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FHWA Resource Center
STRUCTURES TEAM
New York State Department of Transportation
ENGINEERING INSTRUCTION EI 03-000
Title: HIGH PERFORMANCE CONCRETE FOR PRECAST AND PRESTRESSED BRIDGE BEAMS
Distribution:
x Manufacturers (18)
x Main Office (30)
x Local Govt. (31)
x Regions/Agencies (32)
o Surveyors (33)
x Consultants (34)
x Contractors (39)
o ____________( )
Approved:
George Christian - Deputy Chief Engineer (Structures)
ADMINISTRATIVE INFORMATION:
- This EI is effective with projects submitted for the letting
of May 6, 2004.
- This EI does not supersede any other EI or EB.
- The Standard Specification revisions issued with this EI will
be incorporated into the next issuance of the Standard Specifications.
- Special Specifications 16563.0299 M, 16563.60 M ,16563.61 M,
16563.62 M ,16563.63 M, and 16563.64 M are disapproved.
PURPOSE:
This EI adds Section 718-06 to the Standard Specifications of January
2, 2002.
TECHNICAL INFORMATION:
High Performance Concrete For Precast and Prestressed Bridge Beams will
be the standard concrete for Prestressed Concrete Units (Structural).
With this change, the minimum concrete strength of Prestressed Concrete
Units (Structural) will be 70 MPa.
TRANSMITTED MATERIALS:
Shelf Note for revisions to the January 2, 2002, Standard Specifications.
BACKGROUND:
The specification for High Performance Concrete for Prestressed Concrete
Girders has been used successfully to build more than twenty bridges.
Bid prices for the High Performance Concrete have been comparable to bid
prices for standard concrete. The improved durability of this material
and the increased strength make it possible to build longer lasting bridges
without an increase in cost. In some cases, the increased strength makes
it possible to decrease girder size or reduce the number of girders, resulting
in a cost savings.
The disapproved special specifications were used for the High Performance
Concrete bridges that have been built to date. The standard specification
replaces these special specifications.
CONTACT:
Direct questions regarding this EI to Duane Carpenter of the Structures
Design and Construction Division at 518-457-5715 or via e-mail at dcarpenter@dot.state.ny.us.
Make the following changes to Volume 2 of 3 of the Standard Specifications
of January 2, 2002:
Page 5-97, add the following after line 10:
“563-2.05 Concrete. The concrete shall meet the requirements of
§718-06, High Performance Concrete For Precast and Prestressed Bridge
Beams.”
Make the following changes to Volume 3 of 3 of the Standard Specifications
of January 2, 2002:
Page 7-204, replace line 20 with the following:
718-06 High Performance Concrete For Precast and Prestressed Bridge
Beams
SCOPE. This specification covers the material requirements for high performance
concrete for precast and prestressed bridge beams.
MATERIAL REQUIREMENTS. The concrete shall meet the requirements of the
approved Mix Design Sheet, described below, and the PCCM. The concrete
mix shall contain a minimum of 5% microsilica measured as a percent of
the total cementitious material.
MIX DESIGN SHEETS (MDS). These sheets shall contain all the information
on the mix design, materials, material sources, production facilities,
quality control, curing, and preproduction testing of the mix. Once approved
for production, the MDS may be used in any contract requiring high performance
concrete for precast and prestressed bridge beams.
The MDS will have a two-step approval process. The first submittal shall
contain all the information required in A. through N. Complete submittals
that meet the specification requirements will be examined according to
Section 2.5 of the PCCM and, if found acceptable, it will be returned
with the notation “APPROVED FOR TESTING.” Section 2.5.7 of
the PCCM does not apply.
Following required testing of the mix, the MDS shall be submitted to
the D.C.E.S. with the information in O. through Q. added to the sheet.
If the test results meet the requirements of this specification, the drawing
will be returned with the notation “APPROVED.” After approval
for production, no changes in materials sources, production, curing, or
mix design shall be made, except those changes necessitated by a change
in the fineness modulus of the aggregate.
If changes are required after the approval of the MDS, a revised MDS
with all the required changes shall be submitted to the D.C.E.S. After
examining the revised MDS the D.C.E.S. will determine if repetition of
any testing is required for the approval of the revised MDS. If it is
determined that some or all tests shall be repeated, the revised MDS will
be returned marked up, specifying the required tests to be repeated and
stamped “APPROVED FOR TESTING.” Remaining portions of the
approval process will exactly follow the procedure used for the initial
approval of the MDS except that the tests to be performed will be limited
to the tests to be repeated marked up by the D.C.E.S.
If it is determined that there is no need for repeating the preproduction
testing and if the proposed changes are acceptable to the D.C.E.S., the
revised MDS will be approved and returned.
Information Required on MDS. The MDS shall include the following information:
2. The source and type of cement.
3. The specific source of the coarse aggregate.
4. The specific source of the fine aggregate and the fineness modulus
of the material proposed for use in the preproduction testing.
5. The brand and type of all admixtures that will be used.
6. The complete mix design including all ingredient and quantities proposed
for the production concrete.
7. The maximum water-to-total-cementitious-material ratio that is proposed
for production.
8. Description of the concrete batching and mixing facilities, including
the date of last annual inspection and date of last scale calibration
check.
9. Description of the concrete transport equipment.
10. The method of concrete placement.
11. Outline of the curing procedure to be used for the production units
and test samples.
12. Quality control tests and procedures that the fabricator will perform.
13. Detailed description of the preproduction testing procedure to establish
that concrete made from the proposed mix design meets the required performance
criteria.
14. The name and address of the testing laboratory(s) conducting the
tests.
