+------------------+---------------+---------+---------------+--------+
| To:              |               | !       | ***New York   | **EI** |
|                  |               | [](medi | State***      |        |
|                  |               | a/image |               | **03   |
|                  |               | 1.wmf){ | ***Department | -000** |
|                  |               | width=" | of***         |        |
|                  |               | 0.86736 |               |        |
|                  |               | 1111111 | ***Tran       |        |
|                  |               | 1111in" | sportation*** |        |
|                  |               | heigh   |               |        |
|                  |               | t="0.93 | **            |        |
|                  |               | 125in"} | ENGINEERING** |        |
|                  |               |         |               |        |
|                  |               |         | **            |        |
|                  |               |         | INSTRUCTION** |        |
+------------------+---------------+---------+---------------+--------+
| Title: **HIGH    |               |         |               |        |
| PERFORMANCE      |               |         |               |        |
| CONCRETE FOR     |               |         |               |        |
| PRECAST AND      |               |         |               |        |
| PRESTRESSED      |               |         |               |        |
| BRIDGE BEAMS**   |               |         |               |        |
+------------------+---------------+---------+---------------+--------+
| Distribution:    | o Surveyors   | Ap      |               | **     |
|                  | (33)          | proved: |               | Date** |
| x Manufacturers  |               |         |               |        |
| (18)             | x Consultants | George  |               |        |
|                  | (34)          | Chri    |               |        |
| x Main Office    |               | stian - |               |        |
| (30)             | x Contractors | Deputy  |               |        |
|                  | (39)          | Chief   |               |        |
| x Local Govt.    |               | E       |               |        |
| (31)             | o             | ngineer |               |        |
|                  | \_\_\_\_\_\_  | (S      |               |        |
| x                | \_\_\_\_\_\_( | tructur |               |        |
| Regions/Agencies | )             | es**)** |               |        |
| (32)             |               |         |               |        |
+------------------+---------------+---------+---------------+--------+

**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.]{.underline}

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 | AASHTO T22           | \> 70MPa (all  |
| days)                       |                      | tests)         |
+-----------------------------+----------------------+----------------+
| Freeze/Thaw Durability      | AASHTO T161          | x ³ 80%        |
| (x=relative dynamic modulus | Procedure A          |                |
| of elasticity after 300     |                      |                |
| cycles)                     |                      |                |
+-----------------------------+----------------------+----------------+
| Scaling Resistance (y=      | ASTM C672            | y **£** 3      |
| visual rating of surface    |                      |                |
| after 50 cycles)            |                      |                |
+-----------------------------+----------------------+----------------+
| Elasticity (E = modulus of  | ASTM C469 **(See     | E ³ 30GPa      |
| elasticity)                 | Note C)**            |                |
+-----------------------------+----------------------+----------------+
| Shrinkage ( s= microstrain) | AASHTO T160-97 (at   | s \< 600       |
|                             | 56 days)             |                |
+-----------------------------+----------------------+----------------+
| Creep © =                   | ASTM C512 (at 56     | c **£** 60/    |
| microstrain/pressure unit)  | days, 40% f~c~¢)     | MPa            |
+-----------------------------+----------------------+----------------+
| Chloride Penetration (p=    | AASHTO T259 modified | p £ 0.025% at  |
| increase in percent of      |                      | 25 mm          |
| chloride ion by weight of   | **(See Note A)**     |                |
| concrete)                   |                      |                |
+-----------------------------+----------------------+----------------+
| Air Content                 | AASHTO T 152         | A = % selected |
|                             |                      | by contractor, |
|                             |                      | A ³ 3%         |
+-----------------------------+----------------------+----------------+
| W                           | AASHTO TP23-93       | Supplier       |
| ater/Cementitious-Materials |                      | selects W,     |
| ratio (W= mass ratio)       | **(See Note B)**     |                |
|                             |                      | 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)**