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

Page 6-124

Concrete Structures

Prestressing reinforcement not conforming to either Section

will

not be allowed except as otherwise noted. Such reinforcement may be used provided
it is specifically allowed by the Plans or Special Provisions, it satisfies all material and
performance criteria specified in the Plans or Special Provisions, and receives the
Engineer’s acceptance.

From manufacture to encasement in concrete or grout, 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. 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. If the prestressing reinforcement will not be stressed and grouted for more
than 7 calendar days after it is placed in the ducts, the Contractor shall place an accepted
corrosion inhibitor conforming to Federal Specification MIL-I-22110C in the ducts.

The feeding ends of the strand tendons shall be equipped with a bullet nosing or similar
apparatus to facilitate strand tendon installation.

Strand tendons may be installed by pulling or pushing. Any equipment capable to
performing the task may be used, provided it does not damage the strands and conforms
to the following:
1. Pulling lines shall have a capacity of at least 2.5 times the dead weight of the

tendons when used for essentially horizontal tendon installation.

2. Metal pushing wheels shall not be used.

3. Bullets for checking duct clearance prior to concreting shall be rigid and be ⅛ inch

smaller than the inside diameter of the duct. Bullets for checking duct after
concreting shall be less than ¼ inch smaller than the inside diameter of the duct.

6-02.3(26)G Tensioning

Equipment for tensioning post-tensioning reinforcement shall meet the following
requirements:
1. Stressing equipment shall be capable of producing a jacking force of at least

81 percent of the specified tensile strength of the post-tensioning reinforcement.

2. Jacking force test capacity shall be at least 95 percent of the specified tensile

strength of the post-tensioning reinforcement.

3. Wedge seating methods shall assure uniform seating of wedge segments and

uniform wedge seating losses on all strand tendons.

4. Accumulation of differential seating losses during tensioning cycling shall be

prevented by proper devices.

5. Jacks used for stressing tendons less than 20 feet long shall have wedge power

seating capability.

Concrete Structures

6-02

The Contractor shall not begin to tension the tendons until:
1. All concrete has reached a compressive strength of at least 4,000 psi or the strength

specified in the Plans. When tensioning takes place prior to 28-day compressive
strength testing on concrete sampled in accordance with Section 6-02.3(25)H,
compressive strength shall be verified on field cured cylinders in accordance with the
FOP for AASHTO T23.

2. The Engineer is satisfied that all strands are free in the ducts.

Tendons shall be tensioned to the values shown in the Plans (or processed shop drawings)
with hydraulic jacks. When stressing from both ends of a tendon is specified, it need not
be simultaneous unless otherwise specified in the Plans. The jacking sequence shall follow
the processed shop drawings.

Each jack shall have a pressure gauge that will determine the load applied to the tendon.
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 provide one
copy of this chart to the Engineer for use in monitoring. The cylinder extension during
calibration shall be in approximately the position it will occupy at final jacking force.

All jacks and gauges must be recalibrated and recertified: (1) at least every 180 days, and
(2) after any repair or adjustment. The Engineer may use pressure cells to check jacks,
gauges, and calibration charts before and during tensioning.

These stress limits apply to all tendons (unless the Plans set other limits):
1.  During jacking prior to seating: 90 percent of the yield strength of the steel.
2.  At anchorages after seating: 70 percent of the specified tensile strength of the steel.
3.  At service limit state after losses: 80 percent of the yield strength of the steel.

Tendons shall be anchored at initial stresses that will ultimately maintain service loads at
least as great as the Plans require.

