SECTION PRECAST CULVERT STEAM TUNNEL

Transcription

1 SECTION PRECAST CULVERT STEAM TUNNEL -, PART I - GENERAL LI STIPULATIONS - A. The Specification Sections "General Conditions of Contract", "Special Conditions" and "Division 01 - General Requirements" form a part of this Section by this reference thereto, and shall have the same force and effect as if printed herewith in ff DESCRIPTION OF WORK A. The Contractor shall famish all labor, equipment and appurtenancei, and materials necessary for the installation of precast box culvert steam tunnels and manholes in accordance with the Contract Specifications and Drawings, PemIDOT Specifications, or as directed by the Using Agency's Representative. 1.3 RELATED SECTIONS A. Section Site Concrete Reinforcement B. Section Cast-in-Place Concrete, C. Section Aggregates for Earthwork D, Section Trenching 1.4 SUBMIUALS A. Comply with the contract provisions for submittals. B. Certificates 1. Submit materials certificates for material covered by this section and shop drawings as specified signed by material supplier and Contractor, certiing that materials comply ;'ith, or exceed, the requirements of this Section. C. Shop Drawings I. The drawings for precast concrete units shall be furnished by the precast concrete producer for approval. These drawings shall show the design loads and standards have been met. Installation and construction information shall be included on shop drawings upon request. Details of steel reinforcing size and placement shall be submitted. Shop drawings shall be stamped and sealed by a professional engineer. 2. For custom made precast concrete units, in addition to the requirements in B.l, the drawing for submittal shall show locations and dimensions to all penetrations and special embed items. Product dimensions and thicknesses shall be shown, and the drawing shall be to a common architectural scale with the precast producer's information in the title block. D. Precast Concrete Unit Data 1. Anchorage, Lifting Inserts and Devices i, For anchors, lifting inserts and other devices, the precast concrete producer shall provide product data sheets and proper installation instructions upon request. 2.. Accessory Items i. For items including, but not limited to sealants, gaskets, steam tunnel unit pipe entry connectors, steps, racks, and other items installed before or after delivery, the precast concrete producer shall include proper installation instructions and relevant product data DGS Phase 1.1 PRECAST CULVERT STEAM TUNNEL

2 F. Design Data upon request. The precast concrete producer shall supply submittals showing design loading and material specifications for supplied products. At a minimum, the following shall be shown on the submittals: i. Live load used in design ii. iii. iv. Vertical and lateral earth loads used in design Depth of soil fill on the sthicture Water table depth used in calculations 2. Upon request, the precast concrete producer shall supply precast concrete unit design calculations and concrete mix design proportions and appropriate mix design test data. Structural design calculations shall be sealed by a licensed Engineer. F. Submit results for the tests performed on the box culvert and manholes 1.5 REFERENCES A. AASHTO LRFD Bridge Design Specifications, Latest Edition B. AASHTO M55 - Standard Specification for Steel Welded Wire Fabric Plain for Concrete Reinforcement C. AASHTO Ml 98 Standard Specification for Joints for Concrete Pipe. Martholes. and Precast Box Sections Using Preformed Flexible Joint Sealants D. AASHTO M221 - Standard Specification for Steel Welded Wire Reinforceicient, Deformed, for - Concrete E. AASHTO M259 - Standard Specification for Precast Reinforced Concrete Box Sections for Culverts. Storm Drains, and Sewers F. AAS1-ITO M Standard Specification for Precast Reinforced Concrete Box Sections for Culverts, Storm Drains, and Sewers with Less Than 2 ft of Cover Subjected to Highway Loadings G. ACI 305 R - Hot Weather Ccincreting H. ACI 306 R Cold Weather Concreting I. ACT Building Code Requirements for Structural Concrete 3. ACPA - Concrete Pipe Handbook K. ACPA - Design Manual L. ASTM A185 Standard Specification for Steel Welded Wire Reinforcement. Plain. for Concrete M. ASTM A497 - Standard Specification for Steel Welded Wire Reinforcement, Deformed, for Concrete N. ASTM A615 - Standard Specification for Deformed and Plain Carbon-Steel Bars for Concrete Reinforcement 0. ASTM A706 - Standard Specification for Deformed and Plain Low-Alloy Steel Bars for Concrete Reinforcement.-.- DGS Phase 1.1 PRECAST CULVERT STEAM TUNNEL

