Standard Specifications for Road, Bridge, and Municipal Construction 2020 (M 41-10) - page 64

Page 6-108 

Concrete Structures

For some girders, straight temporary top flange strands may be specified in the Plans. The 
lifting locations and concrete release strengths shown in the girder schedule in the Plans 
assume that these temporary strands are pretensioned. Alternatively, these temporary 
strands may be post-tensioned provided the strands are stressed on the same day that 
the permanent prestress is released into the girder and the strands are tensioned prior 
to lifting the girder. These temporary strands shall be of the same diameter and shall 
be tensioned to the same force as the permanent strands. The inside diameter of the 
debonding sleeves shall be large enough such that the temporary strands fully retract 
upon cutting. When temporary top strands are specified for spliced prestressed concrete 
girders, the temporary top strands shall be post-tensioned prior to lifting the assembled 
girder. When the post-tensioned alternative is used, the Contractor shall be responsible 
for properly sizing the anchorage plates, and configuring the reinforcement adjacent to 
the anchorage plates, to prevent bursting or splitting of the concrete in the top flange. 
Temporary strands shall be cut or released in accordance with 

Section 6-02.3(25)N

.

If girders are to be stored, the Contractor shall place them on a stable foundation that will 
keep them in a vertical position. Stored girders shall be supported at the bearing recesses 
or, if there are no recesses, approximately 2 to 3 feet from the girder ends. After post-
tensioning, spliced prestressed concrete girders shall be supported at points between 
2 and 5 feet from the girder ends, unless otherwise shown in the Plans. For long-term 
storage of girders with initial horizontal curvature, the Contractor may wedge one side 
of the bottom flange, tilting the girders to control curvature. If the Contractor elects to 
set girders out of plumb during storage, the Contractor shall have the proposed method 
analyzed by the Contractor’s engineer to ensure against damaging the girder.

6-02.3(25)L1  Girder Lateral Stability and Stresses

The Contractor shall be responsible for safely lifting, storing, shipping and erecting 
prestressed concrete girders.

The Contract documents may provide shipping and handling details for girders including 
lifting embedment locations (L), shipping support locations (L

1

 and L

2

), minimum 

shipping support rotational spring constants (K

θ

), minimum shipping support center-

to-center wheel spacings (W

cc

), vertical deflections and number of temporary top 

strands. These shipping and handling details have been determined in accordance with 

Section 6-02.3(25)L2

.

The Contractor shall submit a Type 2E Working Drawing analyzing girder lateral stability 
and concrete stresses during lifting, storage, shipping and erection in accordance with 
Section 6-02.3(25)L2 in the following cases:
1.  Any of the analysis assumptions listed in Section 6-02.3(25)L2 are invalid. 

Determination of validity shall be made by the Contractor, except that analysis 
assumptions shall be considered invalid if the actual values are outside of the 
provided tolerances.

2.  The Contractor intends to alter the shipping and handling details provided in the 

Contract documents.

3.  The Contract documents do not provide shipping and handling details.

Concrete Structures 

6-02

6-02.3(25)L2  Lateral Stability and Stress Analysis

Analysis for girder lateral stability and concrete stresses during lifting, storage, shipping 
and erection shall be in accordance with the PCI Recommended Practice for Lateral Stability 
of Precast, Prestressed Concrete Bridge Girders, First Edition, Publication CB-02-16-E 
and the AASHTO LRFD Bridge Design Specifications edition identified in the Contract 
documents. The following design criteria shall be met:
1.  Factor of Safety against cracking shall be at least 1.0
2.  Factor of Safety against failure shall be at least 1.5
3.  Factor of Safety against rollover shall be at least 1.5
4.  Allowable concrete stresses shall be as specified in 

Section 6-02.3(25)L3

The analysis shall address any effects on girder vertical deflection (camber), “A” 
dimensions at centerline of bearings and deck screed cambers (C).

Shipping and handling details provided in the Contract documents have been determined 
using the following analysis assumptions:
1.  Girder dimensions, strand locations and lifting embedment locations are within the 

tolerances specified in Section 6-02.3(25)I

2.  Girder horizontal alignment (sweep) is within the tolerance specified in Section 

6-02.3(25)J

3.  Girder vertical deflection (camber) at midspan is less than or equal to the value 

shown in the Plans for shipping

4.  Minimum concrete compressive strength at release (f’ci) has been reached before 

initial lifting from casting bed. Minimum concrete compressive strength at 28 days 
(f’c) has been reached before shipping.

5.  Height of girder bottom above roadway at shipping supports is less than or equal to 

72 inches

6.  Height of shipping support roll center above roadway is 24 inches, ± 2 inches
7.  Shipping support longitudinal placement (L

1

 and L

2

) tolerance is ± 6 inches

8.  Shipping support lateral placement tolerance is ±1 inches
9.  Shipping supports provide the minimum shipping support rotational spring constant 

(K

θ

) and minimum shipping support center-to-center wheel spacings (W

cc

) shown in 

the Plans

10.  For shipping at highway speeds a ±20 percent dynamic load allowance (impact) is 

included with a typical roadway superelevation of 2 percent

11.  For turning at slow speeds, no dynamic load allowance (impact) is included with a 

maximum roadway superelevation of 6 percent

12.  Wind, centrifugal and seismic forces are not considered

Page 6-110 

Concrete Structures

6-02.3(25)L3  Allowable Stresses

Prestressed concrete girder stresses shall be limited to the following values at all stages 
of construction and in service:

Condition

Stress

Location

Allowable Stress 

(ksi)

Temporary 

Stress at 

Transfer and 

Lifting from 

Casting Bed

Tensile

In areas without bonded reinforcement sufficient 

to resist the tensile force in the concrete

6-02.3(25)L3 Allowable Stresses

Prestressed concrete girder stresses shall be limited to the following values at all 

stages of construction and in service:

Condition

Stress

Location

Allowable Stress (ksi)

Temporary 

Stress at 

Transfer and 

Lifting from 

Casting Bed

Tensile

In areas without bonded 

reinforcement sufficient to resist the 

tensile force in the concrete

0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

≤ 0.2

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete

0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

Compressive All locations

0.65𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

Temporary 

Stress at 

Shipping and 

Erection

Tensile

In areas without bonded 

reinforcement sufficient to resist the 

tensile force in the concrete

0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

≤ 0.2

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete

0.19𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete when shipping at 6%

superelevation, without impact

0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Compressive All locations

0.65𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Final 

Stresses at 

Service Load

Tensile

Precompressed tensile zone

0.0

Compressive

Effective prestress and permanent 

loads

0.45𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Effective prestress, permanent loads 

and transient (live) loads

0.60𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Final 

Stresses at 

Fatigue Load

Compressive

Fatigue I Load Combination plus 

one-half effective prestress and 

permanent loads

0.40𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Variables are as defined in the AASHTO LRFD Bridge Design Specifications.

