Standard Specifications for Road, Bridge, and Municipal Construction 2020 (M 41-10) - page 63

Cement Concrete Pavement 

5-05

5-05.3(15)  Concrete Pavement Construction in Adjacent Lanes

Unless otherwise shown in the Plans or in the Special Provisions, the pavement shall 
be constructed in multiple lanes; that is, two or more adjacent lanes paved in a single 
operation. Longitudinal contraction joints shall be used between adjacent lanes that 
are paved concurrently, and construction joints shall be used when lanes are paved 
separately. Tie bars shall be installed during initial lane construction.

The Contractor shall replace, at no expense to the Contracting Agency, any panels on the 
new pavement that are cracked or broken as a result of the Contractor’s operations.

5-05.3(16)  Protection of Pavement

The Contractor shall protect the pavement and its appurtenances from any damage. 
Protection shall include personnel to direct traffic and the erection and maintenance of 
warning signs, lights, barricades, temporary take-down bridges across the pavement with 
adequate approaches, and whatever other means may be necessary to accommodate local 
traffic and to protect the pavement during the curing period or until opened to traffic as 
determined by the Engineer.

The operation of construction equipment on the new pavement will not be allowed until 
the pavement has developed a compressive strength of 2,500 psi as determined from 
cylinders, made at the time of placement, cured under comparable conditions, and tested 
in accordance with FOP for AASHTO T 22. Exceptions would be one track from a slip-
form paving machine when paving adjacent lanes or light vehicles required for sawing 
operations or taking cores.

Placement of Shoulder material may commence when the pavement has developed a 
compressive strength of 1,800 psi as determined from cylinders made at the time of 
placement, cured under comparable conditions, and tested in accordance with AASHTO 
T22 as long as construction equipment is not operated on the new pavement.

A continuous barrier of the design shown in the Plans shall be constructed and 
maintained along the edge of the pavement being constructed and adjacent to the 
portion of the Roadway used for traffic. The barriers shall be left in place until the new 
pavement is ready to be opened to traffic and shall then be removed by the Contractor.

Any damage to the pavement occurring prior to final acceptance shall be replaced or 
repaired in accordance with 

Section 5-05.3(22)

.

5-05.3(17)  Opening to Traffic

The pavement may be opened to traffic when the concrete has developed a compressive 
strength of 2,500 psi as determined from cylinders, made at the time of placement, cured 
under comparable conditions, and tested in accordance with FOP for AASHTO T 22.

Fabrication, curing, and testing of cylinders to measure early strength shall be the 
responsibility of the Contractor. The Contractor shall obtain the services of an 
independent Laboratory to perform these activities and these laboratories shall be 
approved by the Engineer. At the Contractor’s option, the time for opening pavement may 

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Cement Concrete Pavement

be determined through the use of the maturity test in accordance with ASTM C1074. The 
Contractor shall develop the maturity-strength relationship and provide maturity curves 
along with supporting data for approval by the Engineer. The Contractor shall furnish 
all equipment, including thermal or maturity meter, thermocouples, wire, and qualified 
personnel to monitor maturity and provide information to the Engineer. Field procedures 
to monitor maturity shall be submitted to the Engineer for approval prior to use. The 
pavement shall not be opened to traffic until the maturity-strength relationship shows the 
pavement has a compressive strength of 2,500 psi and approved by the Engineer.

The pavement shall be cleaned prior to opening to traffic.

All costs associated with early-strength cylinders shall be at the Contractor’s expense.

5-05.3(18) Vacant

5-05.3(19) Vacant

5-05.3(20) Vacant

5-05.3(21) Vacant

5-05.3(22)  Repair of Defective Pavement Slabs

Broken slabs, slabs with random cracks, nonworking contraction joints near cracks, edge 
slumping and spalls along joints and cracks shall be replaced or repaired as specified at 
no expense to the Contracting Agency, and shall be accomplished prior to completion of 
joint sealing.

Pavement slabs containing more than one crack shall be entirely removed and replaced. 
Pavement slabs containing a single crack shall be removed and replaced such that the 
minimum dimension of the removed slab is 6 feet long and full panel width. The portion 
of the panel to remain in place shall have a minimum dimension of 6 feet in length and 
full panel width, otherwise entire removal and replacement of the slab is required. There 
shall be no new joints closer than 3 feet to an existing transverse joints. Saw cutting full 
pavement depth is required along all longitudinal joints and at transverse locations. Tie 
bars and dowel bars shall be used in accordance 

Section 5-05.3(10)

.

Spalls and edge slumping shall be repaired by making vertical saw cuts at least 3 inches 
outside the affected area and to a minimum depth of 2 inches. Spall repairs that 
encounter dowel bars or are within 6 inches of a dowel bar will not be permitted. 
These spall areas shall be repaired by replacing a half or full panel as permitted by the 
Engineer. Removal of the existing pavement shall not damage any pavement to be left in 
place. If jackhammers are used for removing pavement, they shall not weigh more than 
30 pounds, and chipping hammers shall not weigh more than 15 pounds. All power-
driven hand tools used for the removal of pavement shall be operated at angles less than 
45 degrees as measured from the surface of the pavement to the tool. The patch limits 
shall extend beyond the spalled area a minimum of 3 inches. Repair areas shall be kept 
square or rectangular. Repair areas that are within 12 inches of another repair area shall 
be combined.

