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SECTION 6 - PRESTRESSED CONCRETE

6.1 - DESIGN
The following design sequence shall be followed in selecting a beam section: a) Straight strands, f c = 35 MPa b) Straight strands, f c = 42 MPa c) Unbonded strands, f c = 35 MPa. d) Unbonded strands, f c = 42 MPa Design beams for a maximum tensile value of 3f c, in the flexural area, unless a higher value is allowed by the Director-Structures Design. At the beam ends, the allowable tension values are 7.5fci (initial) and 6f c (final).

Draped strands are to be used only when unbonded (blanketed) strand design is not possible. Do not drape strands in slab beams. Do not use unbonded strands in solid slab (300 mm depth) beams. When unbonding (blanketing) of strands is required by design, the criteria for maximum number of unbonded strands is as follows: a) 30% (max.) of the total number of strands. b) 30% (max.) of the strands in any one horizontal row. The minimum length between unbonded strand cut-off lengths shall be 1.2 meters.

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To avoid conflicts with the anchor rod, do not use center strands in box and slab beams. A minimum 225 mm vertical space between strands is required at one location on each vertical face to avoid conflict with the transverse tendon in that area of the beam, as stated in Subsection 6.5. The Load Fraction for Multi-Beam Precast Concrete Beams shall be determined by Article 3.23.4 of the Standard Specifications for Highway Bridges.

Approval is required by the Director-Structures Design for the use of double rows of strands in the web and/or bottom flange of box beams (additional web width and/or flange depth is required to maintain minimum concrete cover).

All multi-span box beam and slab beam structures shall be designed for continuity under live load, unless prohibited by the nature of the foundation material. Concrete I-beams for new construction shall not be allowed on Thruway structures.

6.2 - WIDTH - BOX BEAMS AND SLAB BEAMS

Widths of beams shall be detailed as 1.2 m and/or 0.9 m when determining the superstructure cross section. The beam deck shall consist of (1) multiples of 1.2 m beams, or (2) a combination of 1.2 m beams and some number of 0.9 m beams, or (3) multiples of 0.9 m beams. The beam deck shall be selected in the order listed. The overall beam deck width shall be the sum of the nominal beam widths and 12 mm to 19 mm allowance per joint, e.g. (to be shown on plans): 8 beams @ 1.2 m nominal + 3 beams @ 0.9 m nominal = 12.42 m 6-2

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When mixing beam widths, consideration shall be given to the combined length of the beams of the same width, chosen for the superstructure cross section. Only beams of the same width may be cast concurrently in a single forming bed. An attempt should be made to utilize the majority of the forming bed, which is typically 61.0 meters wide, even if this results in a slight increase in the total superstructure width.

6.3 - CAMBER
Beam camber information shall appear on the plans. The information shall include the camber at prestress transfer and final camber (after losses) due to prestress force and beam dead load. Deflections for noncomposite dead loads and superimposed dead loads shall also be included on the plans. Camber shall be shown in millimeters.

Beams shall always be designed so that the arithmetic addition of the final beam camber due to prestress force and beam dead load and the deflections due to noncomposite dead load and superimposed dead load results in a positive (upward) camber.

6.4 - DIAPHRAGMS
Internal diaphragms shall be provided on all voided box beams. See Detail 6.4.a, 6.4.b and 6.4.c.

6.4.1 - BOX AND SLAB BEAMS On structures with no skew, internal diaphragms for voided boxes shall be placed normal to the 6-3

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length of the box beam. On skewed structures, internal diaphragms for voided boxes shall be placed parallel to the skew of the box beam. Internal diaphragms or spreaders within the precast beams shall be placed at midspan for spans up to 15.0 meters and at quarter points for spans over 15.0 meters. None are required for slab beams 6.0 meters or less.

6.4.2 - I-BEAMS Concrete I-beams shall not be used on new Thruway structures. On existing structures to be rehabilitated, concrete I-beams shall have end diaphragms that shall be placed parallel to the skew and intermediate diaphragms that are perpendicular to the beams.