As stated in

Section 6-02.3(26)A

, the assumed design friction coefficient “

” and wobble

coefficient “k” shown in the Plans shall be used to calculate the stressing elongation.
These coefficients may be revised by the post-tensioning supplier by the following
method provided it is accepted by the Engineer:

Early in the project, the post-tensioning supplier shall test, in place, two
representative tendons of each size and type shown in the Plans, for the purpose of
accurately determining the friction loss in a strand and/or bar tendon.
The test procedure shall consist of stressing the tendon at an anchor assembly with
load cells at the dead end and jacking end. The test specimen shall be tensioned to
80 percent of the specified tensile strength in 10 increments. For each increment,
the gauge pressure, elongation, and load cell force shall be recorded and the
data furnished to the Engineer. The theoretical elongations and post-tensioning
forces shown on the post-tensioning shop drawings shall be re-evaluated by the
post-tensioning supplier using the results of the tests and corrected as necessary.

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Revisions to the theoretical elongations shall be submitted as a Type 2E Working
Drawing. The apparatus and methods used to perform the tests shall be proposed by
the post-tensioning supplier and be subject to the Engineer’s acceptance.
All costs associated with testing and evaluating test data shall be included in the unit
Contract prices for the applicable items of Work involved.

As tensioning proceeds, the Engineer will be recording the applied load, tendon
elongation, and anchorage seating values.

Elongation measurements shall be made at each stressing location to verify that the
tendon force has been properly achieved. If proper anchor set has been achieved and
the measured elongation of each strand tendon is within plus or minus 7 percent of
the accepted calculated elongation, the stressed tendon represented by the elongation
measurements is acceptable to the Contracting Agency.

In the event discrepancies greater than 7 percent exist between the measured and
calculated elongations, the jack calibration shall be checked and stressing records
reviewed for any evidence of wire or strand breakage. If the jack if properly calibrated
and there is no evidence of wire or strand breakage, a force verification lift off shall
be performed to verify the force in the tendon. The post-tensioning supplier force
verification lift off procedure shall provide access for visual verification of anchor plate
lift off. The jacking equipment shall be capable of bridging and lifting off the anchor plate.
The tendon is acceptable if the verification lift off force is not less than 99 percent of the
accepted calculated force nor more than 70 percent of the specified tensile strength of
the prestressing steel or as accepted by the Engineer.

Elongation measurements shall be recorded for bar tendons to verify proper tensioning
only. Acceptance will be by force verification lift off. The bar tendon is acceptable if the
verification lift off force is not less than 95 percent nor more than 105 percent of the
accepted calculated force or as accepted by the Engineer.

When removing the jacks, the Contractor shall relieve stresses gradually before cutting
the prestressing reinforcement. The prestressing strands shall be cut a minimum of 1 inch
from the face of the anchorage device.

6-02.3(26)H Grouting

Grout for post-tensioning reinforcement shall conform to

Section 9-20.3(1)

. Prepackaged

components of the grout mix shall be used within 6 months or less from date of
manufacture to date of usage. Grout for post-tensioning reinforcement will be accepted
based on manufacturer’s certificate of compliance in accordance with

Section 1-06.3

except that the water-cementitious material ratio of 0.45 maximum shall be field verified.

All grout produced for any single structure shall be furnished by one supplier.

All grouting operations shall be conducted by ASBI-certified grout technicians.

Concrete Structures

6-02

The Contractor shall submit a Type 2 Working Drawing consisting of the grouting
operation Plan. The grouting operation Plan shall include, but not be limited to,
the following:
1. Names of the grout technicians, accompanied by documentation of their ASBI

certification.

2. Type, quantity, and brand of materials used in the grouting operations, including all

manufacturer’s certificates of compliance.

3. Type of equipment to be used, including meters and measuring devices used to

positively measure the quantity of materials used to mix the post-tensioning grout,
the equipment capacity in relation to demand and working conditions, and all back-
up equipment and spare parts.

4. General grouting procedure.
5. Duct leak tightness testing and repair procedures as specified in

Section 6-02.3(26)E

6. Methods used to control the rate of grout flow within the ducts.
7. Theoretical grout volume calculations, and target flow rates recommended by the

grout manufacturer as a function of the mixer equipment and the expected range of
ambient temperatures.

