casting the segments to meet the profile and the alignment shown on the plans. The preparation of casting curves shall recognize all deviations from straight line and deformations due to the final required alignment, dead load, superimposed dead loads, erection loads, post-tensioning stresses including secondary moments, creep, shrinkage, and installation schedule. The preparation of casting curves shall be done at no additional cost and shall be considered incidental to the contract. Because the casting curves are dependent on the Contractor’s erection and sequence schedule, the Contractor shall produce new casting curves whenever there is a change in the erection sequence and/or schedule. Casting curves shall be stamped and signed by a Professional Engineer licensed to practice in New York State and who is, in the opinion of the DCES, experienced in concrete segmental bridge design and construction. 2.2.5.8 Forms for Precast Units with Match Cast Joints Shop drawings shall be submitted for forms and form travelers. The forms used to cast the concrete segments shall be capable of: • Match casting. • Producing the segments within the tolerances permitted. • Accommodating blockouts, openings and protrusions. • Adjusting to changes in segment geometry as shown in the plans, or for correcting previous minor casting errors to prevent accumulation. • Stripping without damage to the concrete. • The form design shall provide a tight, leak-proof joining to the previous segment. The bulkhead shall be capable of connecting the ducts in a manner to hold their position and prevent intrusion of grout. • Where sections of forms are to be joined, on the exterior face of the segment, an offset exceeding 1/16” for flat surfaces and 1/8” for corners and bends will not be permitted. April 2017 2-11 • All side, bottom, inside, and header forms for precast segmental construction shall be constructed of steel unless use of other materials is approved by the DCES. • Forms shall be of sufficient thickness, with adequate external bracing and stiffeners, and shall be sufficiently anchored to withstand the forces due to placement and vibration of concrete. • Internal bracing and holding devices in forms shall be limited to stay bolts in webs which can be removed from the concrete surface to permit patching following form removal. • Joints shall be designed and maintained for mortar tightness. • All form surfaces for casting members shall be constructed and maintained to provide segment tolerances. 2.3 INSTALLATION DRAWINGS If the precast elements that will be fabricated using the approved shop drawings are to be connected together in the field (segmental construction), a separate set of drawings hereinafter referred to as "installation drawings" shall be required. These drawings are required to be submitted together with, and at the same time as, the shop drawings for the approval of the DCES and shall meet the requirements of Sections 2.2.1, 2.2.2, 2.2.3, and 2.2.4. Submission, examination, approval and distribution of these drawings shall be as per Sections 2.4 and 2.5. Supporting documents are sometimes required as part of an installation drawing submittal. Supporting documents include any additional information required by the Concrete Engineering Unit and intended to supplement the installation drawings, such as design calculations, material test results, lifting and handling stress checks, and construction load checks on existing structures. Calculations required as supporting documents to the installation drawings shall be stamped, and signed by a Professional Engineer licensed to practice in New York State and who is, in the opinion of the DCES, experienced in concrete segmental bridge design and construction. These calculations April 2017 2-12 shall meet the requirements of Section 9 Contractor’s Design Calculations of this manual. When calculations are required as supporting documents to installation drawings, each of the drawings shall also be stamped and signed by the same engineer (a Professional Engineer licensed to practice in New York State) who stamped and signed the calculations. All details and notes shall be shown on the Installation Drawings. All calculations shall be considered part of the supporting documents. The requirement for installation drawings and supporting documents may be waived when, in the opinion of the DCES, the plans contain sufficient installation details. The following information is required in Installation Drawing submissions: 2.3.1 Installation Notes The following information shall be provided: • A detailed step-by-step description of the Contractor’s proposed installation procedure. For precast segmental box girders, the construction method (span by span, balanced cantilever, progressive cantilever, etc.) shall be stated. • The Contractor’s proposed installation schedule. • A table of theoretical elevations and alignment of the geometry control points established during casting shall be provided for each segment. This information shall be shown for each stage of erection. • The proposed method for measuring and recording the elevation and alignment of all control points at each stage of installation. 2.3.2 Installation Details Complete details showing how the units will be connected together in the field are required. 2.3.3 Additional Information Required for Precast Post-Tensioned Units For units post tensioned in the field, the following minimum information meeting the requirements of Section 8.5 POST TENSIONING shall be provided. April 2017 2-15 • A description of how the temperature will be measured. • If the Contractor anticipates the ambient temperature will be outside of this range during the mixing, placing, and curing of the concrete or grout, a description of the actions that will be taken (such as adding ice to the mix, applying external heating, etc.) shall be shown. • Preparation of precast surfaces prior to installation of field cast joints or closure pours, including the procedures for surface cleaning and pre-wetting prior to concrete or grout placement. • Procedure for placing the concrete or grout. • Procedure for curing the concrete or grout. • Procedure for finishing the concrete or grout including any required equipment. • Concrete or grout strength requirements for discontinuing the cure, removal of any forms, finishing, and applying service loads. 2.3.5 Temporary Structures and Equipment Complete details and design calculations for falsework, special formwork, erection equipment, and any other temporary construction which will be subjected to calculated stresses shall be provided. This shall include complete information covering the design and details for the scheme to be used to erect, align and secure segments during erection of the structure. 2.3.6 Checks and Modifications of Permanent Structural Components for Construction Loads These documents shall include: • A complete set of calculations, stamped and signed by a Professional Engineer licensed to practiced in New York State, showing that loads imposed on permanent structural components by construction equipment, erection equipment, and temporary falsework will not adversely affect the integrity of the structure and that the allowable stresses as shown on the plans are not exceeded during construction, is required. April 2017 2-16 • Complete detail drawings of any modifications to permanent structural components proposed by the Contractor, with supporting calculations demonstrating that the modifications are both necessary and adequate to accommodate loads due to the proposed erection sequence, are required. Both the detail drawings and supporting calculations shall be stamped and signed by a Professional Engineer licensed to practice in New York State. • Calculations and drawings covering all phases of construction shall be submitted and approved before any erection work can begin. Partial submissions are not allowed unless written permission is granted by the DCES. 2.3.7 Revised Installation Drawings Revised installation drawings shall be resubmitted each time the Contractor proposes to deviate from the requirements listed in Section 