Cement Concrete Pavement 

5-05

The Contractor shall remove material within the perimeter of the saw cut to a depth 
of 2 inches, or to sound concrete as determined by the Engineer. The surface patch 
area shall be sandblasted and all loose material removed. All sandblasting residue shall 
be removed.

When a partial depth repair is placed directly against an adjacent longitudinal joint, 
a bond-breaking material such as polyethylene film, roofing paper, or other material 
as approved by the Engineer shall be placed between the existing concrete and the 
area to be patched.

Patches that abut working transverse joints or cracks require placement of a compressible 
insert. The new joint or crack shall be formed to the same width as the existing joint or 
crack. The compressible joint material shall be placed into the existing joint 1 inch below 
the depth of repair. The compressible insert shall extend at least 3 inches beyond each 
end of the patch boundaries.

Patches that abut the lane/shoulder joint require placement of a formed edge, along the 
slab edge, even with the surface.

The patching material shall be mixed, placed, consolidated, finished, and cured according 
to manufacturer’s recommendations. Slab/patch interfaces that will not receive 
pavement grinding shall be sealed (painted) with a 1:1 cement-water grout along the 
patch perimeter.

The Contractor shall reseal all joints in accordance with 

Section 5-05.3(8)B

.

Opening to traffic shall meet the requirements of 

Section 5-05.3(17)

.

Low areas which grinding cannot feasibly remedy, shall be sandblasted, filled with epoxy 
bonded mortar, and textured by grinding. The epoxy bonding agent shall meet the 
requirements of 

Section 9-26.1(1)B

 for Type II epoxy.

5-05.4 Measurement

Cement concrete pavement will be measured by the cubic yard for the completed 
pavement. The volume will be determined from measurements taken as listed below.
1.  The width measurement will be the width of the pavement shown on the typical 

cross-section in the Plans, additional widening where called for, or as otherwise 
specified in writing by the Engineer.

2.  The length will be measured along the center of each Roadway or ramp.
3.  The depth shall be determined in accordance with Section 5-05.5(1). The depth 

utilized to calculate the volume shall not exceed the Plan depth plus 0.04 feet.

The volume of cement concrete pavement in each thickness lot shall equal the measured 
length × width × thickness measurement.

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6-02

6-02.3(24)G 

Job Control Tests

As the Work progresses, the Engineer may require the Contractor to provide a sample 
splice (thermal or mechanical) to be used in a job control test. The operator shall create 
this sample on the job site with the Engineer present using bars of the same size as 
those being spliced in the Work. The sample shall comply with all requirements of these 
Specifications, and is in addition to all other sample splices required for qualification. 
The Engineer will require no more than two samples on any project with fewer than 
200 splices and no more than one sample per 100 splices on any project with more than 
200 splices.

6-02.3(24)H  Epoxy-Coated Steel Reinforcing Bar

This Work is furnishing, fabricating, coating, and placing epoxy-coated steel reinforcing 
bars as the Plans, these Specifications, and the Special Provisions require. Coating 
material shall be applied electrostatically, by spraying, or by the fluidized-bed method.

All epoxy-coated bars shall comply with the requirements of 

Section 9-07

. Fabrication 

may occur before or after coating.

The Contractor shall protect epoxy-coated bars from damage using padded or nonmetallic 
slings and straps free from dirt or grit. To prevent abrasion from bending or sagging, the 
Contractor shall lift bundled bars with a strong-back, multiple supports, or a platform 
bridge. Bundled bars shall not be dropped or dragged. During shop or field storage, bars 
shall rest on wooden or padded cribbing. The Contractor may substitute other methods 
for protecting the bars if the Engineer concurs. If the Engineer believes the coated bars 
have been badly damaged, they will be rejected.

Metal chairs and supports shall be coated with epoxy (or another inert coating accepted 
by the Engineer). The Contractor may use other support devices with the Engineer’s 
concurrence. Plastic coated tie wires (accepted by the Engineer) shall be used to protect 
the coated bars from being damaged during placement.

The bars shall be placed as the Plans require and held firmly in place during placing and 
setting of the concrete. All bars shall be placed and fastened as specified in 

Section 

6-02.3(24)C

.

In the interval between installing coated bars and concreting the deck, the Contractor 
shall protect the coating from damage that might result from other construction Work.

The Engineer will inspect the coated bars after they are placed and before the deck 
concrete is placed. The Contractor shall patch any areas that show significant damage (as 
defined below).

Significant damage means any opening in the coating that exposes the steel in an area 
that exceeds:
1.  0.05 square inch (approximately ¼ inch square or ¼ inch in diameter or the 

equivalent).