In areas with bonded reinforcement sufficient to 

resist the tensile force in the concrete

6-02.3(25)L3 Allowable Stresses

Prestressed concrete girder stresses shall be limited to the following values at all 

stages of construction and in service:

Condition

Stress

Location

Allowable Stress (ksi)

Temporary 

Stress at 

Transfer and 

Lifting from 

Casting Bed

Tensile

In areas without bonded 

reinforcement sufficient to resist the 

tensile force in the concrete

0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

≤ 0.2

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete

0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

Compressive All locations

0.65𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

Temporary 

Stress at 

Shipping and 

Erection

Tensile

In areas without bonded 

reinforcement sufficient to resist the 

tensile force in the concrete

0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

≤ 0.2

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete

0.19𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete when shipping at 6%

superelevation, without impact

0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Compressive All locations

0.65𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Final 

Stresses at 

Service Load

Tensile

Precompressed tensile zone

0.0

Compressive

Effective prestress and permanent 

loads

0.45𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Effective prestress, permanent loads 

and transient (live) loads

0.60𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Final 

Stresses at 

Fatigue Load

Compressive

Fatigue I Load Combination plus 

one-half effective prestress and 

permanent loads

0.40𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Variables are as defined in the AASHTO LRFD Bridge Design Specifications.

Compressive All locations

6-02.3(25)L3 Allowable Stresses

Prestressed concrete girder stresses shall be limited to the following values at all 

stages of construction and in service:

Condition

Stress

Location

Allowable Stress (ksi)

Temporary 

Stress at 

Transfer and 

Lifting from 

Casting Bed

Tensile

In areas without bonded 

reinforcement sufficient to resist the 

tensile force in the concrete

0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

≤ 0.2

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete

0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

Compressive All locations

0.65𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

Temporary 

Stress at 

Shipping and 

Erection

Tensile

In areas without bonded 

reinforcement sufficient to resist the 

tensile force in the concrete

0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

≤ 0.2

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete

0.19𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete when shipping at 6%

superelevation, without impact

0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Compressive All locations

0.65𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Final 

Stresses at 

Service Load

Tensile

Precompressed tensile zone

0.0

Compressive

Effective prestress and permanent 

loads

0.45𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Effective prestress, permanent loads 

and transient (live) loads

0.60𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Final 

Stresses at 

Fatigue Load

Compressive

Fatigue I Load Combination plus 

one-half effective prestress and 

permanent loads

0.40𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Variables are as defined in the AASHTO LRFD Bridge Design Specifications.

Temporary 

Stress at 

Shipping and 

Erection

Tensile

In areas without bonded reinforcement sufficient 

to resist the tensile force in the concrete

6-02.3(25)L3 Allowable Stresses

Prestressed concrete girder stresses shall be limited to the following values at all 

stages of construction and in service:

Condition

Stress

Location

Allowable Stress (ksi)

Temporary 

Stress at 

Transfer and 

Lifting from 

Casting Bed

Tensile

In areas without bonded 

reinforcement sufficient to resist the 

tensile force in the concrete

0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

≤ 0.2

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete

0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

Compressive All locations

0.65𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

Temporary 

Stress at 

Shipping and 

Erection

Tensile

In areas without bonded 

reinforcement sufficient to resist the 

tensile force in the concrete

0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

≤ 0.2

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete

0.19𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete when shipping at 6%

superelevation, without impact

0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Compressive All locations

0.65𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Final 

Stresses at 

Service Load

Tensile

Precompressed tensile zone

0.0

Compressive

Effective prestress and permanent 

loads

0.45𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Effective prestress, permanent loads 

and transient (live) loads

0.60𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Final 

Stresses at 

Fatigue Load

Compressive

Fatigue I Load Combination plus 

one-half effective prestress and 

permanent loads

0.40𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Variables are as defined in the AASHTO LRFD Bridge Design Specifications.

In areas with bonded reinforcement sufficient to 

resist the tensile force in the concrete

6-02.3(25)L3 Allowable Stresses

Prestressed concrete girder stresses shall be limited to the following values at all 

stages of construction and in service:

Condition

Stress

Location

Allowable Stress (ksi)

Temporary 

Stress at 

Transfer and 

Lifting from 

Casting Bed

Tensile

In areas without bonded 

reinforcement sufficient to resist the 

tensile force in the concrete

0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

≤ 0.2

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete

0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

Compressive All locations

0.65𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

Temporary 

Stress at 

Shipping and 

Erection

Tensile

In areas without bonded 

reinforcement sufficient to resist the 

tensile force in the concrete

0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

≤ 0.2

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete

0.19𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete when shipping at 6%

superelevation, without impact

0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Compressive All locations

0.65𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Final 

Stresses at 

Service Load

Tensile

Precompressed tensile zone

0.0

Compressive

Effective prestress and permanent 

loads

0.45𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Effective prestress, permanent loads 

and transient (live) loads

0.60𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Final 

Stresses at 

Fatigue Load

Compressive

Fatigue I Load Combination plus 

one-half effective prestress and 

permanent loads

0.40𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Variables are as defined in the AASHTO LRFD Bridge Design Specifications.

In areas with bonded reinforcement sufficient 

to resist the tensile force in the concrete when 

shipping at 6% superelevation, without impact

6-02.3(25)L3 Allowable Stresses

Prestressed concrete girder stresses shall be limited to the following values at all 

stages of construction and in service:

Condition

Stress

Location

Allowable Stress (ksi)

Temporary 

Stress at 

Transfer and 

Lifting from 

Casting Bed

Tensile

In areas without bonded 

reinforcement sufficient to resist the 

tensile force in the concrete

0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

≤ 0.2

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete

0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

Compressive All locations

0.65𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

Temporary 

Stress at 

Shipping and 

Erection

Tensile

In areas without bonded 

reinforcement sufficient to resist the 

tensile force in the concrete

0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

≤ 0.2

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete

0.19𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete when shipping at 6%

superelevation, without impact

0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Compressive All locations

0.65𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Final 

Stresses at 

Service Load

Tensile

Precompressed tensile zone

0.0

Compressive

Effective prestress and permanent 

loads

0.45𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Effective prestress, permanent loads 

and transient (live) loads

0.60𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Final 

Stresses at 

Fatigue Load

Compressive

Fatigue I Load Combination plus 

one-half effective prestress and 

permanent loads

0.40𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Variables are as defined in the AASHTO LRFD Bridge Design Specifications.