8.  Grout mixing and pumping procedures.
9.  Direction of grouting.
10.  Sequence of use of the grout injection ports, vents, and drains.
11.  Procedures for handling blockages.
12.  Procedures for postgrouting repairs.

Post-tensioning grout shall be mixed in accordance with the prepackaged grout
manufacturer’s recommendations using high-shear colloidal mixers. Mechanical paddle
mixers will not be allowed. The grout produced for filling post-tensioning ducts shall be
free of lumps and undispersed cement. All equipment used to mix each batch of post-
tensioning grout shall be equipped with appropriate meters and measuring devices to
positively measure all quantities of all materials used to produce the mixed grout. The
field test for water-cementitious materials ratio shall be performed prior to beginning
the grout injection process. Grouting shall not begin until the material properties of each
batch of grout have been confirmed as acceptable.

After tensioning the tendons, the Contractor shall again blow oil-free, compressed air
through each duct. All drains shall then be closed and the vents opened. Grout caps shall
be installed at tendon ends prior to grouting. After completely filling the duct with grout,
the Contractor shall pump the grout from the low end at a pressure of not more than
250 psig, except for transverse tendons in deck slabs the grout pressure shall not exceed
100 psig. Grout shall be continuously wasted through each vent until no more air or water
pockets show. At this point, all vents shall be closed and grouting pressure at the injector
held between 100 and 200 psig for at least 10 seconds, except for transverse tendons
in deck slabs the grouting pressure shall be held between 50 and 75 psig for at least

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Concrete Structures

10 seconds. The Contractor shall leave all plugs, caps, and valves in place and closed for at
least 24 hours after grouting.

Grouting equipment shall:
1. Include a pressure gauge with an upper end readout of between 275 and 325 psig;
2. Screen the grout before it enters the pump with an easily reached screen that has

clear openings of no more than 0.125 inches;

3. Be gravity fed from an attached, overhead hopper kept partly full during pumping;

and

4. Be able to complete the largest tendon on the project in no more than 20 minutes of

continuous grouting.

In addition, the Contractor shall have standby equipment (with a separate power source)
available for flushing the grout when the regular equipment cannot maintain a one-way
flow of grout. This standby equipment shall be able to pump at 250 psig.

The grout mix shall be injected within 30 minutes after the water is added to the cement.
Temperature of the surrounding concrete shall be at least 35°F from the time the grout
injecting begins until 2-inch cubes of the grout have a compressive strength of 800 psi.
Cubes shall be made in accordance with WSDOT

T 813

and stored in accordance

with FOP for AASHTO T 23. If ambient conditions are such that the surrounding
concrete temperature may fall below 35°F, the Contractor shall provide a heat source
and protective covering for the Structure to keep the temperature of the surrounding
concrete above 35°F. Grout temperature shall not exceed 90°F during mixing and
pumping. If conditions are such that the temperature of the grout mix may exceed 90°F,
the Contractor will make necessary provisions, such as cooling the mix water and/or dry
ingredients, to ensure that the temperature of the grout mix does not exceed 90°F.

6-02.3(27) Concrete for Precast Units

Precast units shall not be removed from forms until the concrete has attained a minimum
compressive strength of 70 percent of the specified design strength as verified by
rebound number determined in accordance with FOP for ASTM C805. Type III portland
cement or blended hydraulic cement is permitted to be used in precast concrete units.

Precast units shall not be shipped until the concrete has reached the specified design
strength as determined by testing cylinders made from the same concrete as the
precast units. The cylinders shall be made, handled, and stored in accordance with
FOP for AASHTO T 23 and compression tested in accordance with AASHTO T 22 and
AASHTO T 231.