3 -a W -. P. ASTM C923 - Standard Specification for Resilient Connectors Between Reinforced Concrete Manhole Structures, Pipes, and Laterals Q. ASTM C Standard Specification for Precast Reinforced Concrete Monolithic Box Sections for Culverts, Storm Drains, and Sewers Designed According to AASHTO LRFD R. ASTM D698 - Test Methods for Moisture - Density Re]ations of Soils and Soil - Aggregate Mixtures, Using 5.5 lb (2.49 kg) Rammer and 12 inch (304.8 mm) Drop S. ASTM Dl056 - Standard Specification for Flexible Cellular Materials - Sponge or Expanded Rubber T. ASTM D30l 7-Test Methods for Moisture Content of Soil and Soil - Aggregate Mixtures U. Pennsylvania Department of Transportation (PermDOT) Publication 15 Design Manual, Part 4, latest edition and subsequent supplements and addendums. V. PennDOT Publication 34 Bulletin 14, Aggregate Producers, latest edition W. PennDOT Publication 35 - Bulletin 15, Approved Construction Materials, latest edition X. PennsDOT Publication 72M - Standards for Roadway Construction, latest edition and subsequent supplements and addendums. Y. PennDOT Publication 21 SM - Standards for Bridge Design, BD-600M Series, latest edition and subsequent supplements and addendums. Z. PennDOT Publication Construction Specifications, latest edition and subsequent supplements and addendums. 1.6 REGULATORY REQUIREMENTS A. The specifications indicated are the minimum requirements to be applied to the Work. In instances where Federal, State. and Local codes and/or ordinances conflict with these specifications, the more stringent requirement shall apply. PART 2 PRODUCTS 2.1 MATERIALS A. Precast concrete steam tunnel and manhole unit bedding, unless otherwise indicated, shall be AASHTO No.57 Aggregate. I. Aggregate supplier shall be listed in PennDOT Bulletin 14 B. Precast concrete steam tunnel and manhole units shall be of size and type indicated on the drawings. Precast steam tunnel units must conform to PennDOT Publication 21 SM, BD 632M and Publication 408, Section Precast steam tunnel manholes must conform to PennDOT Publication 72M. RC-39M and RC-46M; Publication 408, Section 605. I. Precast concrete steam tunnel and manhole units and components shall be supplied by a manufacturer approved under PennDOT Bulletin Concrete and masonry materials for construction of precast concrete steam tunnel and manhole units shall conform to Section Cast-in-Place Concrete and PennDOT Standard Specifications and Standard Details. a. Precast steam tunnel and manhole units and components shall be manufactured of PennDOT Class AA concrete (design 28-day minimum compressive strength 5000 psi). DOS Phase 1.] PRECAST CULVERT STEAN TUNNEL

4 3. Flexible sealing compound shall be packaged in extruded preformed shape, sized to completely fill the joint between precast sections, and form permanently flexible watertight seal. The sealing compound shall be non-shrink and meet AASHTO M198B. 4. Iron castings for manholes shall conform to ASTM A48, Class 30. a. Bearing surfaces between cast iron frames and covers shall be machined, fitted together and match marked to prevent rocking. System identi'ing letter 2" high shall be stamped or cast into all covers so that they may be plainly visible. 5. Manhole steps shall conform to the PennDOT Standard Specifications and Standard Details. 6. Reinforcing shall conform to the Construction Drawings, PennDOT Standard Specifications and Standard Details, and Section Site Concrete Reinforcement. C. Resilient Connectors: Flexible, watertight connectors used for pipe/conduit penetrations at precast concrete steam tunnel and manholes shall conform to ASTM C923. D. Waterproofing: Flexible adhesive-backed preformed membrane sheets shall comply with PennDOT Publication 408 Section a or b and Publication 21 SM, BD-632M. 1. Waterproofing material shall be desighèd for buried concrete or masonry construction. 2.2 MANUFACTURE A. Forms 1. Forms for manufacturing precast concrete units shall be of the type and design consistent with industry standards and practices. They should be-capable of consistently providing uniform products and dimensions. Forms shall be constructed so that the forces and vibrations to which the forms will be subjected cause no damage to the precast concrete unit Fdrths shall be cleaned of eoncrete build-up after each use. 3. Form release agents shall be applied according to the manufacturer's recommendations and shall not be allowed to build up on the form casting surface. B. Reinforcement 1. Reinforcement shall comply with PennDOT Publications 72M, 218M. and 408. C. Embedded Items 1. Embedded items shall be positioned at locations specified in the design documents. Inserts and other embeds shall be held rigidly in place so that they do not move significantly during casting operations. D. Concrete 1. Concrete Mixing a. Mixing operations shall produce batch-to-batch uniformity of strength, consistency and app Sran cc b. Batching weight and volume measurement devices shall be annually calibrated by an independent testing laboratory or more frequently if batching irregularities or concrete inconsistencies are observed 2. Concrete placing a. Concrete shall be placed in a manner in which it flows and consolidates without segregation or air entrapment. The freefall of concrete shall be kept to a minimum. DGS Phase 1.1 PRECAST CUL\'ERT STEAM TUNNEL