Compressive All locations

6-02.3(25)L3 Allowable Stresses

Prestressed concrete girder stresses shall be limited to the following values at all 

stages of construction and in service:

Condition

Stress

Location

Allowable Stress (ksi)

Temporary 

Stress at 

Transfer and 

Lifting from 

Casting Bed

Tensile

In areas without bonded 

reinforcement sufficient to resist the 

tensile force in the concrete

0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

≤ 0.2

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete

0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

Compressive All locations

0.65𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

Temporary 

Stress at 

Shipping and 

Erection

Tensile

In areas without bonded 

reinforcement sufficient to resist the 

tensile force in the concrete

0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

≤ 0.2

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete

0.19𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete when shipping at 6%

superelevation, without impact

0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Compressive All locations

0.65𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Final 

Stresses at 

Service Load

Tensile

Precompressed tensile zone

0.0

Compressive

Effective prestress and permanent 

loads

0.45𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Effective prestress, permanent loads 

and transient (live) loads

0.60𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Final 

Stresses at 

Fatigue Load

Compressive

Fatigue I Load Combination plus 

one-half effective prestress and 

permanent loads

0.40𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Variables are as defined in the AASHTO LRFD Bridge Design Specifications.

Final Stresses 

at Service 

Load

Tensile

Precompressed tensile zone

6-02.3(25)L3 Allowable Stresses

Prestressed concrete girder stresses shall be limited to the following values at all 

stages of construction and in service:

Condition

Stress

Location

Allowable Stress (ksi)

Temporary 

Stress at 

Transfer and 

Lifting from 

Casting Bed

Tensile

In areas without bonded 

reinforcement sufficient to resist the 

tensile force in the concrete

0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

≤ 0.2

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete

0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

Compressive All locations

0.65𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

Temporary 

Stress at 

Shipping and 

Erection

Tensile

In areas without bonded 

reinforcement sufficient to resist the 

tensile force in the concrete

0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

≤ 0.2

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete

0.19𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete when shipping at 6%

superelevation, without impact

0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Compressive All locations

0.65𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Final 

Stresses at 

Service Load

Tensile

Precompressed tensile zone

0.0

Compressive

Effective prestress and permanent 

loads

0.45𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Effective prestress, permanent loads 

and transient (live) loads

0.60𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Final 

Stresses at 

Fatigue Load

Compressive

Fatigue I Load Combination plus 

one-half effective prestress and 

permanent loads

0.40𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Variables are as defined in the AASHTO LRFD Bridge Design Specifications.

Compressive

Effective prestress and permanent loads

6-02.3(25)L3 Allowable Stresses

Prestressed concrete girder stresses shall be limited to the following values at all 

stages of construction and in service:

Condition

Stress

Location

Allowable Stress (ksi)

Temporary 

Stress at 

Transfer and 

Lifting from 

Casting Bed

Tensile

In areas without bonded 

reinforcement sufficient to resist the 

tensile force in the concrete

0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

≤ 0.2

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete

0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

Compressive All locations

0.65𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

Temporary 

Stress at 

Shipping and 

Erection

Tensile

In areas without bonded 

reinforcement sufficient to resist the 

tensile force in the concrete

0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

≤ 0.2

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete

0.19𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete when shipping at 6%

superelevation, without impact

0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Compressive All locations

0.65𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Final 

Stresses at 

Service Load

Tensile

Precompressed tensile zone

0.0

Compressive

Effective prestress and permanent 

loads

0.45𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Effective prestress, permanent loads 

and transient (live) loads

0.60𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Final 

Stresses at 

Fatigue Load

Compressive

Fatigue I Load Combination plus 

one-half effective prestress and 

permanent loads

0.40𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Variables are as defined in the AASHTO LRFD Bridge Design Specifications.

Effective prestress, permanent loads and 

transient (live) loads

6-02.3(25)L3 Allowable Stresses

Prestressed concrete girder stresses shall be limited to the following values at all 

stages of construction and in service:

Condition

Stress

Location

Allowable Stress (ksi)

Temporary 

Stress at 

Transfer and 

Lifting from 

Casting Bed

Tensile

In areas without bonded 

reinforcement sufficient to resist the 

tensile force in the concrete

0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

≤ 0.2

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete

0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

Compressive All locations

0.65𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

Temporary 

Stress at 

Shipping and 

Erection

Tensile

In areas without bonded 

reinforcement sufficient to resist the 

tensile force in the concrete

0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

≤ 0.2

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete

0.19𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete when shipping at 6%

superelevation, without impact

0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Compressive All locations

0.65𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Final 

Stresses at 

Service Load

Tensile

Precompressed tensile zone

0.0

Compressive

Effective prestress and permanent 

loads

0.45𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Effective prestress, permanent loads 

and transient (live) loads

0.60𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Final 

Stresses at 

Fatigue Load

Compressive

Fatigue I Load Combination plus 

one-half effective prestress and 

permanent loads

0.40𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Variables are as defined in the AASHTO LRFD Bridge Design Specifications.

Final Stresses 

at Fatigue 

Load

Compressive Fatigue I Load Combination plus one-half 

effective prestress and permanent loads

6-02.3(25)L3 Allowable Stresses

Prestressed concrete girder stresses shall be limited to the following values at all 

stages of construction and in service:

Condition

Stress

Location

Allowable Stress (ksi)

Temporary 

Stress at 

Transfer and 

Lifting from 

Casting Bed

Tensile

In areas without bonded 

reinforcement sufficient to resist the 

tensile force in the concrete

0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

≤ 0.2

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete

0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

Compressive All locations

0.65𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐𝑐𝑐𝑐𝑐

′

Temporary 

Stress at 

Shipping and 

Erection

Tensile

In areas without bonded 

reinforcement sufficient to resist the 

tensile force in the concrete

0.0948𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

≤ 0.2

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete

0.19𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

In areas with bonded reinforcement 

sufficient to resist the tensile force in 

the concrete when shipping at 6%

superelevation, without impact

0.24𝜆𝜆𝜆𝜆�𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Compressive All locations

0.65𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Final 

Stresses at 

Service Load

Tensile

Precompressed tensile zone

0.0

Compressive

Effective prestress and permanent 

loads

0.45𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Effective prestress, permanent loads 

and transient (live) loads

0.60𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Final 

Stresses at 

Fatigue Load

Compressive

Fatigue I Load Combination plus 

one-half effective prestress and 

permanent loads

0.40𝑓𝑓𝑓𝑓

𝑐𝑐𝑐𝑐

′

Variables are as defined in the AASHTO LRFD Bridge Design Specifications.

