TECHNICAL SPECIAL PROVISION T452

CAST-IN-PLACE SEGMENTAL BRIDGE SUPERSTRUCTURE CONSTRUCTION USING

BALANCED CANTILEVER METHOD WITH FORM TRAVELER(S)
T452-1 Description.
Fabricate and erect cast-in-place segmental post-tensioned concrete superstructures constructed
using the Balanced Cantilever construction method with Form Traveler(s), to the established lines and
grades, in accordance with the design, dimensions and details shown on the Plans and in accordance with
this Section.
Reinforcing steel, post-tensioning Tendons, embedded items and all appurtenant items are
included.
T452-2 Qualification Requirements for Supervisory Personnel.
Meet the requirements of FDOT Specifications Section 105.
T452-3 Definitions.
The following definitions apply to cast-in-place segmental bridge construction using the Balanced
Cantilever Construction method with Form Traveler(s):
T452-3.1 Segment: A modular unit of the concrete superstructure consisting of a certain crosssection and length as detailed in the Plans.
T452-3.2 Balanced Cantilever (Erection): The segments are sequentially erected alternately on
either side of a pier / Pier Table in cantilever to a point where a closure Segment is cast-in-place to
complete a span.
T452-3.3 Post-Tensioning System: A proprietary system where the necessary hardware
(Anchorages, ducts, local zone reinforcing, wedge plates, wedges, strands. bars, etc.) is supplied by a
particular manufacture or manufacturers of post tensioning components.
T452-3.4 Tendon: A high strength prestressing steel member made up of a number of strands,
wires, or bars.
T452-3.5 Form Traveler(s): A self-launching structural steel system that is supported off the tip
of the cantilever and used for suspending the formwork required to cast the adjacent cantilever
superstructure Segment along with the weight of the Segment in its final position.
T452-3.6 Anchorage: An assembly of various hardware components, including local zone
confining reinforcement, which secure a Tendon at its ends after it has been stressed and impart the
Tendon force into the concrete.
T452-3.7 Anchor Set: The expected movement of the wedge into the wedge plate or nut into the
bearing plate during the transfer of the prestressing force to the Anchorage assembly.
T452-3.8 Camber: The amount by which the concrete profile at the time of casting must differ
from the theoretical geometric profile grade in order to compensate for all structural dead load, posttensioning, all long term and time dependent deformations (creep and shrinkage) including the
intermediate construction stages and effects (the opposite of deflections), and includes deflection of the
forms and Form Travelers, removal of forms and Form Travelers, and any change in the statical system of
the structure.
T452-3.9 Casting Curve: The curve of casting geometry followed in the forms to achieve the
theoretical profile and alignment after all the final structural and time-dependent (creep and shrinkage)
deformations have taken place, accounting for the sequence and loads applied during construction and
removal of Form Travelers. The curve is a combination of the theoretical bridge geometric profile grade,
alignment, and Camber.

T452-3.10 Pier Table: The first Segment cast over a pier as a starting point to attach a Form
Traveler. Typically, a Pier Table is designed as a non-symmetrical Segment to reduce out of balance load
by about half of a typical Segment on either side of the pier.
T452-3.11 Strong Back: A set of steel beams / trusses clamped to two cantilever tips to align the
two cantilever tips to correct elevation and horizontal alignment prior to casting the closure pour.
T452-4 Working Drawings, Calculations and Manuals.
T452-4.1 General: Use methods and procedures providing adequate safety to the general public
from construction/erection activities and/or falsework placed over or adjacent to traveled roadways,
navigational or recreational waterways or any existing commercial, industrial or other facility.
T452-4.2 Information Required: Submit detailed Working Drawings, calculations, manuals and
other information, including, but not limited to, the following:
T452-4.2.1 Segment Working Drawings
1. A schedule of materials for segment fabrication including concrete, reinforcing
steel, prestressing steel, duct filler, and other similar items. The volume of concrete, weight of
reinforcement and weight of post-tensioning for each Segment and the total weight for reinforcement and
post-tensioning for the superstructure summarized and tabulated.
2. Complete longitudinal Tendon envelope details, including Tendon sizes for the
whole length of the bridge.
3. Fully dimensioned views showing the geometry of each segment, including
widths, lengths, thicknesses, tapers, fillets, radii, working points, notches, recesses, projections, posttensioning Tendons layout, clearances, rebar dimensions (reinforcing bar list) and spacing, embedded
items (inserts, blockouts, temporary openings, geometry control reference hardware [i.e. elevation bolts
serving as survey markers], etc.), holes, Anchorage positions, and other items.
Include fully integrated details showing reinforcing steel, post-tensioning duct,
post-tensioning hardware, inserts and any other items embedded in a Segment. Clearly show details as to
size, spacing and location of mild steel reinforcing including any local zone reinforcing not shown in the
Plans that may be required by the post-tensioning Anchorage system selected by the Contractor. Clearly
indicate details as to the size, type, horizontal and vertical profiles, duct supports, filler inlets / outlets,
and concrete covers of post-tensioning ducts.
4. Post-tensioning requirements as outlined in FDOT Specifications Sections 462
and 960. Check post-tensioning for consistency with pre-approved post-tensioning hardware and provide
part numbers for Department pre-approved systems. Substitution of parts or materials is not allowed.
5. Complete details of the proposed segment fabrication system, including the
forms, Form Travelers, temporary supports, falsework, temporary foundations, and geometry control.
6. A schedule of the timing and sequence of Segment casting and erection
including the sequence of making the cast-in-place closures and continuity between spans. Include a
Segment numbering system and the direction of erection.
7. Details of the disposition and use of form travelers, falsework, temporary
supports and the like, including all loads or reactions from such equipment applied to the structure during
erection and the sequences and timings of these effects in accordance with the erection schedule.
8. Details and calculations for any localized strengthening for concentrated
supports and loads or reactions from form travelers placed in locations not already allowed for in the
Plans.
9. Details and supporting calculations for any modifications to Segment
geometry, cross-section dimensions, or Segment length including any required changes to reinforcing and
post-tensioning.