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2.  0.012 square inches (approximately ⅛ inch square or ⅛ inch in diameter) when the 

opening is within ¼ inch of another opening of equal or larger size.

3.  6 inches long, any width.
4.  0.50 square inch aggregate area in any 1 foot length of bar.

The Contractor shall patch significantly damaged areas with a patching material obtained 
from the epoxy resin manufacturer and accepted by the Engineer. This material shall be 
compatible with the coating and inert in concrete. Areas to be patched shall be clean 
and free of surface contaminants. Patching shall be done before oxidation occurs and 
according to the resin manufacturer’s instructions.

6-02.3(25)  Prestressed Concrete Girders

The Contractor shall perform quality control inspection. The manufacturing plant of 
prestressed concrete girders shall be certified by the Precast/Prestressed Concrete 
Institute’s Plant Certification Program for the type of prestressed member to be produced 
and shall be approved by WSDOT as a Certified Prestress Concrete Fabricator prior to 
the start of production. WSDOT certification will be granted at, and renewed during, 
the annual prestressed plant review and approval process in accordance with WSDOT 

Materials Manual

 M 46-01.04 Standard Practice QC 6.

Prior to the start of production of girders, the Contractor shall advise the Engineer of 
the production schedule. The Contractor shall give the Inspector safe and free access to 
the Work. If the Inspector observes any nonspecification Work or unacceptable quality 
control practices, the Inspector will advise the plant manager. If the corrective action is 
not acceptable to the Engineer, the girder(s) will be subject to rejection by the Engineer.

The Contracting Agency intends to perform Quality Assurance Inspection. By its 
inspection, the Contracting Agency intends only to facilitate the Work and verify the 
quality of that Work. This inspection shall not relieve the Contractor of any responsibility 
for identifying and replacing defective material and workmanship.

The various types of prestressed concrete girders are:

Prestressed Concrete I Girder – Refers to a prestressed concrete girder with a flanged 
I shaped cross section, requiring a cast-in-place concrete deck to support traffic loads. 
WSDOT standard girders in this category include Series W42G, W50G, W58G, and 
W74G.

Prestressed Concrete Wide Flange I Girder – Refers to a prestressed concrete girder with 
an I shaped cross section with wide top and bottom flanges, requiring a cast-in-place 
concrete deck to support traffic loads. WSDOT standard girders in this category include 
Series WF36G, WF42G, WF50G, WF58G, WF66G, WF74G, WF83G, WF95G, and 
WF100G.

Prestressed Concrete Wide Flange Deck Girder – Refers to a prestressed concrete wide 
flange I girder with extended top flange widths designed to support traffic loads, and 
designed to be mechanically connected at the flange edges to adjacent girders at the 

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6-02

job site. WSDOT standard girders in this category include Series WF39DG, WF45DG, 
WF53DG, WF61DG, WF69DG, WF77DG, WF86DG, WF98DG, and WF103DG. 

Prestressed Concrete Wide Flange Thin Deck Girder – Refers to a prestressed concrete 
wide flange I girder with extended top flange widths requiring a cast-in-place concrete 
deck to support traffic loads. Flange edges extend to flange edges of adjacent girders 
at the job site. WSDOT standard girders in this category include Series WF36TDG, 
WF42TDG, WF50TDG, WF58TDG, WF66TDG, WF74TDG, WF83TDG, WF95TDG, and 
WF100TDG. 

Prestressed Concrete Deck Bulb Tee Girder – Refers to a prestressed concrete girder with 
a top flange designed to support traffic loads, and designed to be mechanically connected 
at the flange edges to adjacent girders at the job site. WSDOT standard girders in this 
category include Series W35DG, W41DG, W53DG, and W65DG. 

Prestressed Concrete Slab Girder – Refers to a prestressed concrete slab girder, with 
or without voids. Prestressed concrete ribbed section girders and prestressed concrete 
double tee girders shall conform to the requirements specified for prestressed concrete 
slab girders.

Prestressed Concrete Tub Girder – Refers to prestressed concrete tub girders with a U 
shaped cross section, requiring a cast-in-place concrete deck to support traffic loads. 
WSDOT standard girders in this category include Series U**G* or Series UF**G*, where 
U specifies webs without top flanges, UF specifies webs with top flanges, ** specifies the 
girder height in inches, and * specifies the bottom flange width in feet. 

Spliced Prestressed Concrete Girder – Refers to prestressed concrete girders initially 
fabricated in segments which are longitudinally spliced together with cast-in-place 
concrete closures and post tensioning. Post tensioning materials and construction shall 
conform to 

Section 6-02.3(26)

, except that ducts for prestressed concrete wide flange 

I girders may be 24-gage, semi-rigid, galvanized, corrugated, ferrous metal. WSDOT 
prestressed concrete wide flange I girders in this category include Series WF74PTG, 
WF83PTG, WF95PTG, and WF100PTG. WSDOT prestressed concrete tub girders in this 
category include Series U**PTG* and UF**PTG* where U, UF, **, and * are as defined for 
prestressed concrete tub girders.

