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PART 1 1.1 GENERAL
SECTION INCLUDES A. Pretensioning, fabricating, curing, transporting, storing, and erecting prestressed concrete members.
RELATED SECTIONS A. B. C. D. E. F. Section 03055: Portland Cement Concrete Section 03211: Reinforcing Steel and Welded Wire Section 03310: Structural Concrete Section 03390: Concrete Curing Section 05120: Structural Steel Section 05822: Bearings
REFERENCES A. B. C. D. E. F. G. H. AASHTO M 111: Zinc (Hot-dip Galvanized) Coatings on Iron and Steel Products AASHTO M 169: Steel Bars, Carbon, and Alloy, Cold-Finished AASHTO M 203: Steel Strand, Uncoated Seven-Wire for Prestressed Concrete AASHTO M 270: Structural Steel for Bridges AASHTO/AWS D1.5: Bridge Welding Code AASHTO LRFD Bridge Construction Specifications ASTM C 150: Portland Cement American Institute of Steel Construction (AISC) Prestressed Concrete 03412 – Page 1 of 9 January 1, 2008
article 3. Testing may require 14 calendar days after the date of receipt. This is reduced to 7 days when drawings are submitted electronically. K. Engineer reserves the right to retain these drawings up to 14 calendar days without granting an increase in the number of working days for the project. AISC Simple Steel Bridge Structures (SBR) Certification for structural steel fabrication. materials. 3. including any additions or rearrangement of reinforcing steel and any revision in concrete dimensions from that shown on the plans. working stresses. 3. Do not begin fabrication or installation of prestressing material before approval of the drawings. Certification stating the manufacturer’s minimum guaranteed ultimate tensile strength for each sample of prestressing steel. J. Show complete details and substantiating calculations of the method. at no additional cost to the Department. 1. C. Furnish three 6 ft long strand samples from each heat or lot that will be used on the project. Include the proposed arrangement of the prestressing steel in the members. 4.I. 2008 B. 5. and all other data pertaining to the prestressing operation. and equipment to be used in the prestressing operations. Certifications: 1. Include complete specifications and details of the prestressing steel. Prestressing Steel: 1. 1. 2. Contractor is responsible for costs incurred due to faulty detailing or fabrication. Prestressed Concrete 03412 – Page 2 of 9 January 1.5 Precast/Prestressed Concrete Institute (PCI) US Military Specifications UDOT Quality Management Plans Not Used DEFINITIONS SUBMITTALS A. . Outline the method and sequence of stressing. Include the cutting or release pattern. Submit five sets of working shop drawings of the prestressing system sufficiently before the start of the affected work to allow time for review by the Engineer and correction by the Contractor without delaying the work. The certified calibration chart required by this Section. Do not deviate from the approved shop drawings unless authorized in writing.2 A.4 1. This right applies each time the drawings are submitted. 2. 2.
etc. AVG = average compressive strength of 3 cylinder breaks in psi. low alkali. 1. Price reduction factor is as follows: Price Reduction Factor = 1. signed. connection details. location of lifting points on the bridge members. The Professional Engineer must approve all changes to the erection plan before implementation.1 PRODUCTS CONCRETE A. and properly connected to provide structural integrity and stability. crane location. Department will calculate the amount paid by multiplying the contract unit price for the prestressed concrete member by the price reduction factor.06 f ' c 2 2. 3. secondary members. bracing. 1.00-0. and attachments to bridge members. 4. 2008 . Type III cement: conform to ASTM C 150. lifting devices. 6. Girders may be accepted at a reduced price when the average compressive strength is at least 94 percent of the specified strength. B. Minimum number and arrangement of primary members. and sealed by a Professional Engineer licensed in the State of Utah. or Type III. Table 2. Prestressed Concrete 03412 – Page 3 of 9 January 1. PART 2 2. The erection plan and supporting documents will be approved. crane capacities. 7. connections. The erection schedule and sequence. 5. Complete details for all anticipated phases and conditions during erection. for moderate sulfate resistance. dead-men. article 3.D. Incorporate into the plan the requirements from this Section.7. and any other assumed loads during progressive stages of construction.30 Where: f’c = specified 28-day compressive strength in psi. 2. braced. Temporary supports. guys. UDOT prefers a PCI Certified Erector.6 ACCEPTANCE A. member weights. that must be installed. f 'c − AVG 0. Erection Plan: Submit an erection plan 10 days before beginning erection of prestressed concrete members for documentation purposes only. Fully illustrate the proposed method of erection. The Engineer will not approve the erection Plan. Portland Cement: Type I or Type II. Provide complete details of the process including but not limited to: 1.