Variables are as defined in the AASHTO LRFD Bridge Design Specifications.

6-02.3(25)M Shipping

After the girder has reached its 28-day design strength, the girder and a completed 
Certification of Compliance, signed by a Precast/Prestressed Concrete Institute Certified 
Technician or a Professional Engineer, shall be submitted to the Engineer for inspection. 
If the Engineer finds the certification and the girder to be acceptable, the Engineer will 
stamp the girder “Approved for Shipment”.

No prestressed concrete slab girder shall be shipped for at least 3 days after concrete 
placement. No prestressed concrete wide flange deck, deck bulb tee or tub girder shall 
be shipped for at least 7 days after concrete placement, except that they may be shipped 
3 days after concrete placement when L/(bd) is less than or equal to 5.0, where L equals 
the shipping length of the girder, b equals the girder top flange width (for prestressed 
concrete wide flange deck and deck bulb tee girders) or the bottom flange width (for 
prestressed concrete tub girders), and d equals the girder depth, all in feet. No other 
girder shall be shipped for at least 10 days after concrete placement. 

Concrete Structures 

6-02

Girder support locations during shipping shall be no closer than the girder depth to the 
ends of the girder at the girder centerline.

Girder lateral stability and stresses during shipping shall be in accordance with Section  
6-02.3(25)L1.

If the Contractor elects to assemble spliced prestressed concrete girders into shipping 
configurations not shown in the Contract documents, the Contractor shall submit a Type 
2E Working Drawing analyzing girder lateral stability and concrete stresses in accordance 
with 

Section 6-02.3(25)L2

 before shipping.

6-02.3(25)N  Prestressed Concrete Girder Erection

Before erecting any prestressed concrete girders, the Contractor shall submit an erection 
plan as a Type 2E Working Drawing. The erection plan shall conform Section 6-02.3(25)
L1. The erection plan shall provide complete details of the erection process including at a 
minimum:
1.  Temporary falsework support, bracing, guys, deadmen, and attachments to other 

Structure components or objects;

2.  Procedure and sequence of operation;
3.  Girder stresses during progressive stages of erection;
4.  Girder weights, lift points, lifting embedments and devices, spreaders, and angle of 

lifting cables in accordance with 

Section 6-02.3(25)L

, etc.;

5.  Crane(s) make and model, mass, geometry, lift capacity, outrigger size, and reactions;
6.  Girder launcher or trolley details and capacity (if intended for use); and
7.  Locations of cranes, barges, trucks delivering girders, and the location of cranes and 

outriggers relative to other Structures, including retaining walls and wing walls.

The erection plan shall include drawings, notes, catalog cuts, and calculations clearly 
showing the above listed details, assumptions, and dimensions. Material properties and 
Specifications, structural analysis, and any other data used shall also be included.

The concrete in piers and crossbeams shall reach at least 80 percent of design strength 
before girders are placed on them.

The Contractor shall hoist girders only by the lifting embedments at the ends, always 
keeping the girders plumb and upright. When the girders are to receive a cast-in-place 
concrete deck, lifting embedments shall be removed after erection to provide a minimum 
2½-inch clearance to the top of the deck. When the girders are not to receive a cast-in-
place concrete deck, lifting embedments shall be removed 1-inch below the girder surface 
and grouted with an epoxy grout conforming to 

Section 9-26.3(1)A

.

Page 6-112 

Concrete Structures

The girders shall be braced in accordance with 

Sections 6-02.3(17)F4

 and 

6-02.3(17)F5

. 

When temporary strands in the top flange are used, they shall be cut after the girders 
are braced and before girder deflections are equalized and the intermediate diaphragms 
are cast.

Instead of the oak block wedges shown in the Plans, the Contractor may use Douglas fir 
blocks if the grain is vertical. The height of oak block wedges at the girder centerline shall 
not exceed the width.

The Contractor shall fill all block-out holes with a mortar or grout acceptable to the 
Engineer.

Stop plates and dowel bars for prestressed concrete girders shall be set with either 
epoxy grout conforming to 

Section 9-26.3

 or type IV epoxy bonding agent conforming to 

Section 9-26.1

.

6-02.3(25)O  Girder to Girder Connections

When differential camber between adjacent girders in a span exceeds the tolerance 
in 

Section 6-02.3(25)I

, the Contractor shall submit a method of equalizing deflections 

as a Type 1 Working Drawing. Any temporary strands in the top flange shall be cut in 
accordance with 

Section 6-02.3(25)N

 prior to equalizing girder deflections.

Prestressed concrete girders shall be constructed in the following sequence:
1.  If required, deflections shall be equalized in accordance with the Contractor’s 

equalization plan.

2.  Any intermediate diaphragms shall be placed and any weld ties shall be welded in 

accordance with 

Section 6-03.3(25)

. Welding ground shall be attached directly to the 

steel plates being welded when welding the weld-ties.

3.  Any keyways between adjacent girders shown in the Plans to receive grout 

shall be filled flush with the surrounding surfaces using a grout conforming to 

Section 9-20.3(2)

.

4.  Equalization equipment shall not be removed and other construction equipment shall 

not be placed on the structure until intermediate diaphragms and keyway grout have 
attained a minimum compressive strength of 2,500 psi.

6-02.3(26)  Cast-In-Place Prestressed Concrete

Unless otherwise shown in the Plans, concrete for cast-in-place prestressed bridge 
members shall be Class 4000D in the bridge deck, and Class 4000 at all other locations. 
Air entrainment shall conform to Sections 

6-02.3(2)A

 and 

6-02.3(3)

.

The Contractor shall construct supporting falsework in a way that leaves the 
Superstructure free to contract and lift off the falsework during post-tensioning. Forms 
that will remain inside box girders to support the bridge deck shall, by design, resist girder 
contraction as little as possible.

Concrete Structures 

6-02

Before tensioning, the Contractor shall remove all side forms from girders. 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.

