Report No: PCINER-01-PDPG Title: Precast Deck Panel Guidelines Developing Organization: Precast/Prestressed Concrete Institute New England

Region Technical Committee 116 Radcliffe Road Belmont, MA 02478 617-489-5670 Report Date: May 2001 Status of Report: Final Abstract: Guidelines and details for Precast Prestressed Concrete Deck Panels or Stay in Place (SIP) decking used as a permanent form spanning between girders and designed to act composite with the remain cast in place deck. If a State Standard exists it will take precedence over these guidelines & details. Number of Pages: 13 Revision Date: December 2003

PCI cannot accept responsibility for any errors or oversights in the use of this material. The user must recognize that no guidelines or regulations can substitute for experienced judgement. This guideline is intended for use by personnel competent to evaluate the significance and limitations of its contents and able to accept responsibility for the application of the material it contains.

GUIDELINES FOR DESIGN & DETAILING OF PRECAST DECK PANELS Precast prestressed concrete deck panels used as permanent forms spanning between girders should be designed to act composite with the cast-in-place portion of the deck slab. Design and Detail Requirements 1. The concrete compressive strength at release fci should be a minimum of 27.5 MPa (4000 psi). The 28-day concrete compressive strength should be 40 MPa (6,000 psi). 2. Tension in the precompressed tensile zone under final service conditions after all losses have occurred should be .5 'c (6f ' c ) . C o m p r e s s i o n in the panel at release should be 5.2 MPa (750 +/- psi). 3. Prestressing strands shall be 9.5 mm (3/8) diameter and should extend 100 mm (4 in.) minimum outside the panel ends and shall be centered vertically in the panel. 4. Panel length should be set to provide a minimum grout bed width of 50 mm (2 in.). This requires a minimum of 75 mm (3 in.) from the edge of panel to the edge of steel girder flange and 87 mm (3.5 in.) to the edge of a bulb-tee flange, assuming a 25 mm (1 in.) minimum grout dam width. 5. The minimum thickness of the cast-in-place portion of the slab should be 115 mm (4.5 in.). 6. The minimum thickness of the panel shall be 90 mm (3.5 in.). The top surface shall be broom roughened to an amplitude of approximately 1.5 mm (.06 in.). 7. Design shall be standard AASHTO design of composite sections. Temporary Support System Two Step System: After setting deck panels, a grout bed is placed in the girder haunch area and allowed to cure prior to placing the remainder of the deck. 1. Temporary supports for precast deck panels shall consist of continuous, high-density, expanded polystyrene strips (grout dam) with a minimum compressive strength of 380 Pa (55 psi). If leveling screws are used a 27.2 kg per cubic meter (1.7 pound per cubic foot) polyethylene foam seal shall be used as a grout dam. An approved adhesive should be specified to affix the grout dam to the girder and the deckpanel. 2. If leveling screws are used temporary bracing between the ends of panels shall be installed as required to prevent transverse panel movement that could lead to loss of bearing on the leveling screws.

Precast Deck Panel Guidelines

PCINER-01-PDPG
New England Region

Date Issued May 2001 Date Revised Page Number

3. Deck panels are required to be grouted in place prior to placement of the cast-in-place concrete deck. The grout bed should extend for the full width of the girder flange completely filling the area between the grout dams. The top of the grout bed should be 25 mm (1 in.) clear below the strand extensions. 4. If leveling screws are used they shall be completely removed after the grouting operation and prior to deck placement. Haunch Height The haunch height should take into account the following factors: 1. A minimum midspan blocking distance of 25 mm (1 in.) plus an allowance for cross-slope and camber tolerance is required in order to obtain a minimum grout bed height of 25 mm (1 in.). 2. The flange bolts for field splices of steel girders may interfere with precast concrete deck panels. Provide a haunch depth that accommodates the added thickness of the field splice. Alternatively, panel thickness may be modified along the entire panel width to avoid conflict with field splices. Changing the surface on which the bolt head rests is also an acceptable modification to avoid conflict.

Precast Deck Panel Guidelines

PCINER-01-PDPG
New England Region

Date Issued May 2001 Date Revised Page Number

SPECIFICATION SECTIONS FOR PRECAST DECK PANELS The following information is offered as a supplement to existing concrete and prestressed concrete specifications.