Concrete Structures

6-02

6-02.3(27)A

Use of Self-Consolidating Concrete for Precast Units

Self-consolidating concrete (SCC) may be used for the following precast concrete
structure elements:
1. Precast roof, wall, and floor panels and retaining wall panels in accordance with

Section 6-02.3(28)

2. Precast reinforced concrete three-sided structures, box culverts and split box

culverts in accordance with

Section 7-02.3(6)

3. Precast concrete barrier in accordance with

Section 6-10.3(1)

4. Precast concrete wall stem panels in accordance with

Section 6-11.3(3)

5. Precast concrete noise barrier wall panels in accordance with

Section 6-12.3(6)

6. Structural earth wall precast concrete facing panels in accordance with

Section 6-13.3(4)

7. Precast drainage structure elements in accordance with

Section 9-05.50

8. Precast junction boxes, cable vaults, and pull boxes in accordance with

Section 9-29.2

6-02.3(27)B

Submittals for Self-Consolidating Concrete for Precast Units

With the exception of items 3, 7, and 8 in

Section 6-02.3(27)A

, the Contractor shall

submit the mix design for SCC to the Engineer for annual plant approval in accordance
with

Section 6-02.3(28)B

. The mix design submittal shall include items specified in

require the precast plant to cast one

representative structure acceptable to the Engineer and have the structure sawn in
half for examination by the Contracting Agency to determine that segregation has not
occurred. The Contracting Agency’s acceptance of the sawn structure will constitute
acceptance of the precast plant’s use of SCC, and a concrete mix design submittal is
not required.

6-02.3(27)C

Acceptance Testing of Concrete for Precast Units

Acceptance testing shall be performed by the Contractor and test results shall be
submitted to the Engineer. Concrete shall conform to the requirements specified in

Section 6-02.3(2)A

. 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(27)

. Compressive strength testing shall be performed a minimum of once

per day and once for every 20 cubic yards of concrete that is placed.

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Concrete Structures

Concrete for items 1, 2, 4, 5, and 6 in

Section 6-02.3(27)A

that is not self-consolidating

concrete will be accepted as follows:
1.  Temperature within the allowable temperature band.
2.  Slump below the maximum allowed.
3.  Air content within the required range.

SCC for items 1, 2, 4, 5, and 6 in

Section 6-02.3(27)A

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.

4. J ring passing ability less than or equal to 1.5-inches.
5. Air content within the required range.

SCC for concrete barrier will be accepted in accordance with temperature, air, and
compressive strength testing listed above.

SCC for precast junction boxes, cable vaults, and pull boxes will be accepted in
accordance with the temperature and compressive strength testing listed above.

SCC for precast drainage structure elements will be accepted in accordance with the
requirements of AASHTO M199.

6-02.3(28) Precast Concrete Panels

The Contractor shall perform quality control inspection. The manufacturing plant for
precast concrete panels shall be certified by the Precast/Prestressed Concrete Institute’s
Plant Certification Program for the type of precast member to be produced, or the
National Precast Concrete Association’s Plant Certification Program or be an International
Congress Building Officials or International Code Council Evaluation Services recognized
fabricator of structural precast concrete products, and shall be approved by WSDOT
as a Certified Precast Concrete Fabricator prior to the start of production. WSDOT
Certification will be granted at, and renewed during, the annual precast plant review and
approval process in accordance with WSDOT

Materials Manual

M 46-01 Standard Practice

QC 7. Products that shall conform to this requirement include noise barrier panels,
wall panels, floor and roof panels, marine pier deck panels, retaining walls, pier caps,
and bridge deck panels. Precast concrete panels that are prestressed shall meet all the
requirements of

Section 6-02.3(25)

Prior to the start of production of the precast concrete panels, 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 panel(s) will be rejected.

Concrete Structures

6-02

6-02.3(28)A

Shop Drawings

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

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

The shop drawings shall contain as a minimum:
1.  Panel shapes (elevations and sections) and dimensions.
2.  Finishes and method of constructing the finish (i.e., forming, rolling).
3.  Reinforcing, joint, and connection details.
4.  Lifting, bracing, and erection inserts.
5.  Locations and details of hardware attached to the Structure.
6.  Relationship to adjacent material.