10. Construction stage Casting Curves with Camber shown separately, prepared
in accordance with the casting and erection sequence, schedule, loads, and material properties proposed
by the Contractor. Casting Curves shall allow the determination of control point settings for accurately
casting the Segments. During the preparation of the Casting Curves, recognize all deviations from straight
line and deformations due to the final required alignment and due to dead load, future superimposed dead
loads, construction loads, post-tensioning stresses including secondary moments, creep and shrinkage.
Account for torsional deformations in the curved sections of the bridge. Each Casting Curve submittal
shall be accompanied by all information (loads, casting and erection schedules, construction sequence,
material properties, etc.) considered in its development.
T452-4.2.2 Erection Manual: Meet the requirements in T452-9.4.
T452-4.2.3 Geometry Control and Casting Manual: Meet the requirements in T4529.3.
T452-5 Materials.
T452-5.1 General: Use materials which conform to this Section and the requirements prescribed
in FDOT Specifications Division III, Materials, for the particular kind and type of material specified.
T452-5.2 Concrete: Use concrete as specified in FDOT Specifications Section 346 except as
specifically modified herein. Use No. 67 coarse aggregate in the concrete for segments.
Screenings are not allowed as a substitute for silica sand for use in concrete for cast-inplace superstructure segments.
T452-5.3 Reinforcing Steel: Use ASTM A615, Grade 60 reinforcing steel which meets the
requirements of FDOT Specifications Section 415. When welding reinforcing steel, meet the
requirements of the American Welding Societys Structural Welding Code D1.4. The Engineer may allow
shop prepared welded reinforcing grillages. Field welding of reinforcing steel is not allowed.
T452-5.4 Post-Tensioning Systems: Use post-tensioning hardware components meeting the
requirements of FDOT Specifications Sections 462 and 960 to remain in the completed superstructure,
including temporary erection post-tensioning left in place and permanent post-tensioning for design
capacity. Components are not interchangeable and must comply with the details of the approved shop
drawings. Constituent components of Post-Tensioning Systems include, but are not limited to, Anchorage
assemblies, filler containment assemblies, duct filler material (flexible filler and grout per FDOT
Specifications Section 938), and related steel reinforcement.
T452-6 Equipment.
T452-6.1 General: Equipment shall not be operated from or placed upon any part of constructed
superstructure at any stage of construction other than which has been herein specified, and/or has the
approval of the Engineer. This includes the grout pump, vacuum device, stressing jack, flexible filler
injection equipment and any other equipment whatsoever, and materials of any kind.
Design calculations prepared under the direction of, and signed and sealed by a
Professional Engineer registered in the State of Florida shall be submitted for construction equipment
(including Form Travelers), falsework, and other temporary construction which may be required to
accomplish the work.
T452-6.2 Certification of Form Travelers for Balanced Cantilever Construction: Prior to
beginning casting operations, the Contractors Engineer of Record or a designee must inspect and certify
that the Form Travelers and temporary equipment (such as temporary stability towers) are structurally
adequate for their intended use in the construction process.
T452-6.3 Form Traveler Load Test: At an offsite location, assemble and perform a Form
Traveler static load test to verify the equipment can safely accommodate 1.5 times the maximum Segment