5 b. Cold Weather Concreting Recommendations for cold weather concreting are given in detail in AC! 306 R. Adequate equipment shall be provided for heating concrete materials and protecting concrete during freezing or near-freezing temperatures. All concrete materials, reinforcement, and forms shall be free from frost. In cold weather, the temperature of the concrete at the time of placement shall not be below 45 degrees F. Concrete that freezes before it reaches a compressive strength of 500 psi shall be discarded. c. Hot Weather Concreting i. Recommendations for hot weather concreting are given in detail in ACI 305 R. During hot weather excessive concrete temperatures and water evaporation shall be minimized. The temperature of concrete at the time of placing shall not exceed 95 degrees F. 3. Concrete Curing a. Curing operations shall commence immediately following the initial set of the concrete and completion of surface finishing. b. Curing by moisture retention i. Precast products shall be protected from drafts and wind to prevent plastic shrinkage cracking. ii. Moisture shall be prevented from excessively evaporating from exposed surfaces until adequate strength for stripping the precast concrete unit from the form is reached. - c. Curing with Heat and Moisture i. Concrete shall not be subjected to steam or hot air until after the concrete has attained its initial set. If hot air is used, precautions shall be taken to prevent moisture lass from the concrete. The temperature of the concrete shall not be permitted to exceed ISO degrees F. The temperature gain shall not exceed 40 degrees F per hour. 4. Surface Finish a. The surface finish shall be as specified on the contract documents and/or approved shop drawings. Provide non-slip texture finish on floor. 5. Stripping Precast Concrete Units from Forms a. Precast concrete units shall not be removed from the forms until the concrete reaches the compressive strength for stripping required by design. Stripping strengths shall be routinely measured to ensure product has attained sufficient strength for safe handling. 6. Patching and Repair a. Repairing Minor Defects i. Defects that will not impair the functional use or expected life of the precast concrete unit may be repaired by any method that does not impair the product b. Repairing Honeycombed Areas i.. When honeycombed areas are to be repaired, all loose material shall be removed and the areas cut back into essentially horizontal or vertical planes to a depth at which coarse aggregate particles break under chipping rather than being dislodged. DGS Phase 1.1 PRECAST CULVERT STEAM TUNNEL

6 Proprietary repair materials shall be used in accordance with the manufacturer's instructions. Otherwise, the area shall be saturated with water. Immediately prior to repair, the area should be damp, but free of excess water. A cement-sand grout or an approved bonding agent shall be applied to the chipped surfaces, followed immediately by consolidating an appropriate repair material into the cavity. c, Repairing Major Defects Defects in precast concrete products which impair the functional use or the expected life of products shall be evaluated by qualified personnel to determine if repairs are feasible and, if so, to establish the repair procedure. 7. Shipping Precast Concrete Units a. Precast concrete units shall not be shipped until they have reached at least 70% of their specified 28-day design strength, unless damage will not result, impairing the performance of the product. 2.3 PRODUCT DELIVERY, STORAGE, AND HANDLJNG A. Pre-Cast Concrete Units: 1. Transport units to the site after fabrication and curing. Protect until required for installation. 2. Handle to avoid damage to surfaces, edges and corners to avoid creation of stresses within the units. Remove damaged materials from the job site. B. Delivery and Handling: 1. Do not place materials on private property without written permission of the property owner. 2. Precast concrete units shall be delivered to the site in accordance with the delivery schedule. Upon delivery to the jobsite, all precast concrete units shall be inspected by the customer's agent for quality and final acceptahce: 3. Precast concrete units shall be handled and transported in a manner to minimize damage. Lifting devices or holes shall be consistent with industry standards. Lifting shall be accomplished with methods or devices intended for this purpose as indicated on the shop drawings. Upon request, the precast concrete producer shall provide documentation on acceptable handling methods for the product. 4. Proper implements, tools and facilities shall be provided and used for unloading and distributing materials along the line of the work. Unload and store precast units with minimum handling. Precast units and accessories shall be handled so as to insure delivery to the installed location in sound undamaeed condition. Precast units shall be carried into position and not dragged. Any precast unit or accessory damaged in transportation or handling shall be rejected and immediately removed from the job site. C. Storage: I. Precast concrete units shall be stored in a manner that will minimize potential damage. 2. Materials shall be kept safe from damage. Store materials on site in enclosures or under protective covering as per manufacturer's recommendations. Do not store materials directly on the ground The interior of all steam tunnel unit, fittings, and other appurtenances shall be kept free from dirt or foreign mater at all times..- DGS Phase Li PRECAST CUL\'ERT STEAM TUNNEL