Once the prestressing steel is installed, no welds or welding grounds shall be attached to 
metal forms, structural steel, or reinforcing bars of the structural member.

The Contractor shall not stress the strands until all concrete has reached a compressive 
strength of at least 4,000 psi (or the strength shown in the Plans). This strength shall be 
measured on concrete test cylinders made of the same concrete cured under the same 
conditions as the cast-in-place unit.

All post-tensioning shall be completed before sidewalks and barriers are placed.

6-02.3(26)A 

Shop Drawings

Before casting the structural elements, the Contractor shall submit Type 2E Working 
Drawings of the prestressing system shop drawings.

These shop drawings shall show complete details of the methods, materials, and 
equipment the Contractor proposes to use in prestressing Work. The shop drawings 
shall follow the design conditions shown in the Plans unless the Engineer permits equally 
effective variations.

In addition, the shop drawings shall show:
1.  The method and sequence of stressing.
2.  Technical data on tendons and steel reinforcement, anchorage devices, anchorage 

device efficiency and acceptance test results and records, anchoring stresses, types 
of tendon conduit, and all other data on prestressing operations.

3.  Stress and elongation calculations. Separate stress and elongation calculations 

shall be submitted for each tendon if the difference in tendon elongations exceeds 
2 percent.

4.  That tendons in the bridge will be arranged to locate their center of gravity as the 

Plans require.

5.  Details of additional or modified reinforcing steel required by the stressing system.
6.  Procedures and lift-off forces at both ends of the tendon for performing a force 

verification lift-off in the event of discrepancies between measured and calculated 
elongations.

Couplings or splices will not be permitted in prestressing strands. Couplings or splices in 
bar tendons are subject to the Engineer’s acceptance.

Page 6-114 

Concrete Structures

Friction losses used to calculate forces of the post-tensioning steel shall be based on 

the assumed values used for the design. The assumed anchor set, friction coefficient “μ”, 

and friction wobble coefficient “k” values for design are shown in the Plans. The post-
tensioning supplier may revise the assumed anchor set value provided all the stress and 
force limits listed in 

Section 6-02.3(26)G

 are met.

The Contractor shall determine all points of interference between the mild steel 
reinforcement and the paths of the post-tensioning tendons. Details to resolve 
interferences shall be submitted with the shop drawings for approval. Where reinforcing 
bar placement conflicts with post-tensioning tendon placement, the tendon profile shown 
in the Plans shall be maintained.

The Contractor may deviate from the processed shop drawings only after submitting a 
new Type 2E Working Drawing that describes the proposed changes. 

Before physical completion of the project, the Contractor shall provide the Engineer with 
reproducible originals of the shop drawings (and any processed changes). These shall be 
clear, suitable for microfilming, and on permanent sheets that measure no smaller than 
11 by 17 inches. Alternatively, the shop drawings may be provided in an electronic format 
with the concurrence of the Bridge and Structures Engineer.

6-02.3(26)B 

General Requirements for Anchorages

Post-tensioning reinforcement shall be secured at each end by means of an accepted 
anchorage device, which shall not kink, neck down, or otherwise damage the post-
tensioning reinforcement. The anchorage assembly shall be grouted to the Engineer’s 
satisfaction.

The structure shall be reinforced with steel reinforcing bars in the anchorage zone in 
the vicinity of the anchorage device. This reinforcement shall be categorized into two 
zones. The first or local zone shall be the concrete surrounding and immediately ahead 
of the anchorage device. The second or general zone shall be the overall anchorage zone, 
including the local zone.

The steel reinforcing bars required for concrete confinement in the local zone shall 
be determined by the post-tensioning system supplier and shall be shown in the shop 
drawings. The calculations shall be submitted with the shop drawings. The local zone steel 
reinforcing bars shall be furnished and installed by the Contractor, at no additional cost to 
the Contracting Agency, in addition to the structural reinforcement required by the Plans. 
The steel reinforcing bars required in the general zone shall be as shown in the Plans and 
are included in the appropriate Bid items.

The Contractor shall submit Type 2E Working Drawings consisting of details, certified 
test reports, and/or supporting calculations, as specified below, which verify the 
structural adequacy of the anchorage devices. This requirement does not apply where 
the anchorage devices have been previously accepted by the Contracting Agency for the 
same Structure configuration. The Contractor shall also submit any necessary changes to 
the Contract Plans. The test report shall specify all pertinent test data.

Concrete Structures 

6-02

Dead ended anchorages will not be permitted. Dead ended anchorages are defined as 
anchorages that cannot be accessed during the stressing operations.

Materials and workmanship shall conform to the applicable requirements of Sections 

6-03

 

and 

9-06

.

Before installing the anchorage device, the Contractor shall submit a Manufacturer’s 
Certificate of Compliance.

Anchorage devices shall meet the requirements listed in either Sections 

6-02.3(26)C

 or 

6-02.3(26)D

.

All anchorages shall develop at least 96 percent of the actual ultimate strength of the 
prestressing steel, when tested in an unbonded state, without exceeding anticipated 
set. This anchor efficiency test shall be performed, or inspected and certified, by an 
independent testing agency accepted by the Engineer.

6-02.3(26)C 

Normal Anchorage Devices

Normal anchorage devices, defined as post-tensioning anchorage assemblies conforming 
to the factored bearing resistance requirements specified in this section, shall provide a 
factored bearing resistance greater than or equal to 1.2 times the maximum jacking force. 
The Contractor shall submit Type 2E Working Drawings consisting of calculations showing 
that the factored bearing resistances of the anchorage devices are not exceeded.

The factored bearing resistance of the anchorages shall be taken as:

P

r

 = φf

n

A

b

For which f

n

 is the lesser of:

(

)( )( )

c

'

f

Q

UP

fc

c

'

f

2

−

(

)( )( )

c

f

Q

UP

cores

f

c

f

'

'

85

.

56

.