2.3.1 Installation Notes that are contained in the previously approved installation drawings 2.4 SUBMISSION OF SHOP DRAWINGS AND INSTALLATION DRAWINGS When the shop drawings and installation drawings are completed and independently checked, check prints (along with any supporting documents) shall be submitted to the Concrete Engineering Unit. 2.4.1 Check Prints Check prints shall be submitted electronically using an electronic file management system designated by the Department. After posting check prints to the system, the Contractor shall notify the Concrete Engineering Unit and the Engineer-In-Charge. If the contract involves a railroad, another State Agency (Thruway Authority, Bridge Authority, etc.), or a local authority, the Contractor shall send them paper copies of the check prints. For access to the Department’s electronic file management system or information on the electronic submission of check prints, contact the Concrete Engineering Unit. April 2017 2-17 2.5 EXAMINATION OF SHOP DRAWINGS AND INSTALLATION DRAWINGS 2.5.1 Examination Time The time taken for the examination of shop drawing and installation drawing submissions can vary greatly depending on the construction schedule, the fabricators’ production/shipping schedule, and the Concrete Engineering Unit’s workload. The Concrete Engineering Unit will normally take two work days for the examination of each drawing in a complete set of shop and installation drawings, with a minimum of ten work days per one complete set. A set of shop and installation drawings is defined as all drawings received by the Concrete Engineering Unit from any Contractor for a particular item in a contract on any one day. A set of drawings will be considered complete only if it contains all the information necessary to correctly fabricate, ship, install and fully document the precast member(s) for which the drawings are prepared. If the drawings are detained for examination for a period longer than that stated above, such detention may be taken into account by the Engineer-In-Charge when considering application by the Contractor for an extension of time for the completion of the contract. 2.5.2 Special Circumstances 2.5.2.1 Large Sets of Drawings When a set of shop drawings and/or installation drawings contains more than 20 sheets, the Concrete Engineering Unit will make every effort to limit the total examination time to 40 working days. 2.5.2.2 Design Calculations When a shop drawing and/or installation drawing submittal includes calculations meeting the requirements of Section 9 CONTRACTOR’S DESIGN CALCULATIONS, the examination time for the shop drawings will begin on the date of acceptance of the submitted design calculations. April 2017 2-20 procedure. These drawings shall be submitted at least 30 calendar days prior to the proposed beginning of erection. The Regional Director will review and either approve or reject the erection procedure based upon its structural adequacy and the requirements given in Section 2.6.2 - Required Information. This review will consider, but not be limited to, stability of units during erection, effects on the maintenance of traffic, modifications to existing pavement, the flow of water, etc. The Regional Director’s Office will forward all of the comments to the Contractor for incorporation into the erection procedure. 2.6.2 Required Information The following minimum information shall be placed on the erection drawings for each structure. Erection procedures for similar structures or twin bridges may be shown on the same sheet: • Plan of the work area showing support structures, roads, railroad tracks, canals or streams, utilities including any high voltage power lines, or any other information pertinent to erection. • Erection details for all units, showing how the units will be lifted at the job site. This includes unloading units from trucks, lifting units to and from storage locations, and erecting units onto permanent or temporary supports. • Erection sequence for all units, noting use of holding cranes or temporary supports, false work and bents. • Delivery location of each unit and storage location, if applicable. • Location and range for each pick. • A capacity chart for each crane and boom length used in the work. Cranes lifting over active railroad facilities shall have a minimum lifting capacity of 150 percent of the lift weight. • Pick point location(s) on each member. • Lifting weight of each member, including clamps, spreader beams, etc. • Lift and setting radius for each pick (or maximum lift radius). • Description of lifting devices or other connecting equipment, including capacity. April 2017 2-21 • Beam tie down details or other method of stabilizing erected beam units, if required. • Blocking details, if required, for stabilizing members supported on expansion bearings and on bearings that do not limit movement in the transverse direction. • Crane outriggers or their bearing mats, if used, shall be located no closer to the back of the substructure than a distance defined by a line projected upward from the top of the footing at a one (vertical) to one (horizontal) slope. For crane positions located inside this line, the Contractor shall submit calculations stamped and signed by a Professional Engineer licensed to practice in New York State showing that the crane location will not cause harm to the substructure. The calculations shall be submitted to the Regional Director for review and approval or rejection. April 2017 3-3 perform any fabrication-related activities without the QA Inspector present shall be preapproved by the DCES prior to performing such activities. The QA Inspector shall have the authority to inspect all materials and fabrication procedures to determine whether they conform to the contract documents and the approved shop drawings. Copies of all certifications shall be given to the QA Inspector. Inspection by the QA Inspector is not a substitute for Quality Control by the Contractor. 3.4 INSPECTOR’S MARK OF ACCEPTANCE FOR SHIPMENT When the QA Inspector agrees that a precast concrete unit has been fabricated in accordance with NYSDOT specifications and is ready for shipment from the plant, the QA Inspector shall affix the acceptance stamp to the precast unit and shall complete and sign Part A of the “Report of Acceptance/Shipping of Structural Concrete,” as indicated in Section 3.5. REPORT OF ACCEPTANCE OF STRUCTURAL CONCRETE. This acceptance mark shall be made by paint or indelible ink stamp and shall be placed near the erection mark on the precast unit. The precast unit may then be shipped to the job site or may be stored prior to shipping. The QA Inspector's acceptance stamp indicates that, at the time of acceptance, it was the opinion of the inspector that the precast unit was fabricated from accepted materials, in accordance with the contract documents and the approved shop drawings, and that it met the criteria in Section 6.3 ACCEPTANCE OF UNITS. However, the inspector’s acceptance stamp does not imply that the precast unit will not be subject to rejection by the State after it has been shipped from the plant, or relieve the Contractor of responsibility if the precast concrete unit is subsequently found to be defective or not to be in conformance with the contract documents. 3.5 REPORT OF ACCEPTANCE OF STRUCTURAL CONCRETE The acceptance document for all structural concrete products subject to plant inspection is titled “Report of Acceptance/Shipping of Structural Concrete” (See Section 6.6 SHIPPING OF UNITS and Appendix C REPORT OF ACCEPTANCE /SHIPPING OF April 2017 3-4 STRUCTURAL CONCRETE). Prior to product shipment from the plant, the QA Inspector shall complete and sign Part A of the “Report of Acceptance/Shipping of Structural Concrete”. The QC Inspector or other authorized agent of the Contractor shall sign Part B of the “Report of Acceptance/Shipping of Structural Concrete” at the time of shipping. The completion of Part A of this document shall indicate to the Engineer that the structural precast product may be paid for under the payment rules established by the Department. 