6-02.3(25)A 

Shop Drawings

Shop drawings for prestressed concrete girders shall be submitted as Type 2 Working 
Drawings. The only deviations to the Plans that will be permitted are those approved by 
the annual plant approval process and those listed below:
1.  Addition of inserts for construction purposes including falsework.
2.  Small penetrations no larger than 1-inch diameter for construction purposes 

including overhang bracket supports, deck formwork hangers and temporary girder 
bracing. Penetrations in top flanges shall be offset from the edge of the flange the 
minimum distance shown in the Plans.

3.  Small penetrations no larger than 2-inch in diameter for girder shipping tie-downs.

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4.  Small adjustments in girder length to account for elastic shortening, creep and 

shrinkage

5.  Strand adjustments, as long as the center of gravity of the strands remains at the 

location shown in the plans and concrete cover is not reduced.

6.  Diaphragm web hole vertical adjustments to avoid harped strands.
7.  Substitution of welded wire reinforcement for conventional reinforcing steel.

Shop drawings shall show the size and location of all inserts and penetrations. 
Penetrations for deck formwork and falsework shall match the deck formwork Working 
Drawings. Field-drilled holes in prestressed concrete girders are not allowed.

Deformed welded wire reinforcement conforming to 

Sections 9-07.7

 and 

9-07.8

 may 

be substituted for the mild steel reinforcement shown in the plans. The substitution 
shall be submitted as a Type 2E Working Drawing. The AASHTO LRFD Bridge Design 
Specification requirements (latest edition including interims) shall be satisfied, including at 
a minimum the following Articles:

5.8.2.6 Types of Transverse Reinforcement
5.8.2.8 Design and Detailing Requirements
5.10.3 Spacing of Reinforcement
5.10.6.3 Ties
5.10.7 Transverse Reinforcement for Flexural Members
5.10.8 Shrinkage and Temperature Reinforcement
5.10.10 Pretensioned Anchorage Zones
5.11.2.5 Welded Wire Fabric
5.11.2.6.3 Anchorage of Wire Fabric Reinforcement
5.11.6 Splices of Welded Wire Fabric

Yield strengths in excess of 75.0 ksi shall not be used for welded wire reinforcement.

The spacing of vertical welded wire reinforcement within slabs and girder webs shall 
not exceed 18 inches or the height of the member minus 3 inches, whichever is less. 
Longitudinal wires and welds are permitted in girder flanges but shall be excluded from 
girder webs. For vertical welded wire reinforcement in prestressed concrete slab girders, 
no welded joints other than those required for anchorage shall be permitted. Epoxy-
coated wire and welded wire reinforcement shall conform to 

Section 9-07.3

 with the 

exception that ASTM A884 Class A Type I shall be used instead of ASTM A775.

Shop drawings for spliced prestressed concrete girders shall also conform to 

Section 

6-02.3(26)A

. The Working Drawings for spliced prestressed concrete girders shall 

include all details related to the post-tensioning operations in the field, including details 
of hardware required, tendon geometry, blockout details, and details of additional or 
modified steel reinforcing bars required in cast-in-place closures.

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6-02

6-02.3(25)B Prestressing

Each stressing system shall have a pressure gauge or load cell that will measure jacking 
force. The gauge shall display pressure accurately and readably with a dial at least 
6 inches in diameter or with a digital display. Each jack and its gauge shall be calibrated 
as a unit and shall be accompanied by a certified calibration chart. The Contractor shall 
submit a Type 1 Working Drawing consisting of one copy of this chart. The cylinder 
extension during calibration shall be in approximately the position it will occupy at final 
jacking force.

Jacks and gauges shall be recalibrated and recertified:
1. Annually,
2.  After any repair or adjustment, and
3.  Anytime there are indications that the jack calibration is in error.

The Engineer may use load cells to check jacks, gauges, and calibration charts before and 
during tensioning.

All load cells shall be calibrated and shall have an indicator that shows prestressing force 
in the strand. The range of this cell shall be broad enough that the lowest 10 percent of 
the manufacturer’s rated capacity will not be used to measure jacking force. 

From manufacture to encasement in concrete, prestressing strand shall be protected 
against dirt, oil, grease, damage, and all corrosives. Strand shall be stored in a dry, covered 
area and shall be kept in the manufacturer’s original packaging until placement in the 
forms. If prestressing strand has been damaged or pitted, it will be rejected. Prestressing 
strand with rust shall be spot-cleaned with a nonmetallic pad to inspect for any sign of 
pitting or section loss. Once the prestressing steel has been installed, no welds or grounds 
for welders shall be made on the forms or the steel in the girder, except as specified.

Post-tensioning of spliced prestressed concrete girders shall conform to 

Section 

6-02.3(26)

 and the following requirements:

1.  Before tensioning, the Contractor shall remove all side forms from the cast-in-place 

concrete closures. From this point until 48 hours after grouting the tendons, the 
Contractor shall keep all construction and other live loads off the Superstructure and 
shall keep the falsework supporting the superstructure in place. 