weight to be supported, including formwork and construction loads. Submit certified load test data to the
Engineer for approval prior to Form Traveler use.
T452-7 Duct Filler Mock-Up Testing.
A minimum of 60 days prior to the first flexible filler tendon injection, the Contractor shall have
prepared mock-up testing of the following Tendon profile and successfully performed duct filler injection
(separate tests using grout and flexible filler) to the satisfaction of the Engineer. The test setup shall
include a two-span continuous, 200 feet total length (two 100 feet spans) mock-up utilizing a minimum of
15-0.6-inch diameter strands having an amplitude of 10 feet between the high and low points of the
proposed Tendon vertical profile. Stress the tendons to a maximum of 5% of the jacking force (0.80fpu).
The proposed mock-up system shall be capable of withstanding the proposed jacking force. The strands
shall be fully bearing on the duct at all deviation points during the mock-up testing. Provide transparent
ducts for ease of inspection. Perform an autopsy of both specimens. Repeat the test until successful results
are achieved and accepted by the Engineer.
Submit to the Engineer for approval all plans with detailed dimensions, procedures, equipment,
materials, and location proposed for the mock-up tests to be performed. All materials, means and methods
of construction, and equipment used during the mock-up testing shall be representative of those utilized
during construction.
T452-8 Bearing Considerations.
Temporarily lock guided bearings, if any, during Balanced Cantilever Construction. Submit to the
Engineer, for approval, the means and methods of temporarily locking bearings prior to beginning
cantilever construction.
T452-9 Casting Requirements.
T452-9.1 General: Ensure that all materials, details, and procedures are as specified herein, as
noted in the Plans, or as directed by the Engineer. The construction method shall include casting of the
segments and the method of application of all temporary forces to be used for adjusting horizontal and
vertical alignments. This shall also include control methods to ensure the accuracy of alignment of the
completed superstructure.
Ensure the intermediate static and dynamic stability of the structure during construction.
Submit to the Engineer a statement that the stability of the structure during construction has been fully
considered.
Do not begin casting segments until the Engineer approves the relevant Working
Drawings, calculations, casting manuals, concrete forms and concreting operations and the PostTensioning System components and layout if different from that on the Contract Documents.
T452-9.2 Forms: Take responsibility for the design and engineering of the forms as well
as their fabrication. Form all exposed formed surfaces of each element of the structure with the same
material to produce similar concrete surface textures, color, and appearance. Obtain the Engineers
approval of forms prior to initiating casting operations. Build the details shown on the Contract Plans or
as amended by approved Working Drawings into the forms.
Repair worn, damaged, or otherwise unacceptable forms and obtain the Engineers approval
before casting any Segment.
Where sections of forms are joined, ensure that offsets in flat surfaces do not exceed 1/16 inches
and that offsets with corners and bends do not exceed 1/8 inches.
Ensure that all joints in the forms and contact points with bulkheads and existing segments have
good fitting seals to prevent loss of fine material and cement grout.

