Professional Documents
Culture Documents
DELIVERY
OF PRODUCT
INITIAL COORDINATION INFORMATION
• County
• SR‐#
• Sales Order #
• Structure #
• Phase if applicable
SHIPPING INFORMATION
• Physical address of jobsite
• Instructions on how to access the
site (i.e. road name, direction of
travel, landmarks, etc.)
o Side of the excavation
where installation work
will be preformed
SHIPPING INFORMATION
Important Information to Provide ACM’s Traffic Manager:
• Special instructions for delivery sequence of product
(i.e. wing walls must be placed in the excavation
before the box due to overhead obstructions)
• If a grout pump rental is needed
o If so, does the sales order need to be updated to
include the extra $750
SHIPPING INFORMATION
Important Information to Provide ACM’s Traffic
Manager (cont’d):
• Any barriers that may be present that will cause problems
with permitted loads
• Nearest available area for trucks to turn around
• Do drivers need to back into the site or pull into the crane
• Nearest location to stage the trucks
• Can loaded trailers be stored overnight the
day before delivery?
SHIPPING INFORMATION
Important Information to Provide ACM’s Traffic Manager
(cont’d):
• Delivery time
• Estimated day and time the crane will be up
and fully functional
• Keep in mind…If the pieces are over‐dimensional
they cannot travel outside of legal daylight hours.
Many times, the first piece being set is oversized;
this may affect start time of jobsite unless staged
onsite the day prior.
SHIPPING INFORMATION
A.C. Miller will always make every effort to
accommodate your requested delivery schedule;
however, during peak construction season,
delivery lead times can be up to six to eight
weeks.
• Contact the Traffic Department as early
as possible to discuss tentative delivery
dates.
SHIPPING INFORMATION
• Communicate that the crane needs
four equal length slings and clevises,
then we will supply the adjusting
chains to pick wing walls and the
lifters
DIMENSION AND WEIGHT FOR TRANSPORTATION
Next you need to consider the width of the load traveling down the highway.
After determining the center of gravity of the section, determine the overhang
widths and the overall width of the load. The standard trailers are 8’6” wide.
The following information is presented to let you know what is involved:
• Over 8’6’ wide you will need an over width permit
• From 13 ft. wide to 15 ft. wide you will need one escort car
• From 15 ft. wide to 16 ft. wide you will need front and rear escort
cars
• For 16 ft. and wider loads you will need to have State Police escorts,
a front and rear escort car, and perform a route survey months in
advance
QUALITY CONTROL
QUALITY CONTROL PRACTICES
QUALITY CONTROL PRACTICES
Quality Control Forms
Pre‐Casting Inspection Report Post‐Casting Inspection Report
QUALITY CONTROL PRACTICES
In House Practices (Pre‐pour)
• The process starts with reviewing the approved drawings
• Next, document all of the information from the prints to
our pre‐pour inspection sheet
• When the rebar cage is set on the form, Q.C. visually
inspects the cage and documents everything from rebar
sizes, spacing, block outs, dowel bars, post tensioning
ducts, etc.
• From there, the form is closed and inspected again before
it is poured to assure a quality product.
QUALITY CONTROL PRACTICES
QUALITY CONTROL PRACTICES
QUALITY CONTROL PRACTICES
In House Practices (Post)
• Concrete cylinders are broken each morning to assure we have
the proper stripping strength
• From there, we do 100% product post pour inspection
• The piece is moved into our yard
• It is then stored on proper dunnage in our yard until it is time
to ship
• The day before the job ships, a member of Q.C. (ACM) and Q.A.
(TRC) will recheck every piece. Each piece will receive a stamp
of approval from the Q.A. inspector.
QUALITY CONTROL PRACTICES
Certificates of Compliance
• Rebar Packages
• Dowel Bars
• Grout
• Patch Material
QUALITY CONTROL PRACTICES
On site preparations
It is very important for the contractor to have an area
laid out for materials being shipped to the job site
that may not be used right away. It can be very costly
for the contractor when orders need duplicated
because they were lost or damaged.
QUALITY CONTROL PRACTICES
STRUCTURE
PLACEMENT
LIFTING AND HANDLING
FACTORS FOR SAFE WORKING LOAD (SWL) OF LIFTING DEVICES AND EMBEDS
DEPENDS ON:
1. Style or design of the devices – Size, Shape and Depth of embedment
2. The direction the load is being applied
3. The “Edge Distance” or distance to a free edge or face of the concrete
4. The number of lift points and spacing between the lifting devices
5. The concrete strength during all phases of lifting
6. Normally rated at 3:1 or 4:1 safety factor when embedded in 3500 psi concrete
7. Proper rigging to equalize the load on all lifting devices
8. Fleet angle of the slings – all calculations are based on a minimum fleet angle
of 60 degrees
COMMON LIFTING DEVICES
Tea Cup Lifter
Uses a through hole in
the concrete and engages
full concrete thickness.