6.5 - TRANSVERSE TENDONS FOR BOX AND SLAB BEAMS

On structures with no skew, transverse tendons shall be placed normal to the length of the beam. On skewed structures, transverse tendons shall be placed parallel to the skew of the beam. See Detail 6.4.a, 6.4.b and 6.4.c. Spacing of transverse tendons shall be as follows: A. Spans less than 15.0 meters - three (3) tendons - one (1) at midspan and one (1) at each end, approximately 600 mm from centerline of bearings, measured perpendicular to the centerline of bearings. B. Spans greater than or equal to 15.0 meters - five (5) tendons - one (1) at midspan and each quarter point and one (1) at each end, approximately 600 mm from centerline of bearings measured perpendicular to the centerline of bearings.

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For box and slab beams, transverse tendons shall be placed as close to the mid-depth of the section as possible. The post-tensioning force in each tendon shall be 133 kN. The area of transverse tendon anchor plate shall be at least 13 000 mm2. On box and slab beam structures, the transverse tendon void in all beams and the transverse tendon block out on the fascia beam shall not interfere with the longitudinal prestressing strand and bar reinforcement.

6.6 - CONCRETE SLAB FOR BOX AND SLAB BEAMS

The concrete slab on prestressed concrete beams shall be a minimum of 150 mm thick (normally at centerline of span) which includes a monolithic wearing surface and shall be made composite with the beams. The top 25 mm shall be neglected in the design.

The thickness of bridge decks for prestressed concrete box and slab beams at times greatly exceed the 150 mm minimum shown on the plans. Additional thickness information should be provided to avoid possible claims against the Authority for those decks whose thickness vary considerably from the minimum value. Provide maximum as well as minimum thickness and their locations if the average thickness exceeds 188 mm for a 150 mm minimum deck.

For simple spans, and the positive moment regions of continuous spans, the slab shall be reinforced with galvanized fabric reinforcement. The galvanized fabric reinforcement shall be 152 x 152 MW48 x MW48. Galvanized fabric reinforcement shall be paid for under Item 25556.9810M. At splices, the fabric shall be lapped. Galvanized fabric reinforcement shall be placed to provide a clear 6-8

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cover of 80 mm. All concrete slab reinforcement shall be tied to the exposed reinforcement in the tops of beams as necessary to ensure proper placement and cover.

On stage construction projects, particular care shall be taken so that, due to long-term camber growth on Stage II beams; the required minimum slab thickness can be achieved. The anticipated differential camber (Time Dependent) plus slab dead load deflection for Stage II beams shall be considered when setting the minimum slab thickness for Stage I Construction. The maximum camber differential between Stage I and Stage II beams shall be such that the Stage II slab is at least 138 mm.

If the anticipated camber growth of the Stage II beams exceeds 12 mm, then the minimum slab thickness of the Stage I slab shall be increased to maintain a 138 mm minimum slab thickness for the Stage II slab. The additional slab thickness shall be considered as extra dead load in the beam design computations. For estimating the projected camber growth (Time Dependent), use 50% of the transfer camber (without creep correction) for this value. Example: camber at transfer (w/o creep) = 25 mm. Anticipated camber growth = .5 x 25 mm = 12 mm.

6.7 - SHEAR KEYS

Shear keys shall be provided in all prestressed beams. See Detail 6.7.

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6.8 - MISCELLANEOUS
The maximum desirable skew angle for a bridge using box or slab beams shall be 50. Their use on a bridge having a greater skew angle must be approved by the Director-Structures Design. A constant depth of section is preferable for all spans. At the fascia edges of the structural slab, the Contractor shall have the option of either bending down the galvanized fabric reinforcement as shown on the Plans, or substituting bent galvanized reinforcing bars.

In the negative moment regions of slabs that are continuous over piers or abutments, galvanized bars shall be used in conjunction with the prestressed concrete beams to develop the negative moment. These bars shall be extended from the pier or abutment to provide initial development beyond the point where the fabric or other design reinforcement in the slab can provide the required reinforcement. The bars shall be placed to provide a clear cover of 62 mm. Fabric reinforcement shall not be used in conjunction with design reinforcement in the negative moment region over the piers or abutments. Refer to Section 5 - Reinforcement, for additional information.

Where fabric reinforcement is specified on the Plans, the Contractor shall have the option of substituting a mat of reinforcing bars. If chosen, the mat shall consist of No. 13 Grade 420 reinforcing bars at 300 mm centers in both directions. The mat shall be tied to the exposed reinforcement in the tops of beams as necessary to ensure proper placement and cover. A clear cover of 75 mm shall be maintained. Refer to Section 9 Prestressed Concrete, in the NYSDOT Bridge Manual for additional information. 6-11