3

−

cm

'

f

ci

n

g

ci

n

f

2.25

f

and

,

A

A

f

0.7

f

′

=

′

=

Where:

φ 

=  Resistance factor of 0.70

A 

=  Maximum area of the portion of the supporting surface that is similar to the loaded 

area and concentric with it and does not overlap similar areas for adjacent anchorage 

devices (square inches)

A

b

 

=  Effective net area of the bearing plate calculated as the area A

g

, minus the area of 

openings in the bearing plate (square inches)

A

g

 

=  Gross bearing area of the bearing plate calculated in accordance with the 

requirements specified below (square inches)

f’

ci

 

=  Nominal compressive strength of concrete at the time of application of the tendon 

force (ksi)

Page 6-116 

Concrete Structures

The full bearing plate area may be used for A

g

 and the calculation of A

b

 if the plate 

material does not yield at the factored tendon force and the slenderness of the bearing 
plate, n/t, conforms to:

(n/t) ≤ 0.08(E

b

/f

b

)

0.33

Where:

E

b

 

=  Modulus of elasticity of the bearing plate material (ksi)

f

b

 

=  Stress in the anchor plate at a section taken at the edge of the wedge hole or holes 

(ksi)

 

=  Projection of the base plate beyond the wedge hole or wedge plate, as appropriate 

(inches)

t 

=  average thickness of the bearing plate (inches)

For anchorages with separate wedge plates, n may be taken as the largest distance from 
the outer edge of the wedge plate to the outer edge of the bearing plate. For rectangular 
bearing plates, this distance shall be measured parallel to the edges of the bearing plate. If 
the anchorage has no separate wedge plate, n may be taken as the projection beyond the 
outer perimeter of the group of holes in the direction under consideration.

For bearing plates that do not meet the slenderness requirement specified above, the 
effective gross bearing area, A

g

, shall be taken as:

1.  For anchorages with separate wedge plates, the area geometrically similar to the 

wedge plate, with dimensions increased by twice the bearing plate thickness.

2.  For anchorages without separate wedge plates, the area geometrically similar to the 

outer perimeter of the wedge holes, with dimensions increased by twice the bearing 
plate thickness.

6-02.3(26)D  Special Anchorage Devices

Special anchorage devices, defined as post-tensioning anchorage assemblies that do not 
conform to the factored bearing pressure requirements specified in 

Section 6-02.3(26)C

, 

shall conform to the acceptance test requirements specified below. Acceptance testing 
shall be performed, or inspected and certified, by an independent testing agency accepted 
by the Engineer. Results of the special anchorage device acceptance testing shall be 
recorded and submitted as a Type 1 Working Drawing.

6-02.3(26)D1  Test Block Requirements

The test block shall be a rectangular prism of sufficient size to contain all the special 
anchorage device components that will also be embedded in the concrete of the Structure 
being post-tensioned. The arrangement of the special anchorage device components 
shall conform to practical application to the project and the special anchorage device 
manufacturer’s recommendations. The test block shall contain an empty duct of a size 
appropriate for the maximum tendon size that can be accommodated by the special 
anchorage device.

Concrete Structures 

6-02

6-02.3(26)D2  Test Block Dimensions

The dimensions of the test block perpendicular to the tendon in each direction shall be 
the smaller of twice the minimum edge distance or the minimum spacing specified by the 
special anchorage device manufacturer, with the stipulation that the concrete cover over 
any confining reinforcing steel or supplementary skin reinforcement shall be appropriate 
for the project-specific application and circumstances. The length of the block along the 
axis of the tendon shall be at least two times the larger of the cross-section dimensions.

6-02.3(26)D3  Local Zone Reinforcement for Confinement

The confining reinforcing steel in the local zone of the test block shall be the same as that 
recommended by the special anchorage device manufacturer.

6-02.3(26)D4  Supplementary Skin Reinforcement

In addition to the special anchorage device and the associated local zone reinforcement 
for confinement, supplementary skin reinforcement may be provided throughout the 
test block. Such supplementary skin reinforcement shall be as specified by the special 
anchorage device manufacturer, but shall not exceed a volumetric ratio of 0.01.

The Contractor shall furnish and install supplementary skin reinforcement in the 
anchorage zone of the Structure similar in configuration and equivalent in volumetric ratio 
to the supplementary skin reinforcement used in the test block at no additional cost to 
the Contracting Agency. The steel reinforcing bars shown in the Plans in corresponding 
portions of the general zone may be counted toward this reinforcement requirement.

6-02.3(26)D5  Test Block Concrete Strength

The compressive strength of the test block at the time of acceptance testing shall not 
exceed the compressive strength of the Structure being post-tensioned at the time of 
post-tensioning.

6-02.3(26)D6  Special Anchorage Device Acceptance Testing

Special anchorage device acceptance testing shall be conducted in accordance with one 
of the following test methods:
1.  Cyclic load test.
2.  Sustained load test.
3.  Monotonic load test.

The loads specified for the tests are specified in fractions of the ultimate load F

pu

 of 

the largest tendon that the special anchorage device is designed to accommodate. The 
specimen shall be loaded in accordance with conventional usage of the device in post-
tensioning applications, except that the load may be applied directly to the wedge plate or 
equivalent area.

Page 6-118 

Concrete Structures

6-02.3(26)D7  Cyclic Loading Test

A load of 0.8F

pu

 shall be applied. The load shall then be cycled between 0.1F

pu

 and 0.8F

pu

 

until crack widths stabilize, but for not less than ten cycles. Crack widths are considered 
stabilized if they do not change by more than 0.001 inches over the last three readings. 
Upon completion of the cyclic loading portion of the test, the specimen shall be loaded to 
failure, or, if limited by the capacity of the loading equipment, to at least 1.1F

pu

.

Crack widths and crack patterns shall be recorded at the initial load of 0.8F

pu

, at least at 

the last three consecutive peak loadings before termination of the cyclic loading portion 
of the test, and at 0.9F

pu

. The maximum load shall also be reported.

6-02.3(26)D8  Sustained Loading Test

A load of 0.8F

pu

 shall be applied and held constant until crack widths stabilize, but not 

less than 48 hours. Crack widths are considered stabilized if they do not change by more 
than 0.001 inches over the last three readings. Upon completion of the sustained loading 
portion of the test, the specimen shall be loaded to failure, or, if limited by the capacity of 
the loading equipment, to at least 1.1F

pu

.

Crack widths and crack patterns shall be recorded at the initial load of 0.8F

pu

, at least 

three times at intervals of not less than 4 hours during the last 12 hours of the sustained 
loading time period, and at 0.9F

pu

. The maximum load shall also be reported.

6-02.3(26)D9  Monotonic Loading Test

A load of 0.9F

pu

 shall be applied and held constant for 1 hour. Upon completion of the 

1-hour load hold period, the specimen shall be loaded to failure, or, if limited by the 
capacity of the loading equipment, to at least 1.2F

pu

.

Crack widths and crack patterns shall be recorded at 0.9F

pu

, at the conclusion of the 

1-hour load hold period, and at 1.0F

pu

. The maximum load shall also be reported.