Welding: AASHTO/AWS D1. 2008 . Grade 36. D.0 to 7. Threaded Rods: AASHTO M 270. Use coarse aggregate gradation meeting the ¾ inch No. Class AA(AE) concrete according to Section 03055.44 by weight including free-water in the aggregates. Carbon-Steel Headed Studs: AASHTO M 169. Core tests are not permitted for compressive strength tests. Refer to US Military Specification MIL-P-24441/20. Automatic end welded. Air entraining admixture to provide 5. B.5 percent entrained air. Grade 36.6 inch diameter. 4.5. 2.4 ELASTOMERIC BEARING PADS A. Meet AASHTO M 203. Use ½ inch or 0. 5. 7. D. Minimum compressive strength 5. Grade 270.6 MISCELLANEOUS STEEL ITEMS A. or as specified in the plans. Water-Cementitious ratio must not exceed 0. C. Use coated or corrosion-resistant reinforcing steel as specified in Section 03211. Minimum compressive strength for transfer of prestressing force is 4. 2. Carbon-Steel Shapes and Plates: AASHTO M 270.2 PRESTRESSING STEEL A. 3. Refer to Section 05822. 2.000 psi or as specified in the plans. except as modified below: 1. 2.5 ZINC-RICH PAINT A.000 psi at 28 days.3 REINFORCING STEEL A. Minimum cementitious content must be 611 lb/yd 3. Prestressed Concrete 03412 – Page 4 of 9 January 1. Girders: Reject if the average 28-day compressive strength of representative cylinders is less than 94 percent of the specified strength. Maximum slump is 7 inches. 2. 6. 2. 4 sieve per Section 03055.C.
B. Fabricate structural steel per Section 05120. The prestressing force may be tested by Engineer. safety orders. Calibrate the load cell and provide an indicator to determine the prestressing force in the tendon. B. The range of the load cell must be such that the lower 10 percent of the manufacturer’s rated capacity is not used in determining the jacking stress.3 PRESTRESSING STEEL A. 2008 . All equipment used to stress tendons must be accurate including jacks. Furnish a certified calibration chart. D. Prestressed Concrete 03412 – Page 5 of 9 January 1. Comply with camber and dimensional tolerances of PCI MNL 135. Provide sufficient labor. pressure gauges. and instructions for use. and material to install and support testing equipment at the prestressing tendons and to remove the equipment when testing is completed. structural steel for prestressed concrete members requires AISC Simple Steel Bridge Structures (SBR) Certification. 3. Unless otherwise specified. QUALITY ASSURANCE A. 3. equipment.7 Galvanize all structural steel items permanently cast into concrete per AASHTO M 111. 1.2 PREPARATION A. EXECUTION PART 3 3. Use a Department prequalified supplier of precast concrete products according to the UDOT Quality Management Plan: Precast/Prestressed Concrete Structures. load cells. Calibrate each jack and its gauge as a unit with the cylinder extension in the final jacking force position. place. Clearly mark the shipping package or form with handling instructions and information about the corrosion inhibitor including date. C. 2.E. 2.1 FABRICATION A.
Install and support testing equipment at the prestressing tendons and remove the testing equipment after the testing is completed. Do not oil or grease prestressing strand. Tension all prestressing steel with hydraulic jacks so that the force in the prestressing steel is not less than the value shown. Do not allow the initial stress to exceed 70 percent of the specified minimum ultimate tensile strength. or serious corrosion. C. 2008 E. and concrete elastic compression is as shown on the plans. prestressing steel due to creep and concrete shrinkage. B. and anchorage take ups. Protect against physical damage and corrosion during shipping. Average working stress in the prestressing steel must not exceed 60 percent of the specified minimum ultimate tensile strength of the prestressing steel unless otherwise shown. and storing. Prestressed Concrete 03412 – Page 6 of 9 January 1. Use methods and equipment acceptable to Engineer. These losses include concrete creep and shrinkage. D. Check prestressing steel strands in pretensioned members for loss of prestress not more than 12 hours before placing concrete for the members if tensioned individually. H. Replace prestressing steel that has damage. Anchor the prestressing steel at stresses (initial stress) that result in the ultimate retention of working forces not less than those shown. Slight rusting that occurs after placement in the beds is acceptable if it does not cause visible pits. F. Working force and working stress are the force and stress remaining in the prestressing steel after all losses peculiar to prestressing have either taken place or been provided for. Maximum temporary tensile stress (jacking stress) in prestressing steel must not exceed 75 percent of the specified minimum ultimate tensile strength. G. steel creep. The stress loss in pretensioned. concrete elastic compression. loose rust. 3. D. I.B.4 PRETENSIONING A. steel creep. pitting. handling. . C.