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

Before completion of the Contract, 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 conform with the size
requirements of

Section 6-01.9

6-02.3(28)B Casting

Before casting precast concrete panels, the Contractor and Fabrication Inspector shall
have possession of a processed set of shop drawings.

Concrete shall meet the requirements of

Section 6-02.3(25)C

for annual preapproval of

the concrete mix design and slump. If SCC is used, the concrete shall conform to Sections

6-02.3(27)B

and

6-02.3(27)C

Precast panels shall not be removed from forms until the concrete has attained a
minimum compressive strength of 70 percent of the specified design strength. A minimum
compressive strength at other than 70 percent may be used for specific precast
panels if the fabricator requests and receives acceptance as part of the WSDOT plant
certification process.

Forms may be steel or plywood faced, providing they impart the required finish to
the concrete.

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Concrete Structures

6-02.3(28)C Curing

Concrete in the precast panels shall be cured by either moist or accelerated curing
methods. The methods to be used shall be preapproved in the WSDOT plant
certification process.
1. For moist curing, the surface of the concrete shall be kept covered or moist until

such time as the compressive strength of the concrete reaches the strength specified
for stripping. Exposed surfaces shall be kept continually moist by fogging, spraying,
or covering with moist burlap or cotton mats. Moist curing shall commence as soon
as possible following completion of surface finishing.

2. For accelerated curing, heat shall be applied at a controlled rate following the initial

set of concrete in combination with an effective method of supplying or retaining
moisture. Moisture may be applied by a cover of moist burlap, cotton matting, or
other effective means. Moisture may be retained by covering the panel with an
impermeable sheet.

Heat may be radiant, convection, conducted steam or hot air. Heat the 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. After curing is complete, cool the
concrete no more than 25°F per hour to 100°F. Maintain the concrete temperature above
60°F until the panel reaches stripping strength.

Concrete temperature shall be monitored by means of a thermocouple embedded in the
concrete (linked with a thermometer accurate to plus or minus 5°F). The recording sensor
(accurate to plus or minus 5°F) shall be arranged and calibrated to continuously record,
date, and identify concrete temperature throughout the heating cycle. This temperature
record shall be made available to the Engineer for inspection and become a part of the
documentation required.

The Contractor shall never allow dry heat to directly touch exposed panel surfaces at
any point.

6-02.3(28)D Contractors Control Strength

The concrete strength at stripping and the verification of design strength shall be
determined by testing cylinders made from the same concrete as the precast panels. The
cylinders shall be made, handled, and stored in accordance with FOP for AASHTO T 23
and compression tested in accordance with AASHTO T 22 and AASHTO T 231.

For accelerated cured panels, concrete strength shall be measured on test cylinders cast
from the same concrete as that in the panel. These cylinders shall be cured under time-
temperature relationships and conditions that simulate those of the panel. 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 panel to the Engineer.
When two or more panels are cast in a continuous line and in a continuous operation, a
single set of test cylinders may represent all panels provided the Contractor demonstrates
uniformity of casting and curing to the satisfaction of the Engineer.

Concrete Structures

6-02

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. The Contractor shall let cylinders cool for at least
½ hour before testing for release strength.

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

To measure concrete strength in the precast panel, the Contractor shall randomly select
two test cylinders and average their compressive strengths. The compressive strength in
either cylinder shall not fall more than 5 percent below the specified strength. If these
two cylinders do not pass the test, two other cylinders shall be selected and tested.

6-02.3(28)E Finishing

The Contractor shall provide a finish on all relevant concrete surfaces as defined in

Section 6-02.3(14)

, unless the Plans or Special Provisions require otherwise.

The Contractor may repair defects in precast panels in accordance with Section 6-01.16.

6-02.3(28)F Tolerances

The panels shall be fabricated as shown in the Plans, and shall meet the dimensional
tolerances listed in the latest edition of PCI-MNL-116, unless otherwise required by the
Plans or Special Provisions.