6-02.3(26)D10 Special Anchorage Device Test Performance Requirements

The test block shall conform to the following load requirements under test load:
1.  The maximum test load for cyclic loading and sustained loading tests shall be 1.1F

pu

 

minimum.

2.  The maximum test load for monotonic loading tests shall be 1.2F

pu

 minimum.

The test block shall conform to the following crack width requirements under test load:
1.  Cracks shall not exceed 0.010 inches in width at 0.8F

pu

 at completion of the cyclic 

loading test or sustained loading test, or at 0.9F

pu

 after the 1-hour load hold period 

of the monotonic loading test.

2.  Cracks shall not exceed 0.016 inches at 0.9F

pu

 for the cyclic loading test or the 

sustained loading test, or at 1.0F

pu

 for the monotonic loading test.

Concrete Structures 

6-02

6-02.3(26)D11 Test Series Requirements

A test series shall consist of three test specimens. Each one of the tested specimens 
shall conform to the acceptance criteria specified above. If one of the three specimens 
fails to pass the test, a supplementary test series of three additional specimens shall 
be conducted. The three additional test specimens shall conform to the specified 
acceptance criteria.

6-02.3(26)D12  Special Anchorage Device Acceptance Testing Results 

Report

The special anchorage device acceptance testing results report shall be a Type 1 Working 
Drawing consisting of the following:
1.  Dimensions of the test specimen.
2.  Working drawings with details and dimensions of the special anchorage device, 

including all confining reinforcing steel.

3.  Amount and arrangement of supplementary skin reinforcement.
4.  Type and yield strength of reinforcing steel.
5.  Type and compressive strength of the concrete at the time of testing.
6.  Type of testing procedure and all measurements specified for each specimen under 

the test.

The special anchorage device manufacturer shall specify auxiliary and confining 
reinforcement, minimum edge distance, minimum anchor spacing, and minimum concrete 
strength at the time of stressing required for proper performance of the local zone.

6-02.3(26)E Ducts

Ducts shall be round, except that ducts for transverse post-tensioning of bridge deck 
slabs may be rectangular. Ducts shall conform to the following requirements for internal 
embedded installation and external exposed installation. Elliptical shaped duct may be 
used if allowed by the Engineer.

6-02.3(26)E1  Ducts for Internal Embedded Installation

Ducts, including their splices, shall be semi-rigid, air and mortar tight, corrugated plastic 
ducts of virgin polyethylene or polypropylene materials, free of water-soluble chlorides or 
other chemicals reactive with concrete or post-tensioning reinforcement. Ducts, including 
their splices, shall either have a white coating on the outside or shall be of a white 
material with ultraviolet stabilizers added. Ducts, including their splices, shall be capable 
of withstanding concrete pressures without deforming or permitting the intrusion of 
cement paste during placement of concrete. All fasteners shall be appropriate for use with 
plastic ducts, and all clamps shall be of an accepted plastic material.

Page 6-120 

Concrete Structures

Polyethylene ducts shall conform to ASTM D3350 with a cell classification of 345464A. 
Polypropylene ducts shall conform to ASTM D4101 with a cell classification range 
of PP0340B14541 to PP0340B67884. Resins used for duct fabrication shall have a 
minimum oxidation induction time of 20 minutes, in accordance with ASTM D3895, 
based on tests performed by the duct fabricator on samples taken from the lot of finished 
product. The duct thickness shall be as specified in Section 10.8.3 of the AASHTO LRFD 
Bridge Construction Specifications, latest edition and current interims.

All duct splices, joints, couplings, and connections to anchorages shall be made with 
devices or methods (mechanical couplers, plastic sleeves, shrink sleeves) that are accepted 
by the duct manufacturer and produce a smooth interior alignment with no lips or kinks. 
All connections and fittings shall be air and mortar tight. Taping is not acceptable for 
connections and fittings.

Each duct shall maintain the required profile within a placement tolerance of plus or 

minus ¼ inch for longitudinal tendons and plus or minus ⅛ inch for transverse slab 

tendons during all phases of the work. The minimum acceptable radius of curvature shall 
be as recommended by the duct manufacturer and as supported by documented industry 
standard testing. The ducts shall be completely sealed to keep out all mortar.

Each duct shall be located to place the tendon at the center of gravity alignment shown 
in the Plans. To keep friction losses to a minimum, the Contractor shall install ducts to 
the exact lines and grades shown in the Plans. Once in place, the ducts shall be tied 
firmly in position before they are covered with concrete. During concrete placement, the 
Contractor shall not displace or damage the ducts.

The ends of the ducts shall:
1.  Permit free movement of anchorage devices, and
2.  Remain covered after installation in the forms to keep out all water or debris.

Immediately after any concrete placement, the Contractor shall force blasts of oil-free, 
compressed air through the ducts to break up and remove any mortar inside before it 
hardens. Before deck concrete is placed, the Contractor shall satisfy the Engineer that 
ducts are unobstructed and contain nothing that could interfere with tendon installation, 
tensioning, or grouting. If the tendons are in place, the Contractor shall show that they are 
free in the duct.

Ducts shall be capped and sealed at all times until the completion of grouting to prevent 
the intrusion of water.

Strand tendon duct shall have an inside cross-sectional area large enough to accomplish 
strand installation and grouting. The area of the duct shall be at least 2.5 times the net 
area of prestressing steel in the duct. The maximum duct diameter shall be 4½ inches.

Concrete Structures 

6-02

The inside diameter of bar tendon duct shall at least be ¼ inch larger than the bar 
diameter. At coupler locations the duct diameter shall at least be ¼ inch larger than the 
coupler diameter.

Ducts installed and cast into concrete prior to prestressing steel installation, shall be 
capable of withstanding at least 10 feet of concrete fluid pressure.

Ducts shall have adequate longitudinal bending stiffness for smooth, wobble free 
placement. A minimum of three successful duct qualification tests are required for each 
diameter and type of duct, as follows:
1.  Ducts with diameters 2 inches and smaller shall not deflect more than 3 inches under 

its own weight, when a 10-foot duct segment is supported at its ends.

2.  Ducts larger than 2 inches in diameter shall not deflect more than 3 inches under its 

own weight, when a 20-foot duct segment is supported at its ends.

3.  Duct shall not dent more than ⅛ inch under a concentrated load of 100 pounds 

applied between corrugations by a #4 steel reinforcing bar.

When the duct must be curved in a tight radius, more flexible duct may be used, subject 
to the Engineer’s concurrence.