Typical capacity is 16 to
18 ton but is less affected
by edge distance.
Swivel Pates:
Typically uses a
Lift Pin Systems: through bolt. Various
The most common lifter capacities but not
used. Capacities from 2 to 20 commonly used.
tons. Affected by pin length,
concrete strength, edge
distance and distance
between pins.
LIFTING DEVICES
Adjustable leg slings can help to
equalize loads on the lifters.
LIFTING DEVICES
LIFTING DEVICES
LITING DEVICES
ROTATING SECTIONS
ROTATING PRECAST CULVERT SECTIONS IS A TASK YOU WILL NEED TO
PLAN FOR AND PERFORM IN THE FIELD:
1. Many of the culverts are too tall to be placed on a truck and shipped to
the job site in their position of function. They are shipped “Laid Down”
with the barrel of the culvert as the vertical axis on the truck. They are
usually permitted as oversize loads for both width and weight.
2. Two cranes are not practical in the field and double drum cranes are
often scarce.
3. You will need a sizable area level free of obstruction and utilities to
perform the rotation, along with an adequate number of workers.
4. Done properly you can minimize the dynamic loads placed on the
rigging, crane and precast concrete section.
ROTATING SECTIONS
ROTATING SECTIONS
ROTATING SECTIONS
ROTATING SECTIONS
ROTATING SECTIONS
ROTATING SECTIONS
ROTATING SECTIONS
INSTALLATION OF BOX SECTIONS
BOX CULVERT LAYOUT
1. Stake out the culvert alignment.
2. Generally, you should start at the downstream end of the End Box Culvert
Section. (Note: The box culvert sections will move towards the middle
section of the culvert run). It is important to make allowance for the end
section movement towards the center of the culvert run. Typically, if
there are five joints, the joint material compresses to an average
thickness of 5/8” for a total of 3‐1/8”. You will then have to off‐set the
end section approximately 1‐1/2” from the end mark.
3. There are pulling anchors cast in the interior walls of the culvert for
attaching a come‐a‐long to pull the next section tightly. (Please note that
you can keep the crane hooked to the section as you are pulling so the
box section is in contact with the previous section).
BOX CULVERT INSTALLATION
Open Discussion
BOX CULVERT INSTALLATION
1. Place material (1/8” Masonite or luan plywood ) under the
joints to ensure bedding material stays out of the construction
joints. Note: If there is no uniform distance between the
culvert sections you may have to recheck your grade.
2. When bringing the culvert sections into place you will be
threading the post tensioning cables through the culvert
sections.
3. Now the post tensioning of the box culvert sections will be
ready to start. After the tensioning of the box culvert
sections, it will be time to install the wing walls. The wing
walls will then be installed and post tensioned to the box
culvert in the same fashion.
INLET OR OUTLET WING WALL SECTION BEDDING
Open Discussion
INLET OR OUTLET WING WALL SECTION
Open Discussion
POST TENSIONING
OPERATIONS
POST TENSIONING OPERATION
When the box culvert sections are installed, you will need to center
the post tensioning strands in the box culvert. Please take into
account the wing walls will also be post tensioned after the box
culvert sections.
1. The polymer shield will need to be removed on the strands on the
fixed end at 2 ft. and placed at least 1 ft. on the inside of the
anchor plates.
2. On the jacking end of the culvert, 4 ft. of the polymer shield will
be removed and placed 1 ft. on the inside of the anchor plates
and 3 ft. for the installation of the post tensioning jack.
POST TENSIONING OPERATION (cont’d)
3. The tensioning sequence is on the last page of the approved
shop drawings. You will need to tension the strands three
times in order to increase the pressure each time.
4. After completing the post tensioning of the box culvert, the
wing walls will be installed and post tensioned in the same
fashion.
5. When installing a multi‐pull box culvert, the strands will be
long enough to make two runs of box culvert sections. The
strands will be tensioned and more box sections will be added
and then tensioned.
POST TENSIONING OPERATION (cont’d)
Open Discussion
POST TENSIONING OPERATION (cont’d)
Open Discussion
POST TENSIONING OPERATION (cont’d)
Open Discussion
POST TENSIONING OPERATION (cont’d)
Open Discussion
POST TENSIONING OPERATION (cont’d)
6. Phased construction box culverts require splice connectors to be
installed on the strands before installing the second phase of box
culvert sections. When attaching the splice connectors you will
have to cut the strands with 5” of the strand projecting from the
face construction joint. Slide the splice connectors on the strands
and then bring the Phase II culvert section into position leaving
approximately 3’ between the culvert sections. Install the
strands through the culvert and attach the strands to the splice
connectors. Install the remaining culvert sections.
