ITEM #0601276A – PRECAST SUBSTRUCTURE ELEMENTS

Description:

Work under this item shall consist of furnishing and installing all precast substructure elements
for precast concrete box culverts, concrete relief slabs, and abutment backwalls including all
necessary materials and equipment to complete the work as shown on the plans. The use of cast-
in-place concrete will not be considered for substitution without the Engineer’s approval. These
elements include cut-off wall, return wall, box nose, ballast retainer, relief slab, relief slab
footings, and abutment backwall. Reinforcing, threaded inserts, lifting and seating fixtures, non-
shrink grout, and all other necessary materials and equipment to complete the work shall also be
included.

Due to the accelerated nature of this project, all precast elements shall be cast and approved prior
to the initiation of the track outage.

Materials:

The following list is a summary of materials to be used for various precast substructure elements
of the structures:

Concrete
The concrete shall conform to the requirements of Subarticle M.03, as applicable. The
Contractor shall design and submit to the Engineer for review a concrete mix that shall attain a
minimum 28-day strength (f'c) as shown on the plans.

Reinforcement
Welded wire fabric shall be uncoated and conform to the requirements of ASTM A185.
Deformed steel bars shall be uncoated and conform to the requirements of ASTM A615, Grade
60, and Section M.06.01.

Non-shrink grout
The non-shrink grout shall conform to the requirements of Subarticle M.03.05.

Neoprene bearing pad

The neoprene bearing pad shall be Grade 60 conforming to the requirements of Subarticle
M.17.01.

Preformed Compression Seal

The elastomeric compression seal shall conform to the requirements of Subarticle M.17.02.

Threaded Inserts, Lifting Fixtures and Miscellaneous Hardware

Each precast section shall contain a suitable number of reinforced lifting and/or seating fixtures
to ensure safe and level handling and to prevent structural damage during installation. Devices

170-3192 142
ITEM #0601276A
and attachments shall be of a design satisfactory for the purpose intended. All inserts, fixtures
and hardware cast into precast concrete components shall have a corrosion-resistant coating or be
fabricated from a non-corrosive material suitable for the intended use. The coating shall be
either an epoxy material or galvanization, applied mechanically or by the hot-dip process. All
hardware shall be as specified on the shop or working drawings.

Dowel Bar Splicers

Dowel bar splicer systems shall meet the requirements of Subarticle M.06.02.

Grouted Splice Couplers

Use grouted splice couplers to join precast elements where shown on the plans. The coupler
shall be specifically designed to join reinforcing steel from within a precast concrete element to
projecting bars from an adjacent precast concrete element. The couplers shall use cementitious
grout placed inside a steel casting to develop the strength of the connection. Threaded
connections may be used for the portions of the coupler that are placed within the precast element
if the strength of the coupler meets or exceeds the requirements of this specification.

Grouted sleeve couplers shall be provided by the following, or an approved equal:

NMB Splice-Sleeve
38777 West Six Mile Road, Suite 205
Livonia, MI 48152
(877) 880-3230
www.splicesleeve.com

Lenton Interlok
Pentair USA
34600 Solon Road
Solon, OH 44139
(800) 753-9221
www.erico.com/lenton.asp

Sleeve-Lock
Dayton Superior
1125 Byers Road
Miamisburg, OH 45342
(800) 745-3700
www.daytonsuperior.com

Construction Methods: Prior to fabrication, the Contractor shall submit working drawings to
the Engineer for approval in accordance with Subarticle 1.05.02-2, and as follows:

1. Prepare and submit working drawings for all precast substructure elements to be
fabricated.

170-3192 143
ITEM #0601276A
 2. Dimension pieces on working drawings from working points or working lines to prevent
accumulation of dimensional tolerances. Construct pieces from the same working point or
working line and meet the tolerances required in this specification.
3. Show all lifting inserts, hardware, or devices and locations on the working drawings, and
provide backup calculations for the Engineer’s review.
4. Show locations and details of the lifting devices, including supporting calculations, type,
and amount of any additional reinforcing required for lifting. Design all lifting devices
based on the no cracking criteria in Chapter 5 of the PCI Design Handbook.
5. Supporting calculations shall be signed and sealed by a Professional Engineer licensed in
the State of Connecticut.
6. Show minimum compressive strength attained prior to handling the precast elements.
7. Do not order materials or begin work until receiving final approval of the working
drawings.
8. The Department will reject any elements fabricated before receiving written approval, or
any elements that deviate from the approved drawings. The Contractor is responsible for
costs incurred due to faulty detailing or fabrication.