3.6 FACILITIES FOR INSPECTION The Contractor shall provide all facilities for inspection of material and workmanship at the fabrication site. Each QA Inspector shall have sole access to a safe, secure, and private work station which includes the following minimum requirements: • Desk with a chair. • File cabinet with lock. • Telephone with answering machine or voice mail. • Secure fax machine. • A dedicated computer with an operating system that is compatible with the operating system currently used by NYSDOT, with high-speed internet service. The system shall also include a secure printer and a secure scanner of acceptable quality, as determined by the DCES. 3.7 OBLIGATIONS OF THE CONTRACTOR The Contractor shall be responsible for the acceptability of the fabricated units. The QC Inspector shall take all necessary steps to assure that all materials, fabrication procedures and the final product meet all the requirements of the contract documents and the approved shop drawings. The Fabricator shall give the QA Inspector free access throughout the fabrication site to verify that the work being done is in conformance with the contract documents and the approved shop drawings. If the QA Inspector is not present to witness the work, the Fabricator shall stop the work and immediately notify the Concrete Engineering Unit. April 2017 3-5 Work done while the QA Inspector has been refused access shall be automatically rejected. 3.7.1 Informing the DCES of Work Schedule The Contractor shall notify the Concrete Engineering Unit a minimum of three work days prior to: • Commencement of fabrication.* • Commencement of fabrication after a work suspension of two work days or more. • Unit shipping. * If someone other than the Concrete Engineering Unit is responsible for shop drawing review and approval, the Contractor shall notify the Concrete Engineering Unit a minimum of ten work days prior to commencement of fabrication. 3.7.2 Informing the QA Inspector of Work Schedule The Fabricator or Contractor shall keep the QA Inspector informed of the day-to-day scheduling of operations. January 2019 4-2 o non-prestresssed components that contain only stainless steel or fiber reinforced polymer (FRP) reinforcement. o Precast deck panels. o The Contract Documents state corrosion inhibitor is not required. o All previously approved mix designs that were originally tested with corrosion inhibitor shall contain corrosion inhibitor unless the mix design is retested without the corrosion inhibitor. The corrosion inhibitor must be added to the mix immediately after air entraining and retarding admixtures have been introduced into the batch. The corrosion inhibitor shall be added to the concrete as an aqueous solution at a dosage rate of 5.0 gallons per cubic yard unless otherwise approved by the DCES. An automatic corrosion inhibitor dispensing system shall be required. The dispensing system shall meet the following requirements: Delivery accuracy of ±3% (by weight or volume). Program quantity (gallons, nearest tenth). System interlocks. Print requirements: o Project number and/or batch number. o Date and time. o Delivered quantity (gallons, nearest tenth). Calibration of the dispensing system shall be in accordance with procedures approved by the NYSDOT Materials Bureau. • Air content shall be 7% ±2%. A minimum air content of 3% will be accepted, provided that the Fabricator has previously demonstrated that concrete from an identical mix, at the lower air content, meets the requirements of AASHTO T161 (80% < x, where x = the relative dynamic modulus of January 2019 4-3 elasticity after 300 cycles). • The use of calcium chloride, or an admixture containing calcium chloride will not be permitted. • The water/cementitious material ratio shall not exceed 0.40, as measured by AASHTO T318. The AASHTO T318 test measures the free water available for hydration of the cement plus the bound water in the saturated aggregate. The bound water may amount to 1-2% of the mass of the aggregate. 4.1.2 Materials for Lightweight Concrete If lightweight concrete is required in accordance with the contract documents, the concrete shall meet the requirements of Section 4.1.1, Materials for Concrete, with the following modifications: • Type I, II, or I/II cements conforming to §701-01 Portland Cement shall be used. Type IT or SF blended cements conforming to §701-03 Blended Portland Cement may only be used with the written approval of the DCES. • The minimum cementitious content of lightweight concrete shall be 675 lb./cy. • 15% to 20% pozzolan conforming to §711-10 Fly Ash or §711-12 GGBFS shall be used. 6% to 10% microsilica conforming to §711-11 microsilica shall be used. When a blended cement is used, the addition of microsilica is not required. • Use lightweight aggregate meeting the requirements of §703-10 Lightweight Aggregates of the Standard Specifications. • Lightweight coarse aggregate gradation shall be one of the following, unless approved by the DCES: January 2019 4-4 REQUIRED LIGHTWEIGHT COARSE AGGREGATE GRADATIONS SIZE DESIGNATION % PASSING---SIEVE SIZE---SQUARE OPENINGS 1 in. 3/4 in. 1/2 in. 3/8 in. No. 4 No. 8 No. 16 No. 200 3/4” to 3/16” 100 90-100 --- 10-50 0-15 --- ---- 0-10 1/2” to 3/16” --- 100 90-100 40-80 0-20 0-10 --- 0-10 3/8” to 3/32” --- --- 100 80-100 5-40 0-20 0-10 0-10 • Lightweight coarse aggregate stockpiles shall be continuously and uniformly sprinkled with clean, potable water meeting the requirements of §712-01. Only sprinkler systems approved by the DCES shall be used. The stockpile shall be periodically agitated so as to maintain uniform moisture throughout the pile. Water shall be applied for a minimum of 48 hours, or until the stockpile has achieved a minimum internal moisture content of 15% by weight. At the end of the wetting period, stockpiles shall be allowed to drain for 12 hours immediately prior to use, unless otherwise directed by the DCES. • Produce concrete with an average dry unit weight ranging from 110 to 115 lb./ft3 when tested in accordance with ASTM C567. • The QA Inspector shall take a 1-quart microsilica sample in accordance to Materials Method 9.1 prior to each day’s placement for testing by the Department. • A trial batch is required when lightweight concrete is used. The Contractor shall produce a trial batch using the proposed lightweight concrete mix for the approval of the DCES. At least 10 working days prior to concrete placement, the Contractor shall provide the DCES with the lightweight concrete mix design used for the trial batch along with the following information: January 2019 4-7 the requirements of Section §717-03 Penetrating Type Protective Sealers. Penetrating sealers shall be applied prior to the application of concrete finishing materials. 4.5 MATERIALS FOR INSTALLATION 4.5.1 Transverse Post-Tensioning Steel Prestressing steel used for the transverse post-tensioning of adjacent box beams or slab units shall be a low-relaxation Grade 270 strand meeting the requirements of §709- 06. The strand shall be encased in corrosion inhibitor and a seamless, inert polymer sheath shall be extruded directly onto the strand. 4.5.2 Shear Key and Field Cast Joint Material 4.5.2.1 Adjacent Box Beams Units, Hollow Slab Units and Solid Slab Units Shear key material for adjacent box beam units, hollow slab units and solid slab units shall be a grout meeting the requirements of §701-06, Cement Based Grout Materials for Shear Keys. Rapid Hardening Concrete Repair Material meeting the requirements of §701-09 shall not be used without the approval of the DCES. Field cast joint material, if required on the plans, shall be Ultra High Performance Concrete (UHPC). 