7 4. The Contractor shall be responsible for the safe storage of all material intended for the work. The Contractor shall take all necessary precautions to prevent damage to materials, equipment and work. 5. Rubber gaskets, gasket lubricants and other appurtenances shall be protected from excessive exposure to heat, direct sunlight, ozone (from electric motors and equipment), oil, grease, or other contaminants. Gaskets shall be stored in a cool location, out of direct sunlight. Gaskets shall not come in contact with petroleum products. Gaskets shall be used on a firstin, first-out basis. Rubber gaskets that are not to be installed immediately shall be stored in a cool and dark place. 2.4 QUAlITY ASSURANCE A. The manufacturer of any precast concrete steam tunnel and manhole unit; shall upon the request of the Professional, Contractor, or Using Agency, furnish certified evidence that all material tests and inspections have been performed and that the product has been manufactured in compliance with the applicable specifications. PART 3 EXECUTION 3.1 EXAMINATION A. VerifSi existing site conditions. Veri' that trenching and drainage structures in the area of the storm drainage system installation have been completed to the finished sub-arade elevations. Report any discrepancies to the Professional. I. Any discrepancies discovered must be resolved to the satisfaction of the Professional prior to beginning storm draining system installation. B. Veri' that all bench marks and elevation reference data are in place. 3.2 JOB CONDITIONS A. The Contractor shall provide the services of a competent Civil Engineer or Land Surveyor to establish all lines, levels, grades, bench marks and measurements required to complete the Work. At no cost to the Using Agency, the Contractor shall be responsible to resolve any discrepancies which may arise due to errors resulting from said services, as provided by the Contractor's consultant. 3.3 INSTALLATION A. Install precast concrete steam tunnel units at locations and details indicated on the drawings. I. Normally, the width of the trench shall be forty-eight (48) inches plus the outside wal] to outside wall width of the precast concrete steam tunnel. The trench width shall permit the tunnel units to be laid and joined properly and to allow the bacifll to be placed in accordance with the specifications. When required, trenches shall be wider to permit the placement of timber supports, sheeting, bracing, and appurtenances as required by the safety requirements of the agency having jurisdiction. 2. When trench has been excavated to required depth, the bottom shall be tested to determine its suitability for tunnel support. The french shall be approved by the Professional/inspector and modified as directed if required. a. Remove any loose earth, trash or debris. Hand trim bottom elevation for accurate installation of steam tunnel unit. DGS Phase 1.1 PRECAST CULVERT STEAM TUNNEL