2.  The Contractor shall not tension the post-tensioning reinforcement until the 

concrete in the cast-in-place closures reaches the minimum compressive strength 
specified in the Plans. This strength shall be measured with concrete cylinders made 
of the same concrete and cured under the same conditions as the cast-in-place 
closures.

3.  All post-tensioning shall be completed before placing the sidewalks and barriers on 

the Superstructure.

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6-02.3(25)C Casting

Side forms shall be steel except that cast-in-place concrete closure forms for spliced 
prestressed concrete girders, interior forms of prestressed concrete tub girders, and 
end bulkhead forms of prestressed concrete girders may be wood. Interior voids for 
prestressed concrete slab girders with voids shall be formed by either wax soaked 
cardboard or expanded polystyrene forms. The interior void forms shall be secured in the 
position as shown in the Working Drawings, and shall remain in place.

All concrete mixes to be used shall be preapproved in the WSDOT plant certification 
process. The temperature of the concrete when placed shall be between 50°F and 90°F.

Slump shall not exceed 4 inches for normal concrete nor 7 inches with the use of a high 
range water-reducing admixture, nor 9 inches when both a high range water-reducing 
admixture is used and the water/cement ratio is less than or equal to 0.35. For self-
consolidating concrete (SCC), the slump requirements specified above do not apply, and 
are instead replaced by the target slump flow and slump flow range specified as part of 
the SCC mix design.

Air-entrainment is not required in the concrete placed into prestressed concrete girders, 
including cast-in-place concrete closures for spliced prestressed concrete girders.

6-02.3(25)C1  Acceptance Testing of Concrete for Prestressed Concrete 

Girders

Compressive strength cylinders and concrete acceptance testing shall be performed 
once per prestressed concrete girder or once per fabrication line of prestressed concrete 
girders. Concrete shall not be placed until fresh concrete testing indicates concrete is 
within acceptable limits.

Acceptance testing shall be performed by the Contractor and test results shall be 
submitted to the Engineer. Unless otherwise noted below, the test methods described 
in 

Section 6-02.3(5)D

 shall be followed. Concrete compressive strength shall be in 

accordance with 

Section 6-02.3(25)E

.

Concrete that is not self-consolidating concrete will be accepted as follows:
1.  Temperature within the allowable temperature band.
2.  Slump below the maximum allowed.

Concrete that is self-consolidating concrete will be accepted as follows:
1.  Temperature within the allowable temperature band.
2.  Slump flow within the target slump flow range
3.  VSI less than or equal to 1 in accordance with ASTM C1611, Appendix X1, using 

Filling Procedure B.

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4.  J ring passing ability less than or equal to 1.5-inches.
5.  Rapid assessment of static segregation resistance of self-consolidating concrete 

using penetration test in accordance with ASTM C1712 shall be less than or equal to 
15 mm.

6-02.3(25)D Curing

During curing, the Contractor shall keep the girder in a saturated curing atmosphere until 
the girder concrete has reached the required release strength. If the Engineer concurs, the 
Contractor may shorten curing time by heating the outside of impervious forms. Heat may 
be radiant, convection, conducted steam, or hot air. With steam, the arrangement shall 
envelop the entire surface with saturated steam. Hot air curing will not be allowed, unless 
the Contractor submits Type 2 Working Drawings consisting of the proposed method to 
envelop and maintain the girder in a saturated atmosphere. Saturated atmosphere means 
a relative humidity of at least 90 percent. The Contractor shall never allow dry heat to 
touch the girder surface at any point.

Under heat curing methods, the Contractor shall:
1.  Keep all unformed girder surfaces in a saturated atmosphere throughout the curing 

time; 

2.  Embed a thermocouple (linked with a thermometer accurate to plus or minus 5°F) 

6 to 8 inches from the top or bottom of the girder on its centerline and near its 
midpoint; 

3.  Monitor with a recording sensor (accurate to plus or minus 5°F) arranged and 

calibrated to continuously record, date, and identify concrete temperature 
throughout the heating cycle;

4.  Make this temperature record available for the Engineer to inspect;
5.  Heat concrete to no more than 100°F during the first 2 hours after placing the 

concrete, and then increase no more than 25°F per hour to a maximum of 175°F;

6.  Cool concrete, after curing is complete, no more than 25°F per hour, to 100°F; and 
7.  Keep the temperature of the concrete above 60°F until the girder reaches release 

strength.

The Contractor may strip side forms from prestressed concrete girders once the concrete 
has reached a minimum compressive strength of 3,000 psi. All damage from stripping is 
the Contractor’s responsibility.

Curing of cast-in-place concrete closures for spliced prestressed concrete girders shall 
conform to 

Section 6-02.3(11)

.