4.5.2.2 Deck Bulb Tee Beams, NEXT Type “D” Beams, Precast Concrete Deck Panels, and Precast Concrete Approach Slabs Field cast joint material for deck bulb tee beams, NEXT beams, precast concrete deck panels, or precast concrete approach slabs shall be a grout meeting the requirements of §701-06, Cement Based Grout Materials for Shear Keys, Ultra High Performance Concrete (UHPC) or a concrete mix approved by the DCES. Rapid Hardening Concrete Repair Material meeting the requirements of §701-09 shall not be used without the approval of the DCES. January 2019 4-8 4.5.3 Anchorage Block-Out Grout for Transverse Post-Tensioning The mortar shall consist of one of the following materials: • §701-05, Concrete Grouting Material. • §701-06, Cement Based Grout Material for Shear Keys. • §701-08, Vertical and Overhead Patching Material. • A two-component epoxy system and a completely dry fine aggregate, using a combination of one epoxy and one fine aggregate chosen from the list below: o §721-01, Epoxy Resin System. o §721-03, Epoxy Polysulfide Grout. o §721-05, Epoxy Repair Paste. o §703-03, Mortar Sand. o §703-04, Grout Sand. o §703-07, Concrete Sand. 4.5.4 Anchor Dowel Fill Material 4.5.4.1 Expansion End Material Option • NYS Mat. Spec. §702-0700 - Asphalt Filler. 4.5.4.2 Fixed End Material Option • NYS Mat. Spec. §721-01 - Epoxy Resin System with Sand. Bone-dry, sandblast sand shall be added in the ratio of (1) part epoxy to (2) parts sand by volume. • NYS Mat. Spec. §721-03 - Epoxy Polysulfide Grout with Sand. Bone-dry, sandblast sand shall be added in the ratio of (1) part epoxy to (2) parts sand by volume. • NYS Mat. Spec. §701-05 - Concrete Grouting Material. • NYS Mat. Spec. §701-06 - Cement Based Grout Materials for Shear Keys. January 2019 4-9 4.5.5 Grouted Splice Sleeve Couplers Grouted Splice Sleeves shall meet the requirements of §709-15 Grouted Reinforcing Bar Splice Sleeves, of the NYSDOT Standard Specifications. 4.5.6 Epoxy Bonding Agent for Match-Cast Precast Segments The epoxy bonding agent shall meet the requirements of ASTM C881, Type VI or VII. Finished color shall match that of the finished concrete of segmental units. The manufacturer shall supply the Department with results from an independent AASHTO accredited testing laboratory, certifying that the material satisfies ASTM C881. Testing shall be done by lot. Certification is required for all temperature range formulations anticipated by the Contractor. In its workable state, the epoxy bonding agent shall provide lubrication along the keys as the precast concrete segments are brought together. In its hardened state, the epoxy bonding agent shall provide a watertight seal between the precast concrete segments. Epoxy bonding agents shall be thermosetting 100% solid compositions that do not contain solvent or any non-reactive organix ingredient except for pigments required for coloring. Epoxy bonding agents shall be insensitive to damp conditions during application and after curing shall exhibit high bonding strength to cured concrete, good water resistivity, low creep characteristics and tensile strength greater than the concrete. In addition to the packaging requirements in ASTM C881, the components’ labels shall include the range of substrate (surface of concrete) temperature over which the application is suitable, the date of formulation, the shelf life and manufacturer’s lot number. Instructions shall be furnished by the manufacturer for the storage, handling, mixing and application of the material. The Contractor shall allow sufficient lead team to review test January 2019 4-12 For external post-tensioning systems, smooth plastic duct or steel pipe shall be used. For internal post-tensioning systems, corrugated plastic duct shall be used. Corrugated steel duct can only be used for internal post-tensioning systems with the approval of the DCES. Duct material shall be sufficiently rigid to withstand loads imposed during the placing of concrete as well as internal pressure during grouting operations, while maintaining its shape, remaining in proper alignment, and remaining watertight. Duct systems, including all connectors, connections and components of post-tensioning systems, shall be air and watertight to effectively prevent the entrance of cement past or water into the system and shall effectively contain pressurized grout during the grouting of tendons. Duct systems shall be capable of withstanding water pressure during the flushing of a duct in the event the grouting operation is aborted. Duct systems for bonded tendons shall be capable of transmitting design forces from the grout to the surrounding concrete. For ducts containing prestressing strands, the nominal internal cross sectional area of circular duct shall be at least 2.25 times the net area of the strands; or 2.50 times for strands installed by the pull-through method. In case of space limitations, the minimum duct area may be only 2.00 times the strand area for relatively short tendons up to approximately 100-feet long. For ducts containing a single bar, the internal duct diameter shall be at least ½ in. greater than the maximum outside dimension of the bar. For bars with couplers, the internal duct diameter shall be at least 1/2 in. greater than the maximum outside dimension of the bar or coupler, whichever is greater. January 2019 4-13 4.6.3.1 Metal Ducts Smooth steel pipes shall be galvanized and shall conform to ASTM A53, Type E, Grade B, Schedule 40. Pipes shall have smooth inner walls. When required for curved tendon alignments, the pipe shall be pre-fabricated to the required radius. Corrugated steel ducts, when approved for use by the DCES, shall be spirally wound to the necessary diameter from strip steel with a minimum wall thickness of 26 gage for ducts less than or equal to 2-5/8 in. diameter and 24 gage for ducts greater than 2-5/8 in. diameter. The strip steel shall be galvanized to ASTM A653 with a coating weight of G90. Ducts shall be manufactured with welded or interlocking seams with sufficient rigidity to maintain the correct profile between supports during concrete placement. Ducts shall also be able to flex without crimping or flattening. Joints between sections of duct and between ducts and anchor components shall be made with positive, metallic connections that provide a smooth interior alignment with no lips or abrupt angle changes. 4.6.3.2 Plastic Ducts Smooth plastic duct shall be manufactured from polyethylene resin meeting the requirements of ASTM D3350 with a minimum cell class of 344464C and shall be resistant to degradation from ultraviolet light in accordance with ASTM D1248. Smooth plastic ducts shall have a standard dimension ratio of 17.0 or less. Smooth plastic ducts shall have a minimum pressure rating of 100 psi and be manufactured in accordance with ASTM D3035 or ASTM F715. An Oxidative Induction Time (OIT) test shall be performed on the material in accordance with ASTM D3895. Certifications and test results shall be included in the shop drawing submittal as a part of the supporting documents. Corrugated plastic ducts shall be manufactured from polyethylene resin meeting the requirements of ASTM D3350 with a minimum cell class of 344464C. Corrugated plastic January 2019 4-14 ducts shall have a minimum material thickness of 0.079 in. ±0.010 in. Corrugated plastic duct shall be designed so that a force equal to 40% of the ultimate tensile strength of the tendon will be transferred through the duct into the surrounding concrete in a length of 2-½ feet. Twelve (12) static pull out tests shall be conducted to determine compliance with this requirement. If ten (10) of these tests exceed the specified force transfer before failure, the duct will be deemed acceptable. Components of the corrugated plastic ducts system shall be tested to assure compliance with the requirements of Chapter 6 of FIB Technical Report; Bulletin 75 entitled “Polymer Duct Systems for Internal Bonded Post-Tensioning.” In addition, the manufacturer shall establish, through testing, the minimum bending radius for the duct. The required test shall be a modified duct wear test as described in of Chapter 6, Article 6.8 of FIB Technical Report; Bulletin 75 entitled “Polymer Duct Systems for Internal Bonded Post-Tensioning.” Certifications and test results shall be included in the shop drawing submittal as a part of the supporting documents. 