Prior to erection, the Contractor shall submit an Assembly Plan to the Engineer for review in
accordance with Subarticle 1.05.02-2, and the following:

1. Follow the requirements of the PCI Design Handbook for handling and erection bracing
requirements.
2. Design and detail temporary supports on this submission to provide sufficient
adjustability so that the final in place location of the precast elements meet the tolerance
requirements of this specification.
3. Comply with all requirements of applicable environmental permits.
4. Submit full size 22" x 34" sheets depicting the assembly procedures for the precast
substructure elements.
5. Include a work area plan, depicting items such as utilities overhead and below the work
area and protective measures.
6. Include details of all equipment that will be employed for the assembly of the
substructure.
7. Include details of all equipment to be used to lift substructure elements including cranes,
excavators, lifting slings, sling hooks, and jacks. Include crane locations, operation radii,
and lifting calculations.
8. Include a detailed sequence of construction and a timeline for all operations. Account for
setting and cure time for grouts, shear key concrete, void concrete, and concrete closure
pours.
9. Include methods of providing temporary support of the elements. Include methods of
adjusting and securing the element after placement.
10. Include procedures for controlling tolerance limits both horizontal and vertical.
11. Include methods for curing closure pour concrete and void concrete.
12. Include methods of forming closure pours including the use of backer rods. Do not
assume that the backer rods will restrain the pressure from the grout in vertical grout
joints. Provide additional forming to retain the backer rod.

170-3192 144
ITEM #0601276A
 13. The Assembly Plan shall be bound into one complete document, and shall be prepared,
signed, and sealed by a Professional Engineer licensed in the State of Connecticut.

Fabrication

The fabrication and manufacture of the precast substructure elements shall conform to the latest
edition of the AASHTO LRFD Bridge Design Specifications, including the latest interim
specifications.

Provide the Engineer a casting schedule at least two (2) weeks in advance to make inspection and
testing arrangements. A similar notification is required for the shipment of precast elements to
the job site. Do not place concrete in the forms until the Engineer has inspected the form and has
approved the placement of all materials in the precast elements. Finish the precast elements
according to Section 6.01. Trowel-finish the top surface of all precast concrete elements.

Use bi-level templates and jigs to set the location of grouted sleeve couplers for mating elements
where applicable.

Fabrication and Erection Tolerances: The length of each substructure element measured along its
longitudinal axis shall be equal to that shown on the plans plus or minus 1/8”. The thickness of
each substructure element shall be equal to that shown on the plans plus or minus 1/8”. The
height of each substructure element, measured from the top of the footing to the top of the
substructure element, shall be equal to that shown on the plans plus or minus 1/8”. The top of the
substructure element elevation shall be equal to that shown on the plans plus or minus 1/8”. The
squareness and plumbness shall not exceed plus or minus 1/8”.

Quality Assurance

1. All precast elements shall be fabricated by a CTDOT approved PCI certified fabricator
with a minimum certification of "B1" unless an appropriate alternative is approved by the
Engineer.
2. Permanently mark each precast element with date of casting and supplier identification.
Stamp markings in fresh concrete.
3. Prevent cracking or damage of precast elements during handling and storage.
4. Replace defects and breakage of precast elements:
a. Members that sustain damage or surface defects during fabrication, handling,
storage, hauling, or erection are subject to review or rejection.
b. Obtain approval before performing repairs.
c. Repair work must reestablish the elements’ structural integrity, durability, and
aesthetics to the satisfaction of the Engineer.
d. Determine the cause when damage occurs and take corrective action.
e. Failure to take corrective action, leading to similar repetitive damage, can be
cause for rejection of the damaged element.