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6-02.3(25)E 

Contractors Control Strength

Concrete strength shall be measured on test cylinders cast from the same concrete as 
that in the girder. These cylinders shall be cured under time-temperature relationships 
and conditions that simulate those of the girder. If the forms are heated by steam or hot 
air, test cylinders will remain in the coolest zone throughout curing. If forms are heated 
another way, the Contractor shall provide a record of the curing time-temperature 
relationship for the cylinders for each girder to the Engineer. When two or more girders 
are cast in a continuous line and in a continuous pour, a single set of test cylinders may 
represent all girders provided the Contractor demonstrates uniformity of casting and 
curing to the satisfaction of the Engineer.

The Contractor shall mold, cure, and test enough of these cylinders to satisfy 
Specification requirements for measuring concrete strength. The Contractor may use 4- 
by 8-inch or 6- by 12-inch cylinders.

Test cylinders may be cured in a moist room or water tank in accordance with FOP for 
AASHTO T 23 after the girder concrete has obtained the required release strength. If, 
however, the Contractor intends to ship the girder prior to the standard 28-day strength 
test, the design strength for shipping shall be determined from cylinders placed with the 
girder and cured under the same conditions as the girder. These cylinders may be placed 
in a noninsulated, moisture-proof envelope.

To measure concrete strength in the girder, the Contractor shall randomly select two test 
cylinders. The average compressive strength of the two cylinders shall be equal or greater 
than the specified strength and neither cylinder shall have a compressive strength that is 
more than 5 percent below the specified strength.

If too few cylinders were molded to carry out all required tests on the girder, the 
Contractor shall remove and test cores from the girder under the surveillance of the 
Engineer. If the Contractor casts cylinders to represent more than one girder, all girders 
in that line shall be cored and tested. Cores shall avoid all prestressing strands, steel 
reinforcing bars and interior voids.

For prestressed concrete slab girders, a test shall consist of four cores measuring 3 inches 
in diameter by 6 inches in length (for slabs) or by the thickness of the web (for ribbed and 
double tee sections). Two cores shall be taken from each side of the girder with one on 
each side of the girder span midpoint, at locations accepted by the Engineer. The core 
locations for prestressed concrete ribbed and double tee sections shall be immediately 
beneath the top flange.

For prestressed concrete tub girders, a test shall consist of four cores measuring 3 inches 
in diameter by the thickness of the web. Two cores shall be taken from each web 
approximately 3 feet to the left and to the right of the center of the girder span. 

Concrete Structures 

6-02

For all other prestressed concrete girders, a test shall consist of three cores measuring 
3 inches in diameter by the thickness of the web and shall be removed from just below 
the top flange; one at the midpoint of the girder’s length and the other two approximately 
3 feet to the left and approximately 3 feet to the right.

The cores shall be taken in accordance with AASHTO T 24 and shall be tested in 
accordance with AASHTO T 22. The Engineer may accept the girder if the average 
compressive strength of the all test cores from the girder are at least 85 percent of 
the specified compressive strength with no one core less than 75 percent of specified 
compressive strength. If there are more than four cored holes in a girder, the prestressing 
reinforcement shall not be released until the holes are patched and the patch 
material has attained a minimum compressive strength equal to the required release 
compressive strength.

All cored holes shall be patched and cured prior to shipment of the girder. The girder shall 
not be shipped until tests show the patch material has attained a minimum compressive 
strength of 4,000 psi.

If the annual plant approval includes procedures for patching cored holes, the cored 
holes shall be patched in accordance with this procedure. Otherwise, the Contractor shall 
submit a core hole patching procedure as a Type 2 Working Drawing.

6-02.3(25)F 

Prestress Release

Side and flange forms that restrain deflection shall be removed before release of the 
prestressing reinforcement.

All strands shall be released in a way that will minimize eccentricity of the prestressing 
force about the centerline of the girder. This release shall not occur until tests show each 
girder has reached the minimum compressive strength required by the Plans.

The Contractor may request permission to release the prestressing reinforcement at a 
minimum concrete compressive strength less than specified in the Plans. This request 
shall be submitted as a Type 2E Working Drawing analyzing changes in vertical deflection, 
girder lateral stability and concrete stresses in accordance with 

Section 6-02.3(25)L2

.

6-02.3(25)G  Protection of Exposed Reinforcement

When a girder is removed from its casting bed, all prestressing reinforcement strands 
projecting from the girder shall be cleaned and painted with a minimum dry film thickness 
of 1 mil of paint conforming to 

Section 9-08.1(2)B

, and all steel reinforcing bars, including 

welded wire fabric, projecting from the girder shall be protected in accordance with 

Section 6-02.3(24)B

. During handling and shipping, projecting reinforcement shall be 

protected from bending or breaking. Just before placing concrete around the painted 
projecting bars or strands, the Contractor shall remove from them all spattered concrete 
remaining from girder casting, dirt, oil, and other foreign matter.

Page 6-104 

Concrete Structures

6-02.3(25)H Finishing

The Contractor shall apply a Class 1 finish, as defined in 

Section 6-02.3(14)

, to:

1.  The exterior surfaces of the outside girders; and
2.  The bottoms, sides, and tops of the lower flanges on all girders, including the top of 

the bottom slab between the tub girder webs.