6-02.3(28)G Handling and Storage

The Contractor shall lift all panels only by adequate devices at locations designated
on the shop drawings. When these devices and locations are not shown in the Plans,

Section 6-02.3(25)L

shall apply.

Precast panels shall be stored off the ground on foundations suitable to prevent
differential settlement or twisting of the panels. Stacked panels shall be separated and
supported by dunnage of uniform thickness capable of supporting the panels. Dunnage
shall be arranged in vertical planes. The upper panels of a stacked tier shall not be used
as storage areas for shorter panels unless substantiated by engineering analysis and
accepted by the Engineer.

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Concrete Structures

6-02.3(28)H Shipping

Precast panels shall not be shipped until the concrete has reached the specified design
strength, and the Engineer has reviewed the fabrication documentation for Contract
compliance and stamped the precast concrete panels “Approved for Shipment”. The
panels shall be supported in such a manner that they will not be damaged by anticipated
impact on their dead load. Sufficient padding material shall be provided between tie
chains and cables to prevent chipping or spalling of the concrete.

6-02.3(28)I Erection

When the precast panels arrive on the project, the Engineer will confirm that they are
stamped “Approved for Shipment”. The Engineer will evaluate the present panels for
damage before accepting them.

The Contractor shall lift all panels by suitable devices at locations designated on the shop
drawings. Temporary shoring or bracing shall be provided, if necessary. Panels shall be
properly aligned and leveled as required by the Plans. Variations between adjacent panels
shall be leveled out by a method accepted by the Engineer.

6-02.4 Measurement

Except as noted below, all classes of concrete shall be measured in place by the cubic yard
to the neat lines of the Structure as shown in the Plans.

Exception: concrete in cofferdam seals. Payment for Class 4000W concrete used in these
seals will be based on the volume calculated using the neatline dimensions for the seal
as shown in the Contract Plans. For calculated purposes, the horizontal dimension will
be increased by 1 foot outside the seal neatline perimeter. The vertical dimension is the
distance between the top and bottom neatline elevations. No payment will be made for
any concrete that lies outside of these limits to accommodate the Contractor’s cofferdam
configuration. If the Engineer eliminates the seal in its entirety a Contract change order
will be issued.

Exception: concrete in a separate lump-sum, Superstructure Bid item. Any concrete
quantities noted under this item in the Special Provisions will not be measured. Although
the Special Provisions list approximate quantities for the Contractor’s convenience,
the Contracting Agency does not guarantee the accuracy of these estimates. Before
submitting a Bid, the Contractor shall have verified the quantities. Even though actual
quantities used may vary from those listed in the Special Provisions, the Contracting
Agency will not adjust the lump sum Contract price for Superstructure (except for
processed changes).

The Contracting Agency will pay for no concrete placed below the established elevation
of the bottom of any footing or seal.

Concrete Structures

6-02

Lean concrete will be measured by the cubic yard for the quantity of material placed
in accordance with the producer’s invoice, except that lean concrete included in other
Contract items will not be measured.

No deduction will be made for pile heads, reinforcing steel, structural steel, bolts, weep
holes, rustications, chamfers, edgers, joint filler, junction boxes, miscellaneous hardware,
ducts or less than 6-inch diameter drain pipes when computing concrete quantities for
payment.

All reinforcing steel will be measured by the computed weight of all steel required by
the Plans. The weight of mechanical splices will be based on the weight specified in the
manufacturer’s existing catalog cut for the specific item. Splices noted as optional in
the plans but installed by the Contractor will be included in the measurement. Epoxy-
coated bars will be measured before coating. The Contractor shall furnish (without extra
allowance):
1.  Bracing, spreaders, form blocks, wire clips, and other fasteners.
2.  Extra steel in splices not shown in the Plans or specified in the Plans as optional.
3.  Extra shear steel at construction joints not shown in the Plans when the Engineer

permits such joints for the Contractor’s convenience.