4.6.3.3 Duct Connections, Fittings and Grout Vent Pipes All duct splices, joints and connections to anchorages shall be made with couplings and connectors that produce a smooth interior duct alignment with no lips or kinks. Special duct connectors may be used in match-cast joints between precast segments and similar situations if necessary to create a continuous, air and watertight seal. All fittings and connections between lengths of plastic duct and between ducts and steel components (e.g., anchors or steel pipe) shall be made of materials compatible with corrugated plastic ducts. Plastic materials shall contain antioxidant stabilizers and have an environmental stress cracking of not less than 192 hours as determined by ASTM D 1693 "Standard Test Method for Environmental Stress-Cracking of Ethylene Plastics", Condition C. April 2017 5-1 SECTION 5 FABRICATION REQUIREMENTS 5.1 PLANT FACILITY Precast plants fabricating structural precast and/or prestressed concrete units covered by this manual shall meet the following minimum requirements, as determined by the DCES: • Have well trained and knowledgeable personnel, experienced in the fabrication of structural precast and/or prestressed concrete units. • Have a business office including a computer system with internet access, telephone facilities with an answering machine or voice mail, and a fax machine. • Have inspector facilities as required by Section 3.6 FACILITIES FOR INSPECTION. • Have sufficient area for concrete batch plant and raw material storage if the plant produces concrete. • Have sufficient area for storage of precast and/or prestressed concrete units. • Have prestressing equipment and beds, if necessary. • Have all necessary concrete forms. • Have a Quality Control Manual and an implemented Quality Control Plan. • Have all required quality control equipment. • Have all required equipment for proper curing of concrete units. In addition, precast plants shall meet one of the following requirements: • Is currently PCI certified for the appropriate type of work as defined by PCI. • Has performed similar satisfactory work for NYSDOT within the last five years, as determined by the DCES. • Has been approved for structural precast and/or prestressed concrete fabrication by the DCES. April 2017 5-2 5.2 ORDERING OF MATERIALS The Contractor shall bear all costs for damages and unacceptable material which may result from the ordering of materials prior to the approval of the shop drawings. 5.3 DATA FOR QA INSPECTORS • Certificates of acceptance for all materials shall be provided to the QA Inspector. • A calibration certificate attesting to the fact that the concrete cylinder testing machine to be used has been calibrated within the last 12 months. • A calibration certificate indicating the load calibration of each gauge and hydraulic jack combination used for tensioning. The gauge shall be calibrated from zero, throughout its entire load range. The gauge shall have clearly marked divisions that are easily readable at the initial and final tensioning force. The calibration date of each combination of a gauge and hydraulic jack shall be within the 12-month period immediately prior to use. More than one gauge can be calibrated for one jacking system. 5.4 CONCRETE FORMS 5.4.1 General Forms shall be well constructed, carefully aligned, clean, substantial and firm, securely braced and fastened together and sufficiently tight to prevent leakage of concrete. They shall be strong enough to withstand the action of mechanical vibrators. All forms for each unit shall be approved by the Inspector prior to placing concrete. All form surfaces that come in contact with the concrete shall be thoroughly treated with an approved form coating in the manner and at the rate specified by the Manufacturer. Forms so treated shall be protected against damage and other contamination prior to placing the concrete. Any form coating material that sticks to or discolors concrete shall not be used. April 2017 5-3 5.4.2 Void Producing Forms Void forms shall be waterproof or be coated with a waterproofing material on the outside and shall have a ¾ inch minimum drain placed at each end of each void. All voids shall be vented during curing unless waived by the DCES. The vents shall be plugged with approved material after curing. 5.5 EMBEDDED STEEL 5.5.1 Reinforcing and Prestressing Steel Prior to installation in the units, reinforcing steel and prestressing steel shall be free of frost, dirt, oil, paint, mill scale, corrosion or any foreign material that may prevent a bond between the steel and the concrete. Some rust on steel is acceptable provided the rust is not loose and the steel is not pitted. Tack welding of design bar reinforcement shall not be permitted. Tack welding of redundant steel may be allowed to provide extra rigidity to the steel cage. Reinforcing steel shall be adequately secured by chairs or blocking to forms or by ties to tendons so it maintains its position during the casting of the concrete. Heat bending of prestressing steel is not allowed. 5.5.2 Welded Wire Fabric Welded wire fabric, plain or deformed, may be substituted for the bar reinforcement provided that: • The required cover is maintained. • The design steel area of the fabric equals or exceeds that of the bar reinforcement. • The wire fabric shall be of the same material as the specified bar reinforcement. • Splices to the fabric are made in accordance with the requirements of Section 5.11.2.5 – Welded Wire Fabric, of the LRFD Bridge Design Specifications. • The details shall be indicated on the shop drawings. April 2017 5-6 be calibrated by proving rings or by load cells placed on either side of the movable end carriage. • In multiple strand tensioning, use of a master gauge system to monitor accuracy of hydraulic gauges is acceptable. 5.6.4 Prestressing Strands Prestressing strand shall meet the requirements of §709-06. 5.6.5 Control of Jacking Force Manual or automatic pressure cutoff valves shall be used for stopping the jack at the required load. When manual cutoffs are used, the rate of loading shall be such that the jack can be stopped at the specified load of the strand. If automatic pressure cutoff valves are used, it shall be capable of adjustment to assure that the proper force is induced into the strand. 5.6.6 Wire Failure in Tendons Failure of wires in pretensioned strand is allowed, providing the total area of wire failure is not more than 2% of the total area of tendons in any member. When a prestressing strand fails during tensioning, the gauge that is connected to the tensioning system shall be recalibrated before it is reused. The recalibration may be waived if the gauge is adequately protected by snubbers. 5.6.7 Time Allowed Between Tendon Tensioning and Concrete Placement The maximum time allowed between the tensioning of the tendons and concrete placement shall be 72 hours. 5.6.8 Detensioning of Tendons Prestressing strands can be cut using mechanical means (electric powered saw) or by flame cutting with a torch. In order to reduce the likelihood of the concrete cracking during detensioning of the strands, the following steps shall be taken: April 2017 5-7 • Prestressing strands shall be cut using a symmetrical cutting sequence. Unless otherwise approved by the DCES, strands shall be detensioned from the inner most stands to the outer strands. • To avoid sudden transfer of the strand force to the member when cutting prestressing strands with an electric powered saw, strands shall be cut slowly to avoid cutting all of the wires in the strand at once. • To avoid sudden transfer of the strand force to the member when flame cutting prestressing strands, strands shall be cut with a sweeping motion with a minimum sweep of 3 inches side to side (6 inches total) along the direction of the strand. No extra oxygen shall be applied to the cutting flame to speed up the process. 