6-02.3(26)E2  Ducts for External Exposed Installation

Duct shall be high-density polyethylene (HDPE) conforming to ASTM D3035. The cell 
classification for each property listed in the table below:

Property

Cell Classification

1

3 or 4

2

2, 3, or 4

3

4 or 5

4

4 or 5

5

2 or 3

6

2, 3, or 4

The color code shall be C.

Duct for external tendons, including their splices, shall be water tight, seamless or welded, 
and be capable of resisting at least 150 psi grout pressure.

Transition couplers between ducts shall conform to either the standard pressure 
ratings of ASTM D3035 or the hydrostatic design stresses of ASTM F714 at 73°F. The 
inside diameter through the coupled length shall not be less than that produced by the 
dimensional tolerances specified in ASTM D3035.

Workers performing HDPE pipe welding shall have satisfactorily completed a certified 
HDPE pipe welding course and shall have a minimum of 5 years experience in welding 
HDPE pipe.

Page 6-122 

Concrete Structures

The Contractor shall submit a Type 2 Working Drawing consisting of the name and HDPE 
pipe welding work experience of each HDPE pipe welder proposed to perform this Work 
in the project. The experience submittal for each HDPE pipe welder shall include:
1.  The name of the pipe welder.
2.  The name, date, and location of the certified HDPE pipe welding course, with the 

course completion certificate.

3.  A list of at least three projects in the last 5 years where the pipe welder performed 

HDPE pipe welding, including:
a.  The project name and location, and date of construction.
b.  The Governmental Agency/Owner.
c.  The name, address, and phone number of the Governmental Agency/Owner’s 

representative.

The Engineer may require the HDPE pipe welder to demonstrate test HDPE pipe welding 
before receiving final acceptance.

6-02.3(26)E3 Transitions

Transitions between ducts and wedge plates shall have adequate length to reduce the 
angle change effect on the performance of strand-wedge connection, friction loss at the 
anchorage, and fatigue strength of the post-tensioning reinforcement.

6-02.3(26)E4  Vents, Grout Injection Ports, Drains, and Caps

The Contractor shall install vents at high points and drains at low points of the tendon 
profile (and at other places if the Plans require). Vents at high points shall consist of a 
set of three vents: one to be installed at the high point of the duct, and flanking vents 
to be installed on either side of the high-point vent at locations where the duct profile 
is 8 to 12 inches below the elevation of the high-point vent. Vents shall include grout 
injection ports.

Vents and drains shall have a minimum inside diameter of ¾ inches, and shall be of 
either stainless steel, nylon, or polyolefin materials, free of water-soluble chlorides or 
other chemicals reactive with concrete or post-tensioning reinforcement. Stainless steel 
vents and drains shall conform to ASTM A240 Type 316. Nylon vents and drains shall 
conform to cell classification S-PA0141 (weather-resistant). Polyolefin vents and drains 
shall contain an antioxidant with a minimum oxidation induction time of 20 minutes in 
accordance with ASTM D3895. Polyolefin vents and drains shall also have a stress crack 
resistance of 3 hours minimum when tested at an applied stress of 350 psi in accordance 
with ASTM F2136.

All fasteners shall be appropriate for use with plastic ducts, and all clamps shall be of an 
accepted plastic material. Taping of connections is not allowed. Valves shall be positive 
mechanical shut-off valves. Valves, and associated caps, shall have a minimum pressure 
rating of 100 psi.

Concrete Structures 

6-02

Vents shall point upward and remain closed until grouting begins. Drains shall point 
downward and remain open until grouting begins. Ends of stainless steel vents and drains 
shall be removed 1 inch inside the concrete surface after grouting has been completed. 
Ends of nylon or polyolefin vents and drains may be left flush to the surface unless 
otherwise specified by the Engineer. Vents, except for grout injection, are not required for 
transverse post-tensioning ducts in the bridge deck unless specified in the Plans.

Caps shall be made of either stainless steel or fiber reinforced polymer (FRP). Stainless 
steel caps shall conform to ASTM A240 Type 316L. The resin for FRP caps shall be either 
nylon, polyester, or acrylonitrite butadiene styrene (ABS). Nylon shall conform to cell 
classification S-PA0141 (weather-resistant). Caps shall be sealed with “O” ring seals or 
precision-fitted flat gaskets placed against the bearing plate. Caps shall be fastened to the 
anchorage with stainless steel bolts conforming to ASTM A240 Type 316L.

6-02.3(26)E5  Leak Tightness Testing

The Contractor shall test each completed duct assembly for leak tightness after placing 
concrete but prior to placing post-tensioning reinforcement. The Contractor shall submit a 
Type 2 Working Drawing consisting of the equipment used to conduct the leak tightness 
testing and to monitor and record the pressure maintained in and lost from the closed 
assembly, and the process to be followed in conducting the leak-tightness testing along 
with the post-tensioning system shop drawings in accordance with 

Section 6-02.3(26)A

.

Prior to testing, all grout caps shall be installed and all vents, grout injection ports, and 
drains shall either be capped or have their shut-off valves closed. The Contractor shall 
pressurize the completed duct assembly to an initial air pressure of 50 psi. This pressure 
shall be held for five minutes to allow for internal adjustments within the assembly. 
After five minutes, the air supply valve shall be closed. The Contractor shall monitor and 
measure the pressure maintained within the closed assembly, and any subsequent loss 
of pressure, over a period of one minute following the closure of the air supply valve. 
The maximum pressure loss for duct assemblies equal to or less than 150 feet in length 
shall be 25 psig. The maximum pressure loss for duct assemblies greater than 150 feet 
in length shall be 15 psig. If the pressure loss exceeds the allowable, locations of leakage 
shall be identified, repaired or reconstructed using methods accepted by the Engineer. 
The repaired system shall then be retested. The cycle of testing, repair and retesting 
of each completed duct assembly shall continue until the completed duct assembly 
completes a test with pressure loss within the specified amount.

6-02.3(26)F 

Prestressing Reinforcement

All prestressing reinforcement strand shall comply with 

Section 9-07.10

. They shall not 

be coupled or spliced. Tendon locations shown in the Plans indicate final positions after 
stressing (unless the Plans say otherwise). No tendon made of 7-wire strands shall contain 
more than 37 strands of ½-inch diameter, or more than 27 strands of 0.6-inch diameter.

All prestressing reinforcement bar shall conform to 

Section 9-07.11

. They shall not be 

coupled or spliced except as otherwise specified in the Plans or Special Provisions.