The following table shall be used to compute weight of reinforcing steel:

Steel Reinforcing Bar

Deformed Bar

Designation Number

Nominal Diameter inches

Unit Weight

Pounds per Foot

0.375

0.376

0.500

0.668

0.625

1.043

0.750

1.502

0.875

2.044

1.000

2.670

1.128

3.400

1.270

4.303

1.410

5.313

1.690

7.650

2.260

13.600

Gravel backfill will be measured as specified in

Section 2-09.4

Expansion joint system___seal - superstr. will be measured by the linear foot along its
completed line and slope.

Expansion joint modification will be measured by the linear foot of expansion joint
modified along its completed line and slope.

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Concrete Structures

Prestressed concrete girder will be measured by the linear foot of girder specified in the
Proposal.

Bridge approach slab will be measured by the square yard.

Permeon treatment will be measured by the square yard of concrete surface area
receiving the treatment.

6-02.5 Payment

Payment will be made for each of the following Bid items that are included in the
Proposal:

“Conc. Class ____”, per cubic yard.
“Commercial Concrete”, per cubic yard.
All concrete, except in Superstructure when this is covered by a separate Bid item,
will be paid for at the unit Contract price per cubic yard in place for the various
classes of concrete. All costs in connection with concrete curing, producing concrete
surface finish, and furnishing and applying sealer to concrete surfaces as specified,
shall be included in the unit contract price per cubic yard for “Conc. Class ____”. If
the concrete is to be paid for other than by class of concrete, then the costs shall be
included in the associated item of work.
“Superstructure (name bridge)”, lump sum.
All costs in connection with constructing, finishing and removing the bridge deck test
slab as specified in

Section 6-02.3(10)D1

shall be included in the lump sum Contract

price for “Superstructure___” or “Bridge Deck___” for one bridge in each project, as
applicable.
All costs in connection with providing holes for vents, for furnishing and installing
cell drainage pipes for box girder Structures, and furnishing and placing grout and
shims under steel shoes shall be included in the unit Contract prices for the various
Bid items involved.
All costs in connection with the construction of weep holes, including the gravel
backfill for drains surrounding the weep holes except as provided in

Section 2-09.4

shall be included by the Contractor in the unit Contract price per cubic yard for
“Conc. Class ____”.
“Lean Concrete”, per cubic yard.
Lean concrete, except when included in another Bid item, will be paid for at the unit
Contract price per cubic yard.
“St. Reinf. Bar ____”, per pound.

Concrete Structures

6-02

“Epoxy-Coated St. Reinf. Bar ____”, per pound.
Payment for reinforcing steel shall include the cost of drilling holes in concrete for,
and setting, steel reinforcing bar dowels with epoxy bonding agent, and furnishing,
fabricating, placing, and splicing the reinforcement. In Structures of reinforced
concrete where there are no structural steel Bid items, such minor metal parts as
expansion joints, bearing assemblies, and bolts will be paid for at the unit Contract
price for “St. Reinf. Bar ____” unless otherwise specified.
“Gravel Backfill for Foundation Class A”, per cubic yard.
“Gravel Backfill for Foundation Class B”, per cubic yard.
“Gravel Backfill for Wall”, per cubic yard.
“Deficient Strength Conc. Price Adjustment”, by calculation.
“Deficient Strength Conc. Price Adjustment” shall be calculated and paid for as
described in

Section 6-02.3(5)L

. For the purpose of providing a common Proposal for

all Bidders, the Contracting Agency has entered an amount for the item “Deficient
Strength Conc. Price Adjustment” in the Bid Proposal to become a part of the total
Bid by the Contractor. The item “Deficient Strength Conc. Price Adjustment” covers
all applicable classes of concrete.
“Expansion Joint System _____ - Superstr.”, per linear foot.
“Expansion Joint Modification - ___”, per linear foot.
“Prestressed Conc. Girder ___”, per linear foot.
“Bridge Approach Slab”, per square yard.
The unit Contract price per square yard for “Bridge Approach Slab” shall be full pay
for providing, placing, and compacting the crushed surfacing base course, furnishing
and placing Class 4000A concrete, and furnishing and installing compression seal,
anchors, and reinforcing steel.
“Permeon Treatment”, per square yard.
The unit contract price per square yard for “Permeon Treatment” shall be full pay for
performing the work as specified.