5.7 MATCH CAST SEGMENTS Care shall be exercised in setting up forms for casting segments. All materials to be embedded in concrete shall be properly positioned and supported. Provisions for all projections, recesses, notches, openings, blockouts and other pertinent items shall be made in accordance with the plans. Extreme care shall be taken in positioning the match cast segment in relation to the segment to be cast. The match cast segment shall not be torsionally distorted (twisted). The abutting surface of the bulkhead segment shall be covered with a thin film of bond breaker consisting of flax soap and talc, or other material approved by the DCES. The soap and talc mixture shall be appropriately five parts flax soap to one part talc. The mixture may be varied based on job experience and results. The acceptability of a material other than flax soap and talc shall be determined prior to use in casting of segments by demonstration on a specimen with a facial area of at least four (4) square feet. Prior to each use, the interior surfaces of forms shall be cleaned of all dirt, mortar, and foreign material. Before placing reinforcing steel and other embedded items, forms shall April 2017 5-8 be thoroughly coated with an approved form oil or other equivalent coating that permits the ready release of the forms and that do not discolor the concrete. 5.8 CONCRETE MIX DESIGN AND PROPORTIONING The Fabricator shall be responsible for designing a concrete mix to produce the strength and other requirements specified in the contract documents. If no strength is indicated, the required minimum compressive strength shall be 6500 psi. When water is added in stages, details regarding measuring of water and the mixing operation after such addition shall be clearly stated in the Production Notes. The concrete mixing operation shall exactly follow the approved procedure on the Production Note Sheet. Equipment used for the mixing and/or transportation of an approved concrete mix shall be thoroughly cleaned prior to use to ensure that there will be no contamination from other concrete mixes. The QA Inspector shall be provided with all batch tickets. 5.9 PLACING CONCRETE 5.9.1 Preparation No concrete shall be placed without the QA Inspector’s approval. Compliance with the precasting tolerances listed under Section 7 FABRICATION TOLERANCES of this manual is a prerequisite for approval by the QA Inspector. 5.9.2 Cold Weather When the ambient temperature is below 45 F, the fabrication of the units shall be in accordance with the cold weather concreting procedures, as approved on the approved shop drawings. 5.9.3 Hot Weather When the ambient temperature is above 90 F, the fabrication of the units shall be in April 2017 5-11 • Natural Cure • Low Pressure Steam For both curing methods, the external surface of the concrete shall be covered (saturated cover), as soon as the concrete has started setting and the concrete can be covered without marring the surface. The cover material shall be heavy, water saturated burlap, or other material acceptable to the Inspector. All exposed surfaces shall be kept saturated and the concrete surface temperature shall not drop below 50° F. The Contractor shall submit all materials for covers to the QA Inspector for approval prior to the commencement of work. For match cast segments, both the segment being cast ("wet cast segment") and the segment being cast against ("match cast segment") shall be covered. 5.11.2 Natural Cure The saturated cover shall remain in place until the concrete has reached 70% of its specified compressive strength and any prestressed strands have been detensioned. 5.11.3 Steam Curing After the external surface of the precast unit is covered with a saturated cover, but prior to the application of steam, an enclosure shall be placed over the casting bed. The steam curing cycle shall include a gradual heating period during which the rate of change in temperature within the curing enclosure shall not exceed 40 F per hour. Until the concrete reaches a compressive strength of 500 psi, as indicated by a penetrometer test meeting the requirements of ASTM C403, the temperature within the enclosure shall be maintained between 50° F and 100° F. Once the concrete strength has reached a compressive strength of 500 psi, the temperature within the enclosure shall be maintained between 120° F and 160° F. April 2017 5-12 Once the concrete has reached 70% of its specified compressive strength, the temperature within the curing enclosure shall be decreased at a rate not exceeding 40 F per hour until the temperature within the curing enclosure is within 20 F of the ambient temperature of the storage area (at which time the enclosure can be removed). Once the enclosure is removed and the concrete has reached the required strength for detensioning (as stated on the Production Note Sheet), prestressing strands shall be detensioned. The saturated cover shall remain in place until the concrete has reached 70% of its specified compressive strength and all prestressed strands have been detensioned. 5.11.4 Record of Curing Time and Temperature Temperatures shall be recorded every 100 feet maximum along the length of the precast unit. The recorders shall continuously record curing temperatures for the entire curing process. Sensors shall be carefully placed within the curing enclosure (for steam curing) or on the concrete surface (for saturated cover curing) to ensure that temperature conditions are measured at the designated locations. The ambient temperature shall also be measured. Recorder accuracy shall be certified once every 12 months and the certificate displayed with each recorder. In addition, random temperature checks of each recorder shall be made by the Inspector. Temperature charts shall indicate the casting bed, date of casting, time of commencing, graphic plot and the units that are represented by the chart. The start of artificial heat and the transfer of prestress shall be indicated on each graphic record. After completion of the final curing phase, the charts shall be properly marked and given to the QA Inspector. Temperatures recorded on the charts shall be considered as verification of whether the units have been cured in accordance with the approved shop drawings and the PCCM. April 2017 5-13 5.11.5 Transfer of Prestress Transfer of prestress shall be in the manner approved on the shop drawings. Transfer of prestress shall not occur until the concrete has reached at least 70% of the design compressive strength, unless noted otherwise on the contract plans. 5.12 REMOVAL OF FORMS Forms shall remain in place until the concrete has reached the compressive strength specified on the shop drawings. Care shall be exercised in removing the forms to prevent spalling and chipping of the concrete. For match cast units, prior to moving a unit from its as-cast position, erection marks shall be affixed identifying its location in the structure and order in the erection sequence, and match marks indicating its orientation relative to the adjacent segment. 5.13 PRODUCTION TESTING OF CONCRETE 5.13.1 Testing Cylinders for Strength 5.13.1.1 Casting Test Cylinders The concrete strength shall be determined from concrete test cylinders made in conformance with ASTM C31 or ASTM C1758 (see Section 5.13.1.2. for curing requirements). All cylinders shall be made by the Fabricator in the presence of the QA Inspector. The Fabricator shall cast a sufficient number of concrete test cylinders to fulfill the concrete strength test requirements as stated in Section 5.13.1.3. The expected number of test cylinders to be cast for each unit shall be shown on the shop drawings. The cylinders shall be made from the same batch of concrete actually placed in the precast units. The QA Inspector shall be the sole judge of which cylinders are defective or damaged and are not to be included in the determination of the strength class. April 2017 5-16 5.13.7.3 Visual Stability Index The Visual Stability Index (VSI) shall be measured for each batch as per AASHTO T 351, “Standard Method of Test for Visual Stability Index (VSI) of Self-Consolidating Concrete.” A VSI rating of less than 2 is an indication that the SCC mixture is stable and should be suitable for the intended use. A VSI rating of 2 or greater is an indication that the SCC mixture is unstable and could be cause for rejection. 5.14 GEOMETRY CONTROL OF MATCH CAST SEGMENTS 5.14.1 General After a given segment is cast and before separating it from the adjacent match cast segment, the positions of the two adjoining segments shall be checked from established control points. If the positions do not agree within a specified tolerance with the control point settings from the approved casting curve, corrections to the geometry shall be made in the next segment cast using the established control points. 