Check and inspect forms on a regular weekly basis to ensure proper alignment and geometric
accuracy. Do not use forms which fail to meet the specified casting tolerances until such corrections are
made to produce segments within the specified tolerances. If any settlements or distortions of sufficient
magnitude that may interfere with achieving the required Segment tolerances are measured, discontinue
casting with these forms until the problem is corrected and approved by the Engineer.
The top surface of Segments when finished shall not deviate more than 1/4 inch along a straight
edge 10 feet long placed in any horizontal position of the surface each side of centerline. Local variations
where hand finishing is required may deviate a maximum of 3/4 inch.
T452-9.3 Geometry Control and Casting Manual.
T452-9.3.1 General: Before commencing the casting operation, submit the proposed
method of geometry control for all Segment casting operations to the Engineer for approval. Indicate how
the geometry control is to be performed and the actions proposed to ensure proper casting and
construction of the structure to the final grade shown on the Plans. This submittal must be in the form of
a Casting Manual and include but not necessarily be limited to:
1. All measuring equipment, procedures and the location of control points to be
established on each Segment.
2. The location and values of all permanent benchmarks and reference points for
geometry control.
3. A geometry control procedure for the vertical and horizontal alignment control
for the casting of segments; including survey controls and procedures, observations, checks,
computational and/or graphical methods and correction techniques.
4. The Casting Curves which include the theoretical geometric horizontal
alignment, profile grade and superelevation appropriately combined with the Camber.
5. Regular monitoring of superstructure deflections beginning with the addition
of the first cantilever Segments concluding with the main span closure.
6. Adjusting procedure to utilized for each Segment, including special adjustment
procedures should the cantilever, as constructed, deviate from the predicted alignment by more than 1
inch.
7. Qualifications of personnel who will perform geometry control.
Ensure that the casting manual covers all geometry control operations necessary
and is compatible with the chosen methods of casting and erection, including erection survey, elevation
and alignment control. Prepare the manual in accordance with submittal requirements of this Section.
The Casting Manual shall cover all geometry control operations necessary for
casting and shall conform with the Contractors chosen methods of casting and releasing the
superstructure Segments, including surveys for elevation and alignment control before and after Segment
casting. Do not begin casting without the Engineers approval of the geometry control method.
Immediately after casting of a Segment is completed, references for horizontal
and vertical control shall be established as follows:
Horizontal Control A wire stirrup on the horizontal control line at the
leading free end of the Segment. A line not more than 0.001 inch in width shall be scribed in a permanent
manner into each stirrup. Wire stirrups shall be stainless steel.
Vertical Control A flat head bolt, with a punch hole in the head,
approximately flush with the surface of the concrete over each web at the leading free end of the
Segment. Bolts shall be stainless steel.
The Contractors Engineer of Record shall prepare a table of elevations and
alignments required at each stage of construction, at all control points, and submit the same to the
Engineer.

Survey elevations and alignment of Segments at each stage of construction.

Account for Form Traveler deflections due to Segment dead loads (i.e. ensure geometry control survey
along formwork considers dead load deflection once Segment concrete is cast). Correct any deviation
from the table of elevations and alignment prepared by the Contractors Engineer of Record prior to
casting the adjacent Segment. Maintain a record of all checks, adjustments, and corrections made during
construction.
Establish a minimum of two remote permanent horizontal survey control
triangulation points at the site. Establish permanent benchmarks at locations where they will not be
disturbed by construction activities. The horizontal control points and benchmarks shall be located so as
to be continuously visible from the survey instrument's location.
Do not begin casting the Segment adjacent to the Pier Table until the Form
Travelers are properly secured to the Pier Table. The horizontal and vertical alignment of the Pier Table
shall be within 1/8 inch of that required by the approved construction plans.
Survey the vertical and horizontal alignment of the cantilevers from established
control one hour prior to sunrise each morning after a Segment is cast. If positions as measured by the
Engineer and the Contractor do not agree to within 1/64 inch, make geometry corrections to the next
Segment cast..
If measured elevations deviate from the approved table of elevations submitted
by the Contractor, suspend further casting of superstructure Segments until the cause of the deviation is
discovered and a corrective action plan, submitted by the Contractor, is approved by the Engineer.
Employ precautions to prevent false readings due to temperature differentials.
Use experienced personnel to operate the instruments and supervise the casting
operation. Prior to the commencement of casting, obtain the Engineers approval of the experience and/or
qualifications of the supervisory and instrument operating personnel, particularly with regard to the
observational precision required.
T452-9.3.2 Special Requirements: The following additional requirements shall apply to
geometry control for casting of Segments, for bridges with horizontal curvature and varying
superelevation, and for bridges that are to be constructed using Balanced Cantilever Construction:
1. The instruments used to measure elevations shall be precision automatic levels
capable of obtaining first order control and one piece level rods with centering point bases.
2. The instruments used to make horizontal measurements shall be one-second
theodolites.
3. A micrometer on either the theodolite or the foresight target shall be used for
horizontal measurement readings on Segment control points.
4. Instruments shall read levels and horizontal alignment to an accuracy of 0.01
inch.
5. Personnel who directly supervise layout and geometry control measurements
at the bridge site shall have previous experience in in-place casting of Segments for bridges constructed in
cantilever.
6. The position of two adjacent Segments shall be independently determined by
the Contractor and the Engineer. Horizontal readings shall be taken with the theodolite in both direct and
inverted mode. Casting shall not begin until these surveys agree within the following tolerances:
i. Elevation: 0.01 inch on any control point.
ii. Horizontal: 0.01 inch on a Segment centerline offset and 2 seconds of
arc on any control point.
iii. Twist error on elevation control points: 0.01 inch (with 0.02 inch
maximum on random error).