Page 6-138

Steel Structures

6-03

Steel Structures

6-03.1 Description

This Work consists of furnishing, fabricating, erecting, cleaning, and painting steel
Structures and the structural steel parts of nonsteel Structures

6-03.2 Materials

Materials shall meet the requirements of the following sections:

Structural Steel and Related Materials

9-06

Paints and Related Materials

9-08

Grout

9-20.3

Structural steel shall be classified as:
1. Structural carbon steel (to be used whenever the Plans do not specify another

classification),

2. Structural low alloy steel, and
3. Structural high-strength steel.

Unless the Plans or Special Provisions state otherwise, the following shall be classified as
structural carbon steel: shims; ladders; stairways; anchor bolts and sleeves; pipe, fittings,
and fastenings used in handrails; and other metal parts, even if made of other materials,
for which payment is not specified.

All AASHTO M270 material used in what the Plans show as main load-carrying tension
members or as tension components of flexural members shall meet the Charpy V-notch
requirements of AASHTO M270 temperature zone 2. All AASHTO M270 material used
in what the Plans show as fracture critical members shall meet the Charpy V-notch
requirements of AASHTO M270, Fracture Critical Impact Test Requirements, temperature
zone 2. Charpy V-notch requirements for other steel materials shall be as specified in the
Plans and Special Provisions.

The Contractor shall submit Type 1 Working Drawings describing the methods for visibly
marking the material so that it can be traced. These marks shall remain visible at least
through the fit-up of the main load-carrying tension members. The marking method shall
permit the Engineer to verify: (1) material Specification designation, (2) heat number, and
(3) material test reports to meet any special requirements.

For steel in main load-carrying tension members and in tension components of flexural
members, the Contractor shall include the heat numbers on the reproducible copies of
the as-built shop plans.

Steel Structures

6-03

6-03.3

Construction Requirements

Structural steel fabricators of plate and box girders, floorbeams, truss members, stringers,
cross frames, diaphragms, and laterals shall be certified under the AISC Certification
Program for Steel Bridge Fabricators, Advanced Bridges Category. When fracture critical
members are specified in the Contract, structural steel fabricators shall also meet the
supplemental requirements F, Fracture Critical, under the AISC Quality Certification
Program for Steel Bridge Fabricators.

6-03.3(1) Vacant

6-03.3(2) Facilities for Inspection

The Contractor shall provide all facilities the Inspector requires to inspect material and
workmanship. Inspectors shall be given safe and free access to all areas in the mill and
shop.

6-03.3(3) Inspector’s Authority

The Inspector may reject materials or workmanship that does not comply with these
Specifications. In any dispute, the Contractor may appeal to the Engineer whose decision
shall be final.

By its inspection at the mill and shop, the Contracting Agency intends only to facilitate
the Work and prevent errors. This inspection shall not relieve the Contractor of any
responsibility for identifying and replacing defective material or workmanship.

6-03.3(4) Rejections

Even if the Inspector accepts materials or finished members, the Contracting Agency may
later reject them if defective. The Contractor shall promptly replace or make good any
rejected materials or workmanship.

6-03.3(5) Mill Orders and Shipping Statements

The Contractor shall furnish as many copies of mill orders and shipping statements as the
Engineer requires.

6-03.3(6) Weighing

Structural steel need not be weighed unless the Plans or Special Provisions require
it. When a weight is required, it may either be calculated or obtained by scales. The
Contractor shall furnish as many copies of the calculations or weight slips as the Engineer
requires. If scale weights are used, the Contractor shall record separately the weights of
all tools, erection material, and dunnage.

Standard Specifications for Road, Bridge, and Municipal Construction 2020 (M 41-10) - page 65