5.14.2 Geometry Control Method The Contractor shall submit a Geometry Control Plan to the DCES for approval. 5.14.3 Reference Points and Bench Marks A minimum of two permanent horizontal reference points shall be established in line with the instrument mounting point. A permanent bench mark shall be established at a location where it will not be disturbed by construction activities. The horizontal reference points and bench mark shall be located so as to be continuously visible from the instruments. 5.15 POST-TENSIONING All post-tensioning work done at the precasting facility shall be done according to the approved shop drawings and as per Section 8.5 POST-TENSIONING of this manual. January 2019 6-1 SECTION 6 HANDLING, FINISHING, AND ACCEPTANCE 6.1 HANDLING Segments shall be handled with care to prevent damage. Handling shall be done only by using the devices shown on the approved shop drawings for this purpose. The Contractor shall inspect each segment visually for evidence of damage or defects before, during, and after critical operations and as often as necessary to ensure adequate quality control. The Contractor shall immediately bring all evidence of damage or defects to the attention of the QA Inspector. 6.2 FINISHING 6.2.1 Surface Cleaning All concrete surfaces shall be cleaned by blast cleaning (pressure washing, abrasive blasting, etc.) to remove all laitance, loose particles, etc. Keyway surfaces shall be blast cleaned to remove any material which may prevent bonding (i.e. oil, grease, dirt, etc.) Blast cleaning must be completed prior to coating the surface with a penetrating sealer. 6.2.2 Exposed Steel All exposed steel shall be protected so it is not damaged during blast cleaning. 6.2.3 Sealing of Concrete Units After blast cleaning, all concrete units shall be coated on all surfaces with a penetrating sealer in accordance with Section 6.2.3.2 Sealer Application. Keyway surfaces shall be coated with a penetrating sealer unless otherwise approved by the DCES. The sides of concrete units that will be in contact with field cast joints and/or closure pours using UHPC shall not be coated with penetrating sealer unless approved by the DCES. Penetrating sealers shall meet the requirements of Section 4.4.2 Penetrating Sealers. January 2019 6-2 If water is used to blast clean the concrete, the surfaces shall be allowed to dry for 24 hours before the penetrating sealer is applied. All surface cleaning shall be completed and approved by the QA Inspector, before sealer application can commence. 6.2.3.1 Weather Limitations Sealer materials shall not be applied during wet weather conditions. Any unit exposed to wetting within 12 hours after sealing shall be recoated. Ambient and surface temperatures shall be a minimum of 40 F during sealer application and until the sealed concrete is dry to the touch. Application by spray methods shall not be used during windy conditions. 6.2.3.2 Sealer Application The sealer shall be used as supplied by the manufacturer without thinning or alterations, unless specifically required in the manufacturer’s instructions. Thorough mixing of the sealer before and during its use shall be accomplished as recommended by the manufacturer. Equipment for sealer application shall be clean of foreign materials. A minimum of two (2) coats of sealer shall be applied. The total quantity of sealer applied by each coat shall be equal to the quantity required at the application rate specified in the Approved List and on the shop drawings. Each coat shall be allowed to dry before the next coat is applied. On sloping and vertical surfaces, sealer application shall progress from bottom to top. Care shall be taken to ensure that the entire surface of the concrete is covered and all pores filled. 6.2.4 Finishing Surfaces All surfaces which will be visible in their installed position (as determined by the DCES) shall be finished as described in the Production Notes Sheet (see Section 2.2.5.1 Production Notes) and approved by DCES. Material used for finishing shall meet the requirements of Section 4.4.1 Concrete Finishing Materials. Surface finishing shall not be done until after the penetrating sealer has been applied and is dry to the touch. January 2019 6-5 of structural significance shall be according to the provisions of Section 6.4.3. Repairs of Structural Defects and shall be done in the presence of the QA Inspector. 6.4.3 Repairs of Structural Defects Drawings shall be prepared by the Contractor to completely document the defect(s) on the unit and to describe and document the proposed repair procedure. The drawings shall meet the requirements of Section 2.2.2 Drawing Size and Type of this manual. These drawings shall be prepared, stamped and signed by a Professional Engineer registered in New York State. Any engineering calculations required in accordance with Section 6.4.3.4 Engineering Calculations shall also be stamped and signed by the same Professional Engineer registered in New York State who stamped and signed the drawings. 6.4.3.1 Documentation of Defects The drawings shall completely document the defect(s) by showing appropriate views of the units with all pertinent information about the defect. All information shown shall be verified by the Inspector. If the unit concerned has spalled, honeycombed or heavily cracked (disintegrated) areas, concrete from such areas shall be removed as approved by the QA Inspector before documenting the defect. 6.4.3.2 Description of Repairs The drawing shall show a detailed description of the proposed repair procedure including all preparatory work and materials to be used. A post repair inspection procedure shall be shown. 6.4.3.3 Supporting Material The submittal shall include supporting material such as photographs of the defect, data sheets for materials to be used, etc. 6.4.3.4 Engineering Calculations The submittal shall include all necessary engineering calculations to substantiate the January 2019 6-6 soundness of the proposed repair. The calculations shall meet the requirements of Section 9 CONTRACTOR’S DESIGN CALCULATIONS of this manual. 6.5 STORAGE Units shall be stored on dunnage capable of supporting the unit without damage. The units shall be spaced far enough apart so that visual inspection along the length is possible. No stacking of units will be allowed, unless approved by the DCES. Anchor dowel holes shall be open at the bottom at all times to allow for drainage. The storage area shall have proper drainage. If a precast unit has exposed black rebar or prestressing strands, the rebar and/or strands shall be protected against corrosion during storage in a manner approved by the DCES. If a precast unit with exposed epoxy coated rebar is to be stored outdoors for more than 30 calendar days, all exposed epoxy rebar shall be protected from ultraviolet rays with opaque plastic sheeting or sleeves. The Contractor is responsible for monitoring camber growth of prestressed units in storage. If the measured camber exceeds the anticipated camber at shipping as shown on the shop drawings by more than the tolerance shown in Section 7 FABRICATION TOLERANCES, the Contractor shall contact the Concrete Engineering Unit immediately for directions on how to proceed. Camber measurements shall be taken with precision surveying equipment. String lines shall not be used. 6.6 SHIPPING OF UNITS The QC Inspector shall verify the following prior to shipping: • All units bear the stamp of the QA Inspector, and the QA Inspector has signed Part A of the Report of Acceptance/Shipping of Structural Concrete for each unit. • All units are properly supported and adequately tied to prevent movement during shipping. • Plastic guards or other devices shall be used to protect the concrete where January 2019 6-7 anchor chains would otherwise be in direct contact with the concrete. • The units shipped are free of any unrepaired defect. The QC Inspector shall sign Part B of the Report of Acceptance/Shipping of Structural concrete (see