Clean and paint the exposed strand ends and a 1-inch strip of adjoining concrete. Alternatively. whichever is the greater. Cut off all pretensioned. M. prestressing steel flush with the end of the member except when otherwise shown in the plans. Submit a cutting or release pattern to the Engineer for prior approval. externally. fill the recess with grout. Do not cut or release prestressing steel in pretensioned members until the concrete in the member has attained a compressive strength of not less than the value shown on the plans or 4. Do not allow the jacking stress to exceed 75 percent of the specified minimum ultimate tensile strength. N. C. Increase the calculated prestressing steel elongation in pretensioned members to compensate for the loss in stress when it is tensioned at a temperature appreciably lower than the estimated concrete temperature and the prestressing steel at the time of initial set of the concrete. 3. Avoid displacing reinforcing steel or strands. or both.000 psi. Apply two applications to surfaces that are not covered by concrete or mortar. D. K. 1. 2008 .5 PLACE CONCRETE A. Re-tension all strands that show a loss of prestress in excess of three percent. Do not place concrete into forms until the reinforcement and prestressing steel has been Department inspected and approved.J. L. and finish flush with the girder ends. B. Vibrate the concrete internally. Finish surfaces of cast-in-place concrete that will later be cast against the top surfaces of precast beams or girders to a coarse texture by brooming with a stiff. Use a wire brush or abrasive blast cleaning to remove all dirt and residue not firmly bonded to the metal or concrete surfaces. Clean such surfaces of laitance or other foreign material by sandblasting before shipping. Prestressed Concrete 03412 – Page 7 of 9 January 1. coarse broom. 2. 3. Cover the surfaces with a thick application of zinc-rich paint. cut the strands a minimum of 1 inch back from the girder end. Thoroughly mix the paint at the time of application and work it into any voids in the strands. Maintain a minimum lateral eccentricity of prestress when cutting and releasing prestressing steel in pretensioned members.
article 3. Adequately support the members at all times to prevent dead load bending until after the anchorages for pretensioned members have been released. Prestressed Concrete 03412 – Page 8 of 9 January 1. whichever is longer. warping.7 CURE A.8 DELIVERY. Place stored units so identification marks are clearly visible and units can be inspected. Remove the prestressing member side forms within one to two days provided satisfactory arrangement has been made for curing the concrete. Store units with dunnage across full width of each bearing point unless otherwise specified. 3. Cure as specified in Section 03390. and handling.1 until deck is placed. 2008 B. AND HANDLING A. 1. Take appropriate measures to prevent girder camber from exceeding the tolerances specified in this Section. E.3. C. contact with soil. Secure and protect units from movement and prevent cracking. C. staining. distortion. B. Transport precast girders in an upright position. Do not ship prestressed concrete members until tests on concrete cylinders manufactured from the same concrete and cured under the same conditions as the girders indicate that the concrete of the particular member has attained a compressive strength equal to the specified design compressive strength or for seven days after concrete placement. Prevent cracking or damaging precast units during storage. Support the girders during transportation in approximately the same points they will be supported when installed. STORAGE. D. Store units with adequate dunnage and bracing. F.6 LIMITATIONS A. Installation of lifting devices is permitted provided that any portion of the devices that protrudes above the top of the girder is removed when no longer needed. . and other physical damage. 2. Refer to Section 03310 for hot and cold weather limitations. 3. hoisting.
Erect girders in a manner that prevents damage to all elements of the structure. Temporarily support. the workers. 2008 . E. Use lifting devices in a manner that does not cause damaging. F. including the protection of prestressed concrete members. and brace all superstructure members as detailed in the erection plan before allowing traffic under the bridge. Support. D. Erect all prestressed concrete members in compliance with the erection plan. bending. and the traveling public. and brace all erected superstructure members as necessary for stability and to resist wind or other loads until they are permanently secured to the structure. chipped. Do not open traffic under a partially-erected bridge superstructure.3. anchor. Maintain responsibility for all aspects of girder erection during all stages of construction. C. Design temporary supports and falsework according to the current edition of the AASHTO LRFD Bridge Construction Specifications. broken. and sealed the erection plan. H. Prestressed Concrete 03412 – Page 9 of 9 January 1. or torsional forces. unless allowed in the erection plan or approved by the Professional Engineer who approved. G. Section 3 “Temporary Works. Carefully handle materials so that no parts will be cracked. END OF SECTION B. Clean bearing surfaces and surfaces that will be in permanent contact before the members are erected. signed. I. or otherwise damaged. Follow any match-marks. anchor.” Accurately assemble all parts as specified in the contract documents or erection drawings.9 ERECTION A.
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