15. A fabricator selected identifier for the mix.
16. Test results for the preproduction test mix.
17. Actual fineness modulus of the fine aggregate used in the preproduction
test mix.
18. Graph of compressive strength versus age.
TESTING. The concrete mix design shall be tested prior to making any
bridge beams and shall meet the following performance criteria.
TABLE 718-06-1 TESTING REQUIREMENTS FOR HP CONCRETE
PROPERTY
TEST METHOD
ACCEPTANCE CRITERIA
Compressive Strength (at 56 days)
AASHTO T22
> 70MPa (all tests)
Freeze/Thaw Durability (x=relative dynamic modulus of elasticity after
300 cycles)
AASHTO T161 Procedure A
x ³ 80%
Scaling Resistance (y= visual rating of surface after 50 cycles)
ASTM C672
y £ 3
Elasticity (E = modulus of elasticity)
ASTM C469 (See Note C)
E ³ 30GPa
Shrinkage ( s= microstrain)
AASHTO T160-97 (at 56 days)
s < 600
Creep © = microstrain/pressure unit)
ASTM C512 (at 56 days, 40% fc¢)
c £ 60/ MPa
Chloride Penetration (p= increase in percent of chloride ion by weight
of concrete)
AASHTO T259 modified
(See Note A)
p £ 0.025% at 25 mm
Air Content
AASHTO T 152
A = % selected by contractor, A ³ 3%
Water/Cementitious-Materials ratio (W= mass ratio)
AASHTO TP23-93
(See Note B)
Supplier selects W,
W < 0.40
Note A: The test specimens are to be cured under the same conditions
and for the same time as proposed for production. They shall then be stored
for 28 days in the drying room specified by the AASHTO T259.
Note B: The AASHTO TP23 test shall be corrected for the absorbed water
in the aggregate. This correction shall be made using the mass percentage
of absorption shown under “ABS” in the Approved List of Sources
of Fine and Coarse Aggregates (or as determined by AASHTO T-84 for fine
aggregates and AASHTO T-85 for coarse aggregate) by an A.A.S.H.T.O. accredited
testing laboratory.
Note C: Test two samples. Each sample is to be loaded at 40% of the load
required to break a companion sample cast from the same mix at the same
time as the test sample. Sample 1 is to be loaded when the strength of
a companion sample achieves a strength of 49 MPa ± 3 MPa. Sample
2 is to be loaded when the strength of a companion sample achieves a strength
of 70 MPa ± 5 MPa.
PREPRODUCTION TESTING
The Contractor shall engage an A.A.S.H.T.O. Accredited testing laboratory
for testing of all preproduction concrete specimens except compressive
strength, air content, and water/cementitious-materials ratio. These tests
shall be performed in the presence of the Quality Assurance (QA) Inspector.
The D.C.E.S. may approve laboratories with equivalent certification from
another organization. The testing laboratory shall send a copy of the
test results directly to the D.C.E.S.
The Contractor shall notify the Department at least three work days prior
to casting preproduction test specimens. No test specimens shall be cast
unless the QA Inspector is present to witness the mixing, casting, and
curing of the specimens. The test specimens shall be prepared of concrete
made using materials from sources shown on the “Approved For Testing”
MDS.
The water-to-total-cementitious-materials ratio for concrete mix for
purposes of preparing specimens for chloride penetration testing shall
be 0.03 higher than the maximum water-to-total-cementitious-materials
ratio that is proposed for production. In addition to those specimens
needed for AASHTO T259 testing, the fabricator shall cast eighteen 100
mm x 200 mm cylinders from the chloride penetration test mix, cure the
cylinders in accordance with the approved production curing procedures
for long term independent testing and research. These cylinders shall
be delivered to the testing laboratory designated by the D.C.E.S.
The test mix for all other tests shall be the water-to-total-cementitious-materials
ratio that is proposed for production within a tolerance of 0.01. Include
the total aggregate moisture, as determined according to AASHTO T 255,
in the calculation of the water-to-total-cementitious-materials ratio
with appropriate adjustments. (See Note B in Material Requirements.)
Using the test mix, cast and test compressive strength cylinders at 18
hours, 3 days, 7 days, 28 days, and 56 days. Present the test results
in a graph.
Acceptance of test specimens. All test specimens shall be prepared in
accordance with an “Approved for Testing” MDS. The preparation,
casting, and curing of the test specimens shall be done in the presence
of the QA Inspector. The QA Inspector shall indicate the procedures on
the MDS were followed by affixing the inspection agency stamp on the samples
prior to shipping to the Independent Testing Laboratories.
FABRICATION. The requirements of the PCCM shall apply with the following
modifications:
1. Submitted Shop Drawings shall include approved Mix Design Sheets.
2. The required 56-day strength is 70 MPa, unless shown otherwise in
the Contract Documents.
3. The required minimum strength for imparting prestressing force into
the concrete is 49 MPa unless shown otherwise in the Contract Documents.
4. The fineness modulus of the fine aggregate shall not vary more than
0.2 from the actual fineness modulus used in the preproduction test mix.
5. Water/Cementitious-materials ratio shall be measured by the Fabricator
for the first batch of concrete in a days placement and monitored by slump
tests throughout production. If the QA Inspector has reason to believe
the water/cementitious-materials ratio is changing, or if the slump increases
by more than the allowed increase in the table below, additional water/cementitious-materials
ratio tests may be ordered.
Slump of First Batch
Allowed Increase
Less than 100 mm
25 mm
100 mm or more
37 mm
6. Batch tickets shall be provided to the Inspector to verify the concrete
mix contents.
BASIS OF ACCEPTANCE. Units will be considered for acceptance at the manufacturing
location in accordance with the PCCM.
718-07 THRU 718-29 (VACANT)
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