7. Develop as-built Casting Curves for vertical and horizontal alignments from
these measurements. Complete computed coordinates of all sections cast before casting a new Segment.
T452-9.4 Erection Manual: Before commencing erection operations, submit proposals
for all Segment operations to the Engineer for approval. This submittal must be in the form of an
Erection Manual and include but not necessarily be limited to:
1. A detailed step-by-step sequence for the erection of the Segments including all
intermediate procedures relating to any Form Traveler, construction equipment, falsework, movement of
equipment, counterweights, support jacking, stressing of temporary post-tensioning bars, closure
operations including any temporary jacking, partial stressing across the closure during concrete curing,
location and size of shim blocks, main post-tensioning Tendon sequences, stressing loads and elongations,
Form Traveler launching, field survey and alignment control methods to be employed for setting the
initial and subsequent Segments and any other relevant operations.
2. A sequence in which Segments will be cast and how the individual components
of each Segment will be installed. Include a table of theoretical elevations and alignment of the geometry
control points established during casting of each Segment and computed at each stage of superstructure
construction. A summary of elevations for each joint which gives the elevation history of that joint during
the various stages of construction shall also be furnished.
The table of theoretical elevations and alignments shall be accompanied
by all information (loads, in-place casting schedules, material properties, etc.) considered in developing
the table. Submit to the Engineer and receive approval for a new construction procedure prior to deviating
from the sequence and schedule of construction.
3. Detailed scheduling of all temporary and permanent post-tensioning operations
and sequences in accordance with the Segment erection and closure operations and other required
scheduling.
4. Stressing forces and elongations for post-tensioning.
5. Sequencing of filler injection operations.
6. Any other relevant operations as required and applicable to the structure type
and construction method.
Do not start erection without the Engineers approval of the Erection Manual.
T452-9.5 Embedded Items: In the event of a conflict between post-tensioning ducts and
reinforcing steel, adjust the positioning of the reinforcing steel in a manner approved by the Engineer.
Generally, any bar that cannot be fabricated to clear a post-tensioning Tendon shall be replaced by
additional bars with adequate lap lengths using a method approved by the Engineer. Do not cut out or
remove reinforcing steel to permit proper alignment of post-tensioning ducts. In the plane of the steel
parallel to the nearest surface of concrete, bars shall not vary from plan placement by more than 1/2 inch,
or 0.08 times the spacing between bars, whichever is less. In the plane of the steel perpendicular to the
nearest surface of concrete, bars shall not vary from plan placement by more than 1/4 inch. The top and
bottom clear cover of reinforcing steel shall be within 1/4 inch of the clear cover limits dimensioned on
the plans. The end and edge clear cover of the reinforcing steel shall be within 1 inch of the clear cover
limits dimensioned on the plans.
Embedded ducts for Tendons shall be positioned accurately (within 1/4 inch) in
respect to their vertical, linear and transverse position within each Segment. Ensure that ducts are not
displaced during casting. Secure all embedded post-tensioning ducts to the reinforcement cage at intervals
not exceeding 24 inches (small ducts and very flexible ducts may require closer supports). Methods and
spacing of supports for ducts shall be as shown on the Working Drawings.
After installation in the forms, seal the end of the ducts shall at all times. Install
mandrels in the empty cantilever Tendon ducts prior to casting concrete. Remove mandrels after casting.