Section 3.5 REPORT OF ACCEPTANCE OF STRUCTURAL CONCRETE and Appendix C REPORT OF ACCEPTANCE/SHIPPING OF STRUCTURAL CONCRETE), give the report to the transporter, and direct the transporter to give the report to the EIC at the project site at time of delivery of the units. April 2017 7-2 • Bulkhead (deviation from square or designated skew) o Horizontal: ± 1/8 in. per 1 ft. width, ± 1/2 in. maximum o Vertical: ± 3/16 in. per 1 ft. depth, ± 1 in. maximum • Location of Handling Devices: o Parallel to Length of Member: ±6 in. o Transverse to Length of Member: ±1 in. 7.2.2 Tolerance Check after Detensioning All units shall be checked for compliance with the following tolerances within 24 hours after detensioning, except that shipping camber shall be checked within three days of shipping. • Sweep - (Horizontal misalignment of the outside surface, measured as a deviation from straight line parallel to the centerline of the unit): o ±1/8 in. per 10 ft. length o ±0.1% of unit length but no more than 1 in. for lengths greater than 80 ft. • Local Smoothness of Any Surface: 1/4 in. per 10 ft. • Bearing Area (deviation from plane surface when tested with a straight edge through middle half of unit): ±1/8 in. • Actual Prestressing Strand Elongation Deviation from Calculated Theoretical Elongation on the Shop Drawings: ±3% (Straight Strands), ±5% (Draped Strands). • Camber deviation from release camber on the shop drawings: ± 0.1% of unit length • Camber deviation from shipping camber on the shop drawings: ± 0.1% of unit length • Unless modified in the contract documents, the differential Camber between Adjacent Deck Bulb Tee Beams of the Same Design: ±0.2 % of unit length, 3/4 in. maximum April 2017 7-3 7.3 PRESTRESSED CONCRETE BOX BEAM UNITS, HOLLOW SLAB UNITS, AND SOLID SLAB UNITS 7.3.1 Precasting In accordance with the provisions of Section 5.9 PLACING CONCRETE, all forms, reinforcing and prestressing steel, etc. shall be inspected for compliance with the tolerances listed below. • Length: ± 1 in. • Width (overall): ± 1/4 in. • Depth (overall): + 5/8 in., - 1/4 in. • Width (web): ± 3/8 in. • Depth (top flange): ± 5/8 in. • Depth (bottom flange): + 5/8 in., - 1/8 in. • Location of Dowel Bars Extending from Unit: ± 1/4 in. • Composite Bars (projection above top of the beam): + 0 in., - 3/8 in. • Reinforcement Cover: - 0 in., + 1/4 in. • Position of Pretensioning Strands: ± 1/4 in. • Void Position: ± 1 in. from the end of the void to the center of the transverse tendon hole • Position of Transverse Tendon Holes (distance between hole centers and distance between the centers of holes and the unit ends): ± 3/4 in. • Position of Transverse Tendon Holes (distance between the centers of holes and the bottom of the unit): ± 3/8 in. • Location of Inserts: ± 1/4 in. • Stirrup Bars (longitudinal spacing): ± 1 in. • Bulkhead (deviation from square or designated skew): o Horizontal: ± 1/2 in. o Vertical: ± 1/2 in. • Dowel Tubes (spacing between the centers of tubes and from centers of April 2017 7-4 tubes to the ends of the unit): ± 5/8 in. • Location of Handling Devices: o Parallel to Length of Member: ± 6 in. o Transverse to Length of Member: ± 1 in. 7.3.2 Tolerance Check after Detensioning All units shall be checked for compliance with the following tolerances within 24 hours after detensioning, except that shipping camber shall be checked within three days of shipping. • Sweep - (Horizontal misalignment of the outside surface, measured as a deviation from straight line parallel to the centerline of the unit): o ± 1/4 in. for lengths up to 40 ft. o ± 3/8 in. for lengths from 40 ft. to 60 ft. o ± 1/2 in. for lengths greater than 60 ft. • Local Smoothness of Any Surface: 1/4 in. per 10 ft. • Bearing Area (deviation from plane surface when tested with a straight edge through middle half of unit): ± 1/8 in. • Actual Prestressing Strand Elongation Deviation from Calculated Theoretical Elongation on the Shop Drawings: ±3% • Camber Deviation from Release Camber on the Shop Drawings: ± 0.1% of unit length • Camber Deviation from Shipping Camber on the Shop Drawings: + 0.1%, - 0.05% of unit length • Differential Camber between Adjacent Beams of the Same Design:0.2 % of unit length, 3/4 in. maximum April 2017 7-7 • Depth (overall): ± 1/8 in. • Location of Dowel Bars Extending from Unit: ± 1/4 in. • Reinforcement Cover: - 0 in., + 1/4 in. • Position of Pretensioning Strands: ± 1/4 in. • Position of Post-Tensioning Ducts: ± 1/4 in. • Location of Inserts: ± 1/2 in. • Location of Blockouts: ± 1 in. • Length and Width of Blockouts: ± 1/2 in. • Location of Leveling Devises: ± 1/2 in. • Location of Handling Devices: o Parallel to Length of Member: ± 6 in. o Transverse to Length of Member: ± 1 in. 7.5.2 Tolerance Check after Casting and/or Detensioning All units shall be checked for compliance with the following tolerances after casting. If the panels are prestressed, all units shall be checked for compliance with the following tolerances within 24 hours after detensioning: • Variation from Specified End Squareness or Skew: ± 1/4 in. • Local Smoothness of Any Surface: 1/4 in. per 10 ft. • Sweep - (Horizontal misalignment of the outside surface, measured as a deviation from straight line parallel to the centerline of the unit): ± 1/8 in. If panels are prestressed, all units shall be checked for compliance within 24 hours after detensioning. • If panels are prestressed, the actual prestressing strand elongation deviation from calculated theoretical elongation shown on the shop drawings: ±3% • If panels are prestressed, the differential Camber between Adjacent Units of the Same Design Receiving a Topping (Overlay): 1/4 in. per 10 ft., 3/4 in. maximum April 2017 7-8 • If panels are prestressed, the differential Camber between Adjacent Units of the Same Design Not Receiving a Topping (Overlay): 1/8 in. per 10 ft., 3/8 in. maximum 7.6 PRECAST CONCRETE THREE-SIDED STRUCTURES 7.6.1 Precasting In accordance with the provisions of Section 5.9 PLACING CONCRETE, all forms, reinforcing and prestressing steel, etc. shall be inspected for compliance with the tolerances listed below: • Span: ± 1% of Span Length, ± 1 in. maximum • Rise: ± 1% of Rise, ± 1 in. maximum • Wall and Slab Thickness: - 1/4 in., + 1/2 in. • Haunch dimension: ± 1/4 in. • Length of Section: The underrun in length of any one unit shall not be more than 1/2 in. maximum. • The Laying Length of two adjacent units shall not vary by more than 5/8 in. maximum in any section, except where beveled ends for laying of curves are specified in the plans. • Location of Dowel Bars Extending from Unit: ± 1/4 in. • Reinforcement Cover: - 0 in., + 1/4 in. • Location of Inserts: ± 1/2 in. • Variation from Specified End Squareness or Skew: ± 1/4 in. • Local Smoothness of any Surface: 1/4 in. per 10 ft. • Location of Handling Devices: ± 1 in. 7.6.2 Tolerance Check after Erection After the units have been erected in the field, they shall be inspected for compliance with the tolerances listed below: April 2017 7-9 • Span – Variation from Post-Pour Measurement (On Shipping Paperwork): ± 3/8 in. • Vertical Difference Between Tops Of Adjacent Units: ± ½ in. • Width of Joints Between Adjacent Units: ± 3/8 in. 7.7 PRECAST CONCRETE INVERT SLABS 7.7.1 Precasting In accordance with the provisions of Section 5.9 PLACING CONCRETE, all forms, reinforcing and prestressing steel, etc. shall be inspected for compliance with the tolerances listed below: • Length: ± 1/4 in. • Width: ± 1/4 in. • Depth: ± 1/4 in. • Reinforcement Cover: - 0 in., + 1/4 in. • Location of Dowel Bars Extending from Unit: ± 1/4 in. • Location of Inserts: ± 1/2 in. • Location of Keyways: ± 1/2 in. • Length and Width of Keyways: ± 1/4 in. • Depth of Keyways: ± 1/8 in. • Location of Leveling Devices: ± 1/2 in. • Variation from Specified End Squareness or Skew: ± 1/2 in. • Local Smoothness of Any Surface: 1/4 in. per 10 ft. • Sweep - (Horizontal misalignment of the outside surface, measured as a deviation from straight line parallel to the centerline of the unit): ± 3/8 in. • Location of Handling Devices: o Parallel to Length of Member: ± 6 in. o Transverse to Length of Member: ± 1 in.