All other girder surfaces shall receive a Class 2 finish.

The interface on girders that contact a cast-in-place concrete deck shall have a finish 
of dense, screeded concrete without a smooth sheen or laitance on the surface. After 
vibrating and screeding, and just before the concrete reaches initial set, the Contractor 
shall texture the interface. This texture shall be applied with a steel brooming tool that 

etches the surface transversely leaving grooves ⅛ to ¼ inch wide, between ⅛ and ¼ inch 

deep, and spaced ¼ to ½ inch apart.

On prestressed concrete wide flange deck girders, deck bulb tee girders, ribbed section 
girders and double tee girders, the Contractor shall test the top surface for flatness and 
make corrections in accordance with 

Section 6-02.3(10)D3

 except that the straightedge 

need not exceed the width of the girder top flange when checking the transverse 
direction. The top surface shall be finished in accordance with

 Section 6-02.3(10)D6

. 

The Contractor may repair defects in prestressed concrete girders in accordance with 
Section 6-01.16.

6-02.3(25)I 

Fabrication Tolerances

The girders shall be fabricated as shown in the processed shop drawings, and shall meet 
the dimensional tolerances listed below. Construction tolerances of cast-in-place closures 
for spliced prestressed concrete girders shall conform to the tolerances specified for 
spliced prestressed concrete girders. Actual acceptance or rejection will depend on how 
the Engineer believes a defect outside these tolerances will affect the Structure’s strength 
or appearance:
1.  Length:  

± ¼ inch per 25 feet of beam length,  

 

up to a maximum of ± 1½ inches

2. Width:

 

Flanges and webs: 

+ ⅜ inch, - ¼ inch

 

Slab girders: 

± ¼ inch

3.  Girder Depth (overall): 

± ¼ inch

4.  Flange Depth: 

± ¼ inch

5.  Strand Position:
 

Individual strands: 

± ¼ inch 

Bundled strands: 

± ½ inch 

Harped strand group center of  

 gravity at the girder ends: 

± 1 inch

Concrete Structures 

6-02

6.  Longitudinal Location of Harp Points for Harped 
 

Strands from Design Locations: 

± 20 inches

7.  Position of an Interior Void, vertically  

 and horizontally: 

± ½ inch

8.  Bearing Recess (center of recess to girder end):  ± ⅝ inch

9.  Girder Ends (deviation from square or designated skew):

 

Horizontal: 

± ⅛ inch per foot of girder width, 

 

 

up to a maximum of ± ½ inch 

Vertical: 

± 3/16 inch per foot of girder depth, 

 

 

up to a maximum of ± 1 inch

10.  Bearing Area Deviation from Plane  

 (in length or width of bearing): 

± ⅛ inch. 

11.  Stirrup Reinforcing Spacing: 

± 1 inch.

12.  Stirrup Projection from Top of Girder:
 

Wide flange thin deck and slab girders: 

± 

1/2

 inch 

All other girders: 

± ¾ inch

13.  Mild Steel Concrete Cover:  

- ⅛ inch, + ⅜ inch.

14.  Local smoothness of any surface:  

± ¼ inch. in 10 feet

15.  Differential Camber between Girders in a Span (measured in place at the job site):

 

For wide flange deck and deck bulb tee girders with a cast-in-place reinforced 
concrete deck:
 

Cambers shall be equalized when the differences in cambers between 
adjacent girders exceeds ± ¾ inch

 

For wide flange deck, deck bulb tee and slab girders without a cast-in-place 
reinforced deck:
 

Cambers shall be equalized when the differences in cambers between 
adjacent girders exceeds ± ¼ inch

16.  Position of Inserts for Structural Connections:  ± 1 inch. 
17.  Position of Lifting Embedments: 

± 3 inches longitudinal, ± ¼ inch 

transverse.  

18.  Weld Ties: 

± ½ inch longitudinal, ± ⅛ inch 

vertical.

19.  Position of post tensioning ducts in  

 spliced prestressed concrete girders: 

± ¼ inch. 

20.  Deviation from a smooth curve for post-tensioning  

ducts at closures based on the sum total of duct  

placement and alignment tolerances: 

± ⅜ inch.

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Concrete Structures

6-02.3(25)J 

Horizontal Alignment

The Contractor shall check and record the horizontal alignment (sweep) of each girder at 
the following times:
1.  Initial – Upon removal of the girder from the casting bed
2.  Shipment – Within 14 days prior to shipment; and
3.  Erection – After girder erection and cutting temporary top strands but prior to any 

equalization, welding ties or placement of diaphragms.

Horizontal alignment of the top and bottom flanges shall be checked and recorded. 
Alternatively, the Contractor may check and record the horizontal alignment of the web 
near mid-height of the girder. Each check shall be made by measuring the maximum offset 
at mid-span relative to a chord that starts and stops at the girder ends. The Contractor 
shall check and record the alignment at a time when the girder is not influenced by 
temporary differences in surface temperature. Records for the initial check (item 1 above) 
shall be included in the Contractor’s prestressed concrete certificate of compliance. 
Records for all other checks shall be submitted as a Type 1 Working Drawing.