Following each concrete placement operation, demonstrate that all empty ducts are free of water and are
unobstructed and undamaged. Immediately prior to installation of the prestressing steel, again
demonstrate, to the satisfaction of the Engineer, that all ducts are unobstructed and free of water and
debris.
Supporting devices for Form Travelers or other construction equipment
incorporated in superstructure Segments shall be adequate to distribute stresses as to not damage the
Segment. The use of driven or drilled types of Anchorages for fastening form supports to concrete will not
be permitted.
Thoroughly clean the joint face of the old, previously cast Segment prior to
casting the concrete for the new Segment.
Recess the anchoring devices for transverse and vertical Post-Tensioning in the
end Segments and Pier Tables so that the ends of the prestressing steel and all ends of anchoring devices
will have at least a 2-inch minimum clearance to the top deck surface and a 2-inch clearance to all other
surfaces of the Segment.
After grouting the transverse deck Post-Tensioning, fill the recess at the
Anchorages with an epoxy grout pourback in accordance with FDOT Specifications Section 462. Any
required longitudinal or transverse post-tensioning anchors shall be placed into the form before the
concrete is cast.
T452-9.6 Concrete Placement and Consolidation: Do not deposit concrete into the
forms until the entire set-up of the forms, reinforcement, ducts, anchorages and embedded items have
been thoroughly inspected and checked. Do not place concrete until the Engineer is satisfied that all the
above items have been properly inspected and checked, and the rate of producing and placing the concrete
will be sufficient to complete the casting and finishing operations within the scheduled time, that
experienced concrete finishers are available where required for finish work and that all necessary
finishing tools and equipment are on hand at the site of the work and are in satisfactory condition for use.
Use concrete placement equipment of a size and design which permits placing
concrete within the specified time. Clean all equipment at the end of each operation or workday and, just
prior to reuse, check the equipment again and clean off hardened concrete and foreign materials.
Place all concrete during daylight hours unless prior approval by the Engineer is
obtained and an adequate lighting system is provided.
Intentionally roughen Segment joints with shear keys a minimum of 1/4" in depth
provided (as a part of the Segment bulkhead formwork) along the height of the web. These shear keys
shall have a height of 12", a vertical clear spacing of 6", and a width 1" narrower than the clear spacing
between longitudinal reinforcing bars along the height of the web.
Consolidate all concrete by means of approved mechanical vibrators together
with any other equipment necessary to perform the work as specified. Internal vibrators shall have a
minimum frequency of 8,000 impulses per minute and sufficient amplitude to consolidate the concrete
effectively.
After placing the concrete, use vibrators to work the concrete thoroughly around
reinforcement and embedded fixtures and into corners and angles of the forms. Exercise caution not to
damage the post-tensioning ducts. Use a mandrel in the cantilever duct to keep the duct undeformed
during concreting. Do not use vibrators to move the concrete. Completely consolidate all Segment
concrete.
Provide at least two standby vibrators in working condition. Vibrating of concrete
shall be done with care and in such a manner as to avoid displacement of reinforcing, ducts, and other
embedded items.
No construction joints are allowed within a Segment.

T452-9.7 Fabrication Tolerances: The following tolerances apply to the fabrication of

all cast-in-place Segments:

Length of Segment

1/2 inch but less than 2 inches total per cantilever

Web Thickness

1/4 inch

Depth of Top or Bottom Slab

1/4 inch

Overall Top or Bottom Slab Width

1/4 inch

Diaphragm Dimensions

3/8 inch

Grade of Form Edge and Soffit

1/8 inch in 10 feet

Tendon Hole Location

1/8 inch

Overall Depth of Segment

1/4 inch

Ends

1/4 inch per 20 feet width or depth not to exceed 1/2

inch

Flat Surface (deviation from a plane

at any location)

1/8 inch in 5 feet, not to exceed 1/4 inch

Size of Access Openings

1/4 inch

Location of Access Openings

1/2 inch

Abide by the duct installation tolerances provided in Table 7.2.1.1-1 of FDOT

Specifications Section 462.
T452-9.8 Form Removal: Remove forms in accordance with the requirements of FDOT
Specifications Section 400-14.
Apply curing compound immediately after formwork removal without leaving
the concrete time to dry. For concrete surfaces protected from direct sun or wind, the maximum time
between form removal and start of curing shall not exceed 2 hours. For concrete unprotected more than 2
hours, provide application of moisture.
Exercise care during form removal to prevent spalling and chipping of the
concrete. Employ a form removal sequence that will maintain the stability of the newly cast Segments and
prevent damage to Segment and formwork.
T452-9.9 Test Samples: Provide test samples and testing for compressive strength on
each cast-in-place Segment and field closure joints in accordance with FDOT Specifications Section 346
and the requirements specified herein. Make test cylinders, in accordance with FDOT Specifications
Section 346, cured in the same manner as the structural components to ensure adequate compressive
strength has been achieved in accordance with the Plans requirements prior to stressing of transverse and
longitudinal post-tensioning and partial form removal necessary to complete these operations.
Submit the results of the compression testing of one or more test cylinders for controlling
the time of execution of the various construction operations. Obtain the Engineers approval for meeting
the requirements specified herein on casting, curing and testing of concrete test cylinders.
T452-9.10 Curing Concrete: Concrete curing shall be in accordance with the
requirements of FDOT Specifications Section 400. Take precautions to promote proper curing by methods
approved by the Department and in accordance with FDOT Specifications Section 400. Such precautions
must meet or exceed the following:
1. To prevent moisture loss, cover all exposed surfaces (those not in contact with
a form) as soon as possible after casting with a moisture tight covering (wet curing blankets or other
approved equal systems). Avoid spoiling the deck surface. Keep the cover on or within 12 inches of the
deck surface. Water for mats shall be potable. Constantly monitor all mats used to ensure that the
concrete remains wet.

