Section VII.

Works Requirements

SECTION 5.09 CONCRETE BRIDGES & ERECTION PROCEDURES

5.09.1 SCOPE

This work shall consist of erecting bridge structures and decks in the conformity with the
lines, grades and dimensions shown on the Drawings and in accordance with the
Specification.

5.09.2 MATERIALS

The materials shall conform to the requirements of the following sections of the
Specification:

Concrete - Sections 5.01 and 5.02

Forms and Falsework - Section 5.04 "Forms, Formwork and Falswork"

Reinforcement - Section 5.03 "Steel Reinforcement and Fixing"

Prestressing - Section 5.07 "Prestressed Concrete Construction"

5.09.3 CONSTRUCTION

A. Precast Beam and Slab Construction

A.1Manufacture of Prestressed Beams

A.1.1 The details of method of manufacture shall be approved by the Engineer before work
is started. No changes shall subsequently be made without the consent of the Engineer.

A.1.2 The Contractor shall inform the Engineer in advance of the date of commencement of
manufacture and the dates when tensioning of tendons, casting of members and transfer of
stress will be undertaken for the first time for each type of beam.

CONCRETE BRIDGES & ERECTION PROCEDURES 5.09 - Page 1 of 3

N17036-0100D-TD-SPC-BR-07 REV 0
Section VII. Works Requirements

A.1.3 The Contractor shall submit to the Engineer, not more than 7 days after the transfer of
stress, a certificate showing the force and strain in the tendons immediately after they were
anchored, the strength and age of the test cylinders cast in accordance with this Specification,
and the minimum age in hours of the concrete at the time stress was applied to the members.
Copies of all 28-day cylinder test results relating to the work shall be kept so that the identity
of those who stressed the tendons, cast the concrete and transferred the stress, on any member
or line of members, can be traced.

A.1.4 Where the Engineer requires tests to be carried out on beams, the beams to which
these tests relate, shall not be dispatched to Site until the tests have been satisfactorily
completed.

A.2 Storage and Handling of Prestressed Members

Members shall be firmly supported at such bearing positions as will ensure that the stresses
induced in them are always less than the permissible design stresses. Members shall be lifted
or supported only at the points specified and shall be handled and placed without impact.

A.3Tolerance in Pre-Cast Members

Dimensional Variations shall not exceed the tolerances given below:

- Length +12 mm
- Width and depth +6 mm
- Bow in the vertical plane +15 mm or -0 mm
- Bow in the horizontal plane +12 mm
- Difference between longest and
shortest dimensions (check for
squareness of beam) in any plane 6mm
- Twist (measured by the deviation
of any corner from the plane
containing the other 3 corners) 6 mm
- Flatness (the maximum deviation
from a 1.5 meter straightedge
placed in any position on
nominally plane surface) 6 mm
- Cover to reinforcement +5 or -0 mm
- Prestressing tendons 3 mm in any direction
- Dowel holes 3 mm in any direction

A.4Composite Slab Construction

CONCRETE BRIDGES & ERECTION PROCEDURES 5.09 - Page 2 of 3

N17036-0100D-TD-SPC-BR-07 REV 0
Section VII. Works Requirements

A.4.1 Where in-situ concrete deck is cast to act compositely with pre-cast beams, the beams
shall be installed to correct line and level, starting from the outer most beam and working
inwards progressively. When the beams are laid side by side just before erection the
difference in soffit level between adjacent beams shall nowhere exceed 6 mm. Where
permanent soffit shutters are used, they shall be to the approval of the Engineer and they shall
be fixed securely so that there is no movement or grout loss during deck concreting.

A.4.2 The in-situ concrete deck over any one span shall be poured in one continuous
operation and shall be placed in such a sequence that the advancing edge of the freshly
deposited concrete over the full width of deck or between longitudinal construction joints is
approximately parallel to the deck supports. Lateral displacement of beams shall be
prevented during the placing of in-situ concrete.

A.4.3 The width of the in-situ deck shall be within +25 mm of that specified. On curved
bridge deck, the in-situ deck may be in a series of straights such that the width is within +25
mm of that specified.

B. In-situ Construction

Where bridge decks are constructed in-situ, the details of all forms and falsework shall first
be approved by the Engineer. Dimensional variations shall not exceed the following
tolerances:

- Length +12 mm
- Width +10 mm
- Thickness +6 mm
- Levels +10 mm or -0 mm
- Void Location 6 mm in any direction
- Cover to reinforcement +5 mm or -0 mm
- Prestressing tendons 5 mm in any direction

CONCRETE BRIDGES & ERECTION PROCEDURES 5.09 - Page 3 of 3

N17036-0100D-TD-SPC-BR-07 REV 0