POST TENSIONING OPERATION
Safety & Crew Size
1. Always stay clear of the ends of post tensioning strands/tendons and
DO NOT stand behind the post tension jack when you are performing
the tensioning operation.
• Open the jack gripper
• Position jack on strand until nose bears on the anchor
o NEVER attempt to adjust the position of the jack once the load
has been applied. If necessary remove jack and reposition.
• Make sure the strand is in proper position within the jack gripper
• Make sure the jack grippers are parallel to avoid damage
• Use of the pendent switch allows the operator to stand to the side
and stay out of harm’s way, should anything fail
• After the proper gauge pressure is achieved, switch the valve to
the retract position
POST TENSIONING OPERATION (cont’d)
Safety & Crew Size (cont’d)
2. Crew size for post tensioning operation is a minimum of five members:
• Two people to handle the tensioning jack
• One to two people on top of the Box Culvert to assist with
moving the from strand to strand by pulling and holding a rope
that is attached to the jack
• One person to operate the hydraulic power pack and monitor
the pressure gauge
3. Carry by the handle and be sure to keep hands clear of the jack’s pinch
points when releasing the pressure and returning the cylinder in to the
closed position.
POST TENSIONING OPERATION (cont’d)
Safety & Crew Size (cont’d)
What NOT to do…
• Do not use the jack if it does not seat properly on the
anchor
• Do not over‐stress tendons
• Do not continue stressing if you suspect something is not
working properly
• Do not hammer or beat on the cylinders or jack
• Do not stand behind or under the jack
POST TENSIONING OPERATION
Equipment & Tools
• Ladders
• Generator with extension cords
• 4‐1/2” grinder with metal cutting discs
• Utility knives (hooked blades work the best for removing the
polymer coating from the strands
• Hammer
• Screw drivers
• Channel lock pliers
• Gloves
• Eye protection
• Shop Towels
POST TENSIONING OPERATION
Helpful Hints
Make sure that…
1. The hydraulic quick connects are clean and free of any dirt
before putting together and that the check ball is
completely depressed.
2. The three wedge set is installed correctly with even spacing
between the wedges and that you have one wedge at the
top of the anchor plate.
3. The nose of the jack is clean.
POST TENSIONING OPERATION
POST TENSIONING OPERATION
POST TENSIONING OPERATION
POST TENSIONING OPERATION
POST TENSIONING OPERATION
GROUTING
OPERATIONS
GROUTING OPERATION
Post tensioning strands in the box culverts are un‐bonded strands
with a corrosion inhibiting grease between the steel strand and
the polymer coating. This is the primary corrosion protection
and the grout in the ducts provide a secondary protection against
corrosion.
The grouting of the post tensioning ducts is done generally right
after the box culvert post tensioning is completed. This may take
place the same day or the following work day. If the grouting is
not going to be done right away then you will have to make sure
that ducts are kept clean and free of water contamination.
GROUTING OPERATION (cont’d)
A sample precaution of closing the valve on the pumping and
venting grout tubes and sealing over the ends of the strands is
required. The box culvert excavation needs to be monitored and
kept free from flooding or standing water until the post
tensioning ducts are grouted.
GROUTING OPERATION
1. Allow one batch of grout for every 150 lineal feet of 1‐1/2” duct.
2. One batch of grout consist of three 94 lb. bags of Type II port and
cement; one pre‐measured bag of Specrete IP Type “ C “ intrusion
aid; and 12 gallons of clean water. Note: Maximum allowable
water is 15 gallons.
3. The “best practices” method of grouting the strands is to pump
from the downstream end with all vents open. Pumping would
continue until all bleed water and air has been expelled from the
duct and only grout is streaming from the vent pipe. At that time
the vent valve should be closed followed by the pumping valve.
The process is repeated for the remaining ducts.
GROUTING OPERATION
Safe Operation of Grout Pump
• Wear proper PPE, including safety glasses and gloves
• Don’t place your hands, feet or other body parts between the
placement of the hose and the object
• When pumping, wear snug‐fitting clothing
• Handle plug‐ups carefully; don’t disconnect slick lines or walk on
the hose to find a rock jam until pressure has been relieved
• The safest way to clean out the hose is with water
CLEAN‐UP AND
DEMOBILIZATION
CLEAN‐UP AND DEMOBILIZATION
• When the installation and post tensioning operation are
completed, we will need to clean and put all of the
equipment back in the A. C. Miller job box
• Before the crane breaks down make sure that the job
box is loaded on the A.C. Miller consultant's truck and
trailer
• If the A.C. Miller grout pump is rented please follow the
consultant’s directions to properly clean all of the grout
equipment and load it on the job trailer