2. Keep the moisture-tight covering substantially in place throughout succeeding

operations such as geometry control survey, stripping of forms, etc. Keep the concrete surface wet
throughout these operations.
3. After stripping of the side and core forms, continue curing of the concrete by
the application of a Type 2 (white pigmented) membrane curing compound as specified in FDOT
Specifications Section 925-2 to all exposed surfaces (including Segment exterior once exposed by
removal from the form).
4. Maintain the moisture tight covering for a minimum of 72 hours.
T452-9.11 Stressing Sequence: Stress transverse post-tensioned Tendons prior to
stressing cantilever post-tensioned Tendons.
If more than one Tendon is present per web, no more than one Tendon may be
stressed at a time in each web.
T452-9.12 Segment Quality.
T452-9.12.1 General: Inspect each Segment visually for evidence of damage or
defect before, during, and after critical operations and as often as necessary to ensure adequate quality
control. Immediately bring all such evidence of damage or defect to the attention of the Engineer.
Immediately notify the Engineer of any damage. Do not proceed with
casting the subsequent Segment without written authorization from the Engineer.
T452-9.12.2 Damaged or Defective Segments: Isolated defects are defects or
damage which occur randomly and infrequently, as determined by the Engineer.
Recurring defects are defects or damages of the same general type and
nature, which continue to be found in the same general location of the Segments at an unacceptable
frequency, as determined by the Engineer.
As a minimum, jointly inspect the first five Segments constructed at the
site with the Engineer. Identify and categorize all Segment defects during this inspection. Examine the
defects and propose to the Engineer, in writing:
1. The measures to be taken to prevent recurring defects in future
Segments.
2. The method of repair of all defects discovered as a result of
the inspection as required herein.
If recurring defects continue following implementation of the
Contractor's preventive measures, or as detected at any time during the construction, the Engineer will
instruct the Contractor, in writing, to cease operations producing such defective Segments. The
Contractor shall make no repairs until the Engineer has approved the repair method.
The Engineer will determine what constitutes damage or defect, whether
the damage or defect is isolated or recurring, and will categorize the damage or defects. Three categories
of defects are identified for this purpose:
a. Cosmetic: Cosmetic defects or damages are those which do
not affect the ability of the Segment to resist construction or service loads or reduce the life expectancy of
the structure. This category of defect includes a superficial discontinuity such as non-structural cracks
(per FDOT Specifications Section 400), small spalls or honeycombed areas (not over 1 inch deep), or any
defect that does not extend beyond the centerline of any reinforcing steel, or to any elements of the PostTensioning System. Staining of concrete is also considered as a cosmetic defect.
The Engineer may also designate cosmetic defects of
other types and causes.

Repair of cosmetic defects shall be made in such a

manner that the aesthetics and the structural integrity of the Segments are restored.
b. Structural: This category of defect shall include any defect
which will impair the ability of the Segment to adequately resist construction or service loads or reduce
the life expectancy of the structure. Any defect or damage that extends beyond the centerline of any
reinforcing steel or into any element of the Post-Tensioning System or occurs in the deck portion of the
Segment is considered a structural defect. The Engineer will evaluate and determine if casting of the next
Segment is permitted prior to repair.
Examples of such defects include, but not limited to,
structural cracks (per FDOT Specifications Section 400), large spalls and honeycombed areas, major
segregation or breakage of concrete, strand corrosion, cracked wedges, and duct filler voids. The Engineer
may also designate structural defects of other types and causes.
Examples of such defects also include portions of the
Segments that do not meet the casting tolerances and geometry error listed in this attachment.
The Contractor shall be responsible for construction load
analysis, service load analyses, and life expectancy determinations.
Repair of structural defects shall be such that the
aesthetics and structural integrity of the Segment shall be completely restored to a condition to be
expected had the defect or damage not occurred.
c. Rejectable: A rejectable defect is any defect or damage, as
determined by the Engineer, which will impair the ability of the Segment to adequately resist service
loads or construction loads, or will compromise the life expectancy of the structure and which cannot be
successfully repaired such that the structural integrity is completely restored. Any Segment with a
rejectable defect will be deemed unacceptable and shall be removed from the work and replaced by the
Contractor at no additional cost.
The Engineer may also reject damaged or defective
Segments for the following reasons:
i.