For each check (items 1 to 3 above), the alignment shall not be offset more than ⅛ inch 

for each 10 feet of girder length. Girders not meeting this tolerance for the shipment 
check (item 2 above) shall require an analysis of girder lateral stability and stresses in 
accordance with Section 6-02.3(25)L1. The Contractor shall perform this analysis and 
submit it as a Type 2E Working Drawing prior to shipment of the girder. Any girder that 

exceeds an offset of ⅛ inch for each 10 feet of girder length for the erection check (item 
3 above) shall be corrected at the job site to the ⅛ inch maximum offset per 10 feet of 

girder length before concrete is placed into the diaphragms. The Contractor shall submit a 
Type 2 Working Drawing for any required corrective action.

The maximum distance between the side of a prestressed concrete slab girder, or the 
edge of the top flange of a wide flange deck, wide flange thin deck or deck bulb tee girder, 
and a chord that extends the full length of the girder shall be ± ½ inch after erection (item 
3 above).

6-02.3(25)K 

Vertical Deflection

The Contractor shall check and record the vertical deflection (camber) of each girder at 
the following times:
1.  Initial – Upon removal of the girder from the casting bed; 
2.  Shipment – Within 14 days prior to shipment;
3.  Erection – After girder erection and cutting temporary top strands but prior to any 

equalization, welding ties or placement of diaphragms.

At a minimum, survey data shall be taken at each girder end and at midspan. The 
Contractor shall perform and record each check at a time when the alignment of the 
girder is not influenced by temporary differences in surface temperature. Records for the 
initial check (Item 1 above) shall be included in the Contractor’s Prestressed Concrete 

Concrete Structures 

6-02

Certificate of Compliance. Records for all other checks shall be submitted as a Type 
1 Working Drawing.

Girders with vertical deflections not meeting the limit shown in the Plans for the shipment 
check (item 2 above) shall require an analysis of girder lateral stability and stresses in 
accordance with Section 6-02.3(25)L1. The Contractor shall perform this analysis and 
submit it as a Type 2E Working Drawing prior to shipment.

The “D” dimensions shown in the Plans are computed upper and lower bounds of girder 
vertical deflections at midspan based on a time lapse of 40 and 120 days after release 
of the prestressing strands. Any temporary top strands are assumed to be cut 30 days 
prior to these elapsed times (10 and 90 days after release of the prestressing strands). 
Any diaphragms are assumed to be placed. The “D” dimensions are intended to advise 
the Contractor of the expected range of girder vertical deflection at the time of deck 
placement. A positive (+) “D” dimension indicates upward deflection.

If the girder vertical deflection measured for the erection check (item 3 above) is not 
between the lower “D” dimension bound shown in the Plans and the upper “D” dimension 
bound shown in the Plans plus ¾ inches, the Engineer may require corrective action. The 
Contractor shall submit a Type 2 Working Drawing for any required corrective action.

6-02.3(25)L 

Handling and Storage

During handling and storage, each prestressed concrete girder shall always be kept plumb 
and upright. It shall be lifted only by the lifting embedments (strand lift loops or high-
strength threaded steel bars) at either end. 

For strand lift loops, only ½-inch diameter or 0.6-inch diameter strand conforming to 

Section 9-07.10

 shall be used, and a minimum 2-inch diameter straight pin of a shackle 

shall be used through the loops. Multiple loops shall be held level in the girder during 
casting in a manner that allows each loop to carry its share of the load during lifting. The 
minimum distance from the end of the girder to the centroid of the strand lift loops shall 
be 3 feet. The loops for all prestressed concrete girders, with the exception of prestressed 

concrete slab girders, shall project a minimum of 1′-6″ from the top of the girder. The 

loops for prestressed concrete slab girders shall project a minimum of 4 inches. Loops 
shall extend to within 3 inches clear of the bottom of the girder, terminating with a 9-inch 
long 90-degree hook. Loads on individual loops shall be limited to 12 kips, and all girders 
shall be picked up at a minimum angle of 60 degrees from the top of the girder.

For high-strength threaded steel bars, a minimum of two 1⅜-inch diameter bars 

conforming to 

Section 9-07.11

 shall be used at each end of the girder. The lifting 

hardware that connects to the bars shall be designed, detailed, and furnished by the 
Contractor. The minimum distance from the end of the girder to the centroid of the 
lifting bars shall be 3 feet. Lifting bars shall extend to within 3 inches clear of the bottom 
of the girder and shall be anchored in the bottom flange with steel plates and nuts. The 
minimum size of embedded plates for lifting bars shall be ½ inch thick by 3 inches square. 
Lifting forces on the lifting bars shall not exceed 58 kips on an individual bar, and shall be 
within 10 degrees of perpendicular to the top of the girder.