170-3192 145
ITEM #0601276A
 f. Cracks that extend to the nearest reinforcement plane and fine surface cracks that
do not extend to the nearest reinforcement plane but are numerous or extensive
are subject to review and rejection.
g. Full depth cracking and breakage greater than one foot are cause for rejection.
5. Construct precast elements to tolerances shown on these specification and on the plans.
Where tolerances are not shown, follow tolerance limits in the latest edition of PCI
MNL116, “Manual for Quality Control for Plants and Protection of Structural Precast
Concrete Products”.
6. The plant will document all test results. The quality control file will contain at least the
following information:
a. Element identification.
b. Date and time of cast.
c. Concrete cylinder test results.
d. Quantity of used concrete and the batch printout.
e. Form-stripping date and repairs if applicable.
f. Location/number of blockouts and lifting inserts.
g. Temperature and moisture of curing period.
h. Document lifting device details, requirements, and inserts.
7. The concrete strengths required for various operations shall be indicated on the Assembly
Plan. The Contractor shall demonstrate that these minimum strengths have been met
through the use of material testing. As such, the Contractor will be required to perform
strength testing at the Contractor's own expense, and shall be responsible for taking a
sufficient number of concrete cylinders and/or cubes to meet this requirement. The
Contractor shall not rely solely on compressive tests conducted by CTDOT, as the
CTDOT testing schedule may not be changed to accommodate Contractor’s scheduling
requirements for interim testing.
8. Do not proceed with the installation of elements above the cast in place components until
the compressive test result of the cylinders for the cast in place concrete has reached the
specified minimum values in the approved Assembly Plan.

Erection

Procedure for installation of elements:

1. Review the approved Assembly Plan. If changes are warranted due to varying site
conditions, resubmit the plan for review and approval.
2. Dry fit adjacent precast elements in the precaster’s shop or yard prior to shipment.
3. Establish working points, working lines and benchmark elevations prior to placement of
all elements.
4. Check the condition of the receiving bonding surface prior to connecting elements and
take any necessary measures to remove items such as dust, rust, and debris to provide the
satisfactory bonding required between the protruding reinforcing bars element and the
grouted couplers.
5. Place elements in the sequence and according to the methods outlined in the Assembly
Plan. Adjust the height of each element by means of leveling devices or shims.

170-3192 146
ITEM #0601276A
 a. Lift substructure element as shown in the Assembly Plan using lifting devices as
shown on the shop drawings.
b. Set the substructure element in the proper horizontal location. Check for proper
alignment within specified tolerances.
c. Adjust the devices prior to full release from the crane if vertical leveling devices
are used. This will reduce the amount of torque required to turn the bolts in the
leveling devices. Check for proper grade within specified tolerances.
d. Drill and epoxy threaded rods and install tie plates, if required.
e. Fill voids with high early strength concrete or non-shrink grout as shown on the
plans. Allow concrete to flow partially under the substructure element. The entire
underside of the substructure element need not be filled with concrete.
f. Do not remove the installation bolts (if used) or proceed with the installation of
elements above the cast in place work until the compressive test result of the
cylinders for the pile connection concrete has reached the specified minimum
values.
6. Upon connecting precast elements to mating elements and setting to proper location,
grout the splice couplers and allow to cure. Do not remove temporary supports until the
couplers can resist 100% of the specified minimum yield strength of the bar.
7. Remove all temporary supports, grout holes and finish flush.

Method of Measurement:

This work will be measured for payment by the cubic yards of precast elements, of the size
indicated, complete and accepted.

For all precast elements the various materials to fill voids and shear keys cast into the elements
shall be considered included in this Item and not measured separately for payment. The
calculation of the volume of concrete used for the payment of this Item shall include all voids
and keys and be based on the overall plan and elevation dimensions of the elements.

Items considered incidental to the construction and included in the unit price per cubic yard of
concrete shall include, shear key concrete, neoprene seals, backer rods, preformed and premolded
filler, grout ports, leveling devices, reinforcing steel, grouted splice couplers, lifting hardware,
non-shrink grouts, and all other work involved in furnishing and placing the precast concrete
elements

Basis of Payment:

This work will be paid for at the contract unit price per cubic yard for “Precast Substructure
Elements”, complete and accepted. Price shall include but not be limited to design, delivery,
temporary bracing and installation of all precast concrete elements, development of Assembly
Plan, all tools, material, equipment, labor and work incidental to the construction.

Pay Item Pay Unit

170-3192 147
ITEM #0601276A
Precast Substructure Elements CY

170-3192 148
ITEM #0601276A