MATERIALS
Temporary Supports/Grout Dams Temporary supports/grout dams for precast deck panels shall consist of continuous, highdensity, expanded polystyrene strips (grout dam) with a minimum compressive strength of 380 Pa (55 psi). If leveling screws are used, a 27.2 kg per cubic meter (1.7 pound per cubic foot) polyethylene foam seal shall be used as a grout dam. An approved adhesive should be specified to affix the grout dam to the girder and the deck panel. Grout Bed This work shall consist of furnishing and placing a grout bed using high density low slump concrete, including high range water reducing admixture, beneath the ends of prestressed concrete deck panels and on the girder top flange as shown on the contract plans and conforming to the following material requirements: 1. Concrete CONCRETE CLASS AA STRENGTH Mpa (psi) 27.5 (4,000) CEMENT kg (lbs) 400 (882.5) MAXIMUM W/C 0.38 PERCENT ENTRAINED AIR 7 to 9

2. Portland Cement shall conform to AASHTO M 85 Type II. 3. Coarse aggregate for Concrete Class AA, including high range water reducing admixture, shall meet the following gradation:

Sieve Size % Passing

12.5 mm 1/2" 100

9.5 mm 3/8" 90-100

4.75 mm 2.36 mm 1.18 mm 0.30 mm No. 4 No. 8 No. 16 No. 50 20-55 5-30 0-10 0-5

Precast Deck Panel Guidelines

PCINER-01-PDPG
New England Region

Date Issued May 2001 Date Revised Page Number

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CONSTRUCTION

Dimensional Tolerances Panels shall be manufactured in conformity with the following tolerances: a, Length of panel 6 mm (1/4 inches) b, Width of panel 6 mm (1/4 inches) c, Depth of panel -3 mm, +6 mm (-1/8, +1/4 inches) d, Vertical position of strand group -3 mm, +0 mm (-1/8, +0 inches) (Measured from bottom of panel) d, Vertical position of individual strands 3 mm (1/8 inches) e, Horizontal strand position 6 mm (1/4 inches) f, Bowing 3 mm (1/8 inches) g, Strand projection 12 mm (1/2 inches) h, Donnage location 150 mm (6 inches) i, Sweep 3 mm (1/8 inches) j, Horizontal alignment 6 mm (1/4 inches) (Deviation from straight line parallel to centerline of panel) k, Squareness 12 mm (1/2 inch) (max.) (Difference in diagonals) Warping 5 mm per meter (1/16 inch per foot) of distance from nearest adjacent corner

Precast Deck Panel Guidelines

PCINER-01-PDPG
New England Region

Date Issued May 2001 Date Revised Page Number

11

Cracking Detensioning procedures causing member cracking shall be revised before detensioning the next bed. A revised detensioning sequence shall be submitted for review. Rejection Any of the following conditions will be cause for rejection of prestressed deck panels: 1. Any crack transverse or diagonal to the strand pattern and crossing more than one strand. Any crack parallel to a strand and longer than 1/3 of the panel length. Cracks shorter than 1/3 of the panel length and present at more than 25% of the total number of strands in the panel. Voids or honeycombed areas with exposed strand.

2. 3.

4.

Panels with cracks or with damage less severe than the conditions stated above shall be repaired by the Contractor, using an approved procedure, at no cost to the Department. Panels stored prior to shipment shall be inspected by the Contractor prior to being delivered to the site to identify damage that would be cause for repair or rejection. The Contractor shall ensure that sufficient acceptable panels are available for anticipated placement so that unacceptable delays to the project completion can be avoided. Installation The panels shall be installed as shown on the plans. The temporary supports shall be attached to the top flange of the girder with an approved adhesive in accordance with the Manufacturers recommendations. The temporary supports shall be cut in the field to the required height after the blocking depth has been determined. Multiple panels shall not be stacked on a panel after it has been placed on the temporary supports. Panels shall not be used to support heavy loads until the full deck concrete is cast and cured. Construction loads on individual panels shall be uniformly applied and shall not exceed an average loading of approximately 2000 Pa (40 pounds per square foot).

Precast Deck Panel Guidelines

PCINER-01-PDPG
New England Region

Date Issued May 2001 Date Revised Page Number

12

After the panels have been placed on the temporary supports, the area under the ends of the panels and on the girder flanges up to the bottom of the panels shall be completely filled with Concrete Class AA, Including High Range Water Reducing Admixture as shown on the plans. This concrete shall cure a minimum of three (3) days prior to placing the concrete deck. If leveling screws are used, they shall be completely removed and the holes filled with grout prior to the placement of deck concrete. Adequate precautions shall be taken to protect freshly placed concrete from sudden or unexpected rain. The Contract Administrator may order removal of any material damaged by rainfall. The grout bed shall not be placed when air or deck temperature is below 10C (50F). It may be placed when these temperatures are a minimum of 10C (50F) and rising air temperature is predicted. Prior to placement of the deck concrete, laitance or other contaminates that would interfere with full bond to the panels, shall be removed by an approved method.

Precast Deck Panel Guidelines

PCINER-01-PDPG
New England Region

Date Issued May 2001 Date Revised Page Number

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