Failure of the Contractor to propose acceptable

repair procedures.
ii.
Failure of the Contractor to execute the repair
according to approved repair procedures.
iii.
Rejection of the proposed repair procedure or
repair by the Engineer.
iv.
Failure of the Contractor to provide the required
certification or demonstration that the repair was
successful and that the defect no longer exists,
as required below.
v.
Failure of the Contractor to eliminate recurring
defects.
T452-9.13 Repairs: Perform cosmetic repairs following procedures prepared by the
Contractor, submitted to and approved by the Engineer. Identify those areas required to be repaired prior
to post-tensioning, and those that must be repaired after post-tensioning.
Where staining has occurred outside the surfaces to receive a Class V finish
coating, restore the concrete to its original color.

Perform structural repairs following procedures prepared by the Contractors

Engineer of Record. The repair procedures shall be signed and sealed. The structural repair procedures
shall be submitted in writing to the Engineer, and shall include the following minimum information:
1. A detailed description and sketch of the defect, including dimensions
and location map of all defects.
2. The magnitude and type of the most critical construction loading and
service life condition to which the defective area will be subjected.
3. Detailed reinforcement requirements, material types, surface
treatments, curing methods and general repair procedures proposed. Clearly indicate in the procedure
those areas required to be repaired before erection, and those areas to be repaired after erection.
4. The specific nondestructive testing method and procedure by which
the Contractor shall demonstrate to the Engineer that the defect no longer exists and the Segment has been
restored to a condition to be expected had the defect or damage not occurred.
T452-9.14 Construction Alignment Tolerances After Segment Casting: The following
tolerances shall apply to the superstructure Segments after casting:
1. The maximum differential between the outside face of adjacent
Segments in the erected position shall not exceed 1/4 inch.
2. Transversely, the deviation from the theoretical slope difference
between two successive Segment joints shall not exceed 0.1 percent, measured between edges of deck, at
any point along the span.
3. Longitudinally, the deviation from the theoretical slope change
between two successive Segments shall not exceed 0.3 percent.
4. The difference in roadway elevation at the connection of two adjacent
Segments (measured perpendicular to the deck surface) and across closure Segment shall be no greater
than 1/8 inch.
5. The horizontal and vertical position of a Pier Table Segment shall be
within 1/4 inch of the longitudinal alignment, grade and cross-slope required by the approved
construction plans. The longitudinal slope shall not vary more than 0.05 percent from that required by the
Plans.
Adjust dimensions from Segment to Segment so as to compensate for any
deviations within a single Segment so that the overall dimensions of the completed structure will conform
to the dimensions shown on the plans such that the accumulated maximum error shall not exceed 0.001
times the length of the completed cantilever for either vertical profile and/or horizontal alignment.
Identify deviations exceeding the construction tolerances listed above which are discovered during
casting operations by after-cast surveys before subsequent adjacent Segments are cast. Corrections for
these deviations must be approved by the Engineer prior to casting the next Segment.
T452-9.15 Closure Segments: Align and restrain vertically, longitudinally, and
transversely by closure the superstructure Segments adjacent to each side of the closure Segments so that
the applied concrete closure devices or the Form Traveler during the construction of the closure Segment
loads. Do not remove restraining device Strong Backs until the closure concrete has reached its specified
strength and longitudinal continuity Tendons are tensioned.
Place cast-in-place closure concrete at the time of minimum daily differential
temperatures between the top and bottom slabs of the superstructure.
The closure procedure, including jacking or restraints and forces applied so the
structure, if required, shall be prepared by the Contractors Engineer of Record and submitted to the
Engineer for review at least 10 days prior to the concrete placement. The closure procedure shall also
include geometry control, Tendon stressing, and counterweights, if required.

Concrete for closure joints shall comply with the same specifications and criteria
as the concrete in the Segments. Concrete shall reach the minimum required strength as shown on the
plans prior to stressing the longitudinal post-tensioning. Adequately support formwork to take all loads
applied and do not remove them until the concrete in the joints has reached its required strength, and
longitudinal and transverse Tendons have been stressed.
T452-10 Bridge Deck Surface: Provide a Class 4 Deck Finish in accordance with FDOT
Specifications Section 400 for Long Bridges upon completion of superstructure construction and prior to
opening to traffic.
T452-11 Final Clean Up: Before final acceptance, clean the interior of the concrete box
girders of all rubbish, excess materials, loose concrete, dirt and debris. The interior of the box girders
shall then be swept out. The final clean up shall be performed after all work on the interior of the box
girders, including filler injection of all Tendons and electric work, has been completed.