PRESTRESSED CONCRETE CONSTRUCTION MANUAL

1 NEW york STATE department OF transportation OFFICE OF STRUCTURES PRESTRESSED CONCRETE CONSTRUCTION MANUAL APRIL 2017 PRESTRESSED CONCRETE CONSTRUCTION MANUAL 3rd Edition April, 2017 NEW york STATE department OF transportation OFFICE OF STRUCTURES About the Cover: Roslyn Viaduct over Hempstead Harbor Designer: Hardesty & Hanover, LLP Contractor: Tully CONSTRUCTION Co., INC i April, 2017 New york State department of transportation PRESTRESSED CONCRETE CONSTRUCTION MANUAL Table of ContentsTABLE OF CONTENTS .. i FOREWORD .. xiv SECTION 1 INTRODUCTION .. 1-1 PURPOSE.

2 1-1 APPLICABILITY .. 1-1 Locally Administered Federal Aid Projects .. 1-2 Design-Build Projects .. 1-2 SECTION 2 DRAWINGS .. 2-1 CONTRACT DRAWINGS .. 2-1 Definition .. 2-1 Requests for Clarification .. 2-1 Dimensions .. 2-1 Errors .. 2-1 Principal Controlling Dimensions and Material Properties .. 2-2 Fabricating Dimensions .. 2-2 SHOP DRAWINGS .. 2-2 Preparation .. 2-2 Drawing Size and Type .. 2-3 Standard Size .. 2-3 Neatness and Clarity .. 2-3 ii April, 2017 Title Block .. 2-3 Returned Without 2-4 Electronic Format.

3 2-4 Information Required in Shop Drawings Submissions .. 2-4 Production Notes .. 2-4 Additional Information Required in the Production Notes for Pretensioned Units.. 2-5 Layout Details .. 2-6 Precast Unit Details .. 2-6 Additional Information Required for Precast Units which will be Installed Using Segmental CONSTRUCTION (Non-Match Cast Joints).. 2-8 Additional Information Required for Precast Units with Post-Tensioning (Match Cast and Non-Match Cast Joints).. 2-8 Additional Information Required for Precast Units which will be Installed Using Segmental CONSTRUCTION (Match Cast Joints).

4 2-9 Geometry Control .. 2-9 Casting Curves .. 2-9 Forms for Precast Units with Match Cast Joints .. 2-10 INSTALLATION DRAWINGS .. 2-11 Installation Notes .. 2-12 Installation Details .. 2-12 Additional Information Required for Precast Post-Tensioned Units .. 2-12 Calculations of Theoretical Elevations and Alignment .. 2-14 iii April, 2017 Additional Information Required for Precast Units Connected Together with Field Cast Joints or Closure Pours .. 2-14 Temporary Structures and Equipment .. 2-15 Checks and Modifications of Permanent Structural Components for CONSTRUCTION Loads.

5 2-15 Revised Installation Drawings .. 2-16 SUBMISSION OF SHOP DRAWINGS AND INSTALLATION DRAWINGS .. 2-16 Check Prints .. 2-16 EXAMINATION OF SHOP DRAWINGS AND INSTALLATION DRAWINGS .. 2-17 Examination Time .. 2-17 Special Circumstances .. 2-17 Large Sets of Drawings .. 2-17 Design Calculations .. 2-17 Contract Changes .. 2-18 Contract Award .. 2-18 CONCRETE Mix Designs .. 2-18 Approved as Noted .. 2-18 Returned with Comments .. 2-18 Final Approval .. 2-19 Distribution of Approved Shop Drawings and Installation Drawings.

6 2-19 ERECTION DRAWINGS .. 2-19 General .. 2-19 Required Information .. 2-20 iv April, 2017 SECTION 3 INSPECTION .. 3-1 QUALITY .. 3-1 Quality Control .. 3-1 Quality Assurance .. 3-1 QUALIFICATIONS OF INSPECTORS .. 3-2 Qualifications of QC and QA Inspectors .. 3-2 QC Tests .. 3-2 RESPONSIBILITIES OF INSPECTORS .. 3-2 Quality Control Inspector .. 3-2 Quality Assurance Inspector .. 3-2 INSPECTOR S MARK OF ACCEPTANCE FOR SHIPMENT .. 3-3 REPORT OF ACCEPTANCE OF STRUCTURAL CONCRETE .

7 3-3 FACILITIES FOR INSPECTION .. 3-4 OBLIGATIONS OF THE CONTRACTOR .. 3-4 Informing the DCES of Work Schedule .. 3-5 Informing the QA Inspector of Work Schedule .. 3-5 SECTION 4 MATERIAL REQUIREMENTS .. 4-1 CONCRETE .. 4-1 Materials for CONCRETE .. 4-1 Materials for Lightweight CONCRETE .. 4-3 Materials for High Performance CONCRETE .. 4-5 REINFORCEMENT AND PRESTRESSING STEEL .. 4-5 MATERIALS FOR CURING .. 4-6 MATERIALS FOR FINISHING .. 4-6 CONCRETE Repair Materials .. 4-6 Penetrating Sealers.

8 4-6 v April, 2017 MATERIALS FOR INSTALLATION .. 4-7 Transverse Post-Tensioning Steel .. 4-7 Shear Key and Field Cast Joint Material .. 4-7 Adjacent Box Beam Units, Hollow Slab Units, and Solid Slab .. 4-7 Deck Bulb Tee Beams, NEXT Type D Beams, Precast CONCRETE Deck Panels, and Precast CONCRETE Approach Slabs .. 4-7 Anchorage Block-Out Grout for Transverse Post-Tensioning .. 4-8 Anchor Dowel Fill Material .. 4-8 Expansion End Material Option .. 4-8 Fixed End Material Option .. 4-8 Grouted Splice Sleeve Couplers .. 4-9 Epoxy Bonding Agent for Match-Cast Precast Segments.

9 4-9 MATERIALS FOR POST-TENSIONING .. 4-10 Post-Tensioning Anchorages .. 4-10 Post-Tensioning Couplers .. 4-11 Ducts .. 4-12 Metal Ducts .. 4-13 Plastic Ducts .. 4-13 Connections, Fittings and Grout Vent Pipes .. 4-14 Grout for Post-Tensioning Ducts .. 4-16 SECTION 5 FABRICATION REQUIREMENTS .. 5-1 PLANT FACILITY .. 5-1 ORDERING OF MATERIALS .. 5-2 DATA FOR QA INSPECTORS .. 5-2 CONCRETE FORMS .. 5-2 General .. 5-2 Void Producing Forms .. 5-3 vi April, 2017 EMBEDDED STEEL .. 5-3 Reinforcing and Prestressing Steel.

10 5-3 Welded Wire Fabric .. 5-3 Inserts .. 5-4 STRESSING REQUIREMENTS FOR PRETENSIONING .. 5-4 General .. 5-4 Tensioning of Tendons .. 5-4 Methods of Force Measurement .. 5-5 Initial Tensioning .. 5-5 Final Tensioning .. 5-5 Gauging System .. 5-5 Prestressing Strands .. 5-6 Control of Jacking Force .. 5-6 Wire Failure in Tendons .. 5-6 Time Allowed Between Tendon Tensioning and CONCRETE Placement .. 5-6 Detensioning of Tendons .. 5-6 MATCH CAST SEGMENTS .. 5-7 CONCRETE MIX DESIGN AND PROPORTIONING.