8 b. Where bottom of trench cannot be made suitable to support the tunnel unit, provide concrete cradles. Deposit concrete the full width of trench, 8" deep minimum, to bottom of tunnel. Reinforce continuous])' with two (2) No. 4 reinforcing bars. Before concrete is set, embed tunnel unit evenly, deposit remainder of concrete to three (3) feet above bottom of turmel unit and tamp in a manner to avoid disturbing tunnel. 3. Place twelve (12) inches of PennDOT No. 2A aggregate for bedding. Place materials in 4 inch loose lifts with mechanical tamper or 8 inch loose lifts if vibratory compaction is used. Compact each layer to not less than 97% of the dry weight density of the material, as determined in accordance with the Standard Proctor method (ASTh4 D 698). Form the bedding material to provide uniform contact under and around the tunnel unit. After the tunnel unit is satisfactorily laid, backfill the trench with PennDOT No. 2A in 4 inch loose lifts to the recommended by the precast concrete tunnel manufacturer (12" minimum). Thoroughly compact each layer of backfill with mechanical tampers, or by other acceptable methods for the full trench width. Compact to not less thani 00% of the dry weight density of the material, as determined in accordance with the Standard Proctor method (ASTM D 698). Tunnel units that are damaged or moved out of alignment shall be replaced and/or re-aligned by the Contractor at his expense. 4. Lay tunnel units to slope grade as shown on the drawings. Grade by measuring with rod from overhead grade line or centerline batter boards. 5. Fit tunnel unit ends together per manufacturer's recommendations and seal joints water tight. 6. As tunnel unit laying progresses, clear interior of dirt or other superfluous materials. During work stoppage periods provide effective plugs or covers for open ends of ttiimel units to prevent foreign matter from entering. a. Clean joint contact surfaces immediately prior to jointing. Use lubricants, primers or adhesives as recommended by joint manufacturer. 7. Each section of tunnel unit shall be inspected before being lowered into the trench. Defective, damaged or unsound tunnel units shall be rejected and removed from the site 8. Connect tunnel units to manholes per manufacturer's recommendations. Provide lean concrete support for tunnel units at manholes as required. Provide minor adjustments in openings as required to provide proper fit and maintain slope of tunnel. 9. Trench excavations shall not be backfilled until all test and inspections covering the installation of the steam tunnel system have been performed and approved. 10. Backfill shall be as described in the Drawings and Section Trenching of these Specifications. II. Install flexible adhesive-backed preformed waterproofing membrane sheets per PennDOT Publication 408 Section 680 and manufacturer's recommendation with the exception that the membrane must be installed on entire exterior side walls and roof of steam tunnel units. B. Install precast concrete steam manholes to locations, elevations, sizes, and types indicated on the Construction Drawings. I. Precast concrete steam manhole components shall be installed true and plumb. Thejoints between components shall be sealed with a pre-form flexible gasket material specifically manufactured for this type of application and shall be watertight. - DGS Phase 1.1 PRECAST CULVERT STEAM TUNNEL

9 1 Adjust riser, if applicable, with a maximum of two concrete grade rings so that the top section is at the required elevation. Cutting the top section is not acceptable. 3. Set cast iron frames and covers in full bed of stiff mortar or bituminous masticjointing compound at final e]evations so as to pmvent rocking. a. Install cover flush with sidewalk, if applicable. b. In unpaved areas, the rim elevation shall be 2 inches above the adjacent finish grade or as directed by the Using Agency's Representative. 4. The wall that supports access rungs or ladder shall be 90 degrees vertical from the floor of structure to manhole cover. 5. Chamfer exposed edges (¼." x /2"), except as noted. 6. Precast concrete steam manholes shall be installed on a bedding of 12" PennDOT No. 2A. 7. Install flexible adhesive-backed preformed waterproofing membrane sheets per PennDOT Publication 408 Section 680 and manufacturer's recommendation with the exception that the membrane must be installed on entire exterior side walls and roofs of steam manholes. 3.4 TOLERANCES A. Precast steam tunnel units shall be installed to the slope gradient shown on the drawings with a maximum variation of 1/8" (0.1 25") in ten feet (I 0_0t1). 3.5 FIELD QUALITY CONTROL A. Afterjoints have been inspected and approved, tunnel trench shall be filled with bedding material to a I' minimum above top of tunnel or as directed by tunnel unit manufacturer. Before remainder of trench is backfilled, the tunnel shall be checked for displacement and alignment. I. All inspections shall be conducted under the supervision of the Professional, and all governmental agencies having jurisdiction and evidence of compliance shall be forwarded to Using Agency's Representative prior to acceptance. B. Steam Tunnel bedding, backfilling and compaction operations shall be observed by the inspector or Using Agency's Representative. Field density and moisture tests shall be performed by the Contractor's Agent. 1. The Contractor shall re-compact, over-excavate, backfill, moisture control or otherwise modi& in place any material that does not meet compaction tests to the satisfaction ofthe Professional, Inspector, or Using Agency's Representative. C. Final field elevations shall be verified and documented. 3.6 RESTORATION damage done by the contractor to existing pipe lines, underground structures, utilities, etc., shall be fepaired by him at his expense in a manner acceptable to the owner of the damaged property. The contractor shall report any existing damage to the Professional prior to beginning the Work. B. The contractor shall restore an)' pavement or public right-of-way that is disturbed by the Work to equivalent or better than original condition. C. At completion of work, remove all waste materials and debris resulting from operations and leave everything in a complete and satisfactoiy condition as approved by the Professional. END OF SECTJON DGS Phase 1.1 PRECAST CULVERT STEAM TUNNEL