SPECIFICATION 828

PRECAST CONCRETE MEMBERS

Copyright MAIN ROADS Western Australia
Specification 828 Precast Concrete Members – 04/10139 Issued 03/04/2023

REVISION REGISTER
Clause Authorised
Description of Revision Issue Date
Number By
Clause 828.06.1 Sub-clause amended SDSE 28/04/2023
Clause 828.06.2 Sub-clause amended SDSE 28/04/2023
Clause 828.08.1 Increased positive cover tolerance SDSE 28/04/2023
Clause 828.09.8 Hold point: stressing calculation submission time SDSE 28/04/2023
increased from 1 day to minimum 5 days
Clause 828.09.11 Additional subclause has been added for SDSE 28/04/2023
prestressing requirements
Clause 828.11.4 Sub-clause amended SDSE 28/04/2023
Clause 828.13.2 Sub-clause amended SDSE 28/04/2023
Clause 828.91.1.1 Sub-clause amended SDSE 28/04/2023
Whole document Reformatted SCO 03/05/2017
Clause 828.02 Redundant AS 1554.3 removed A/SDSE 11/06/2010
Whole document Complete revision of Issue 1.3 to new format MCP 01/08/2006

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Contract No: XXX/XX [Contract Name]
Specification 828 Precast Concrete Members – 04/10139 Issued 03/04/2023

Table of Contents
GENERAL 4
828.01 SCOPE 4
828.02 REFERENCES 4
828.03 – 828.05 NOT USED 4

MANUFACTURE 4
828.06 GENERAL 5
828.07 FORMWORK 5
828.08 REINFORCEMENT 5
828.09 PRESTRESS 5
828.10 CONCRETE 6
828.11 TRANSFER OF PRESTRESS 7
828.12 RECORDS 7
828.13 MEMBER TOLERANCES 7
828.14 MARKING OF MEMBERS 7
828.15 – 828.25 NOT USED 7

TRANSPORT, HANDLING AND STORAGE 7

828.26 GENERAL 8
828.27 LIFTING 8
828.28 TRANSPORT 8
828.29 STACKING 8
828.30 – 828.40 NOT USED 8

INSTALLATION 8
828.41 GENERAL 8
828.42 WELDING OF POSITIVE MOMENT CONNECTION REINFORCEMENT AT BEAM
ENDS 9
828.43 PLANK JOINTS 9
828.44 DECK CONCRETE OVERLAY 9
828.45 – 828.80 NOT USED 9

AS BUILT AND HANDOVER REQUIREMENTS 9

828.81 – 828.90 NOT USED 9

CONTRACT SPECIFIC REQUIREMENTS 9

828.91 – 828.99 NOT USED 9

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Contract No: XXX/XX [Contract Name]
Specification 828 Precast Concrete Members – 04/10139 Issued 03/04/2023

SPECIFICATION 828

PRECAST CONCRETE MEMBERS

GENERAL
828.01 SCOPE

1. The work under this specification consists of the supply and installation of
precast concrete members (beams and planks).

828.02 REFERENCES

1. Australian Standards, MAIN ROADS Western Australia Standards and

MAIN ROADS Western Australia Test Methods are referred to in
abbreviated form (e.g. AS 1234, MRS 67-08-43 or WA 123). For
convenience, the full titles are given below:

Australian Standards
AS 1349 Bourdon Tube Pressure and Vacuum Gauges
AS 5100 Bridge Design

Australian/New Zealand Standards

AS/NZS 1554.3 Structural Steel Welding - Welding of Reinforcing
Steel
AS/NZS 4680 Hot-dip Galvanised (Zinc) Coatings on Fabricated
Ferrous Articles

Other Standards
Concrete Institute of Australia Precast Concrete Handbook (2002)

MAIN ROADS Specifications

Specification 820 CONCRETE FOR STRUCTURES
Specification 821 FORMWORK
Specification 822 STEEL REINFORCEMENT
Specification 824 PRESTRESSING OF CONCRETE

828.03 – 828.05 NOT USED

MANUFACTURE

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Contract No: XXX/XX [Contract Name]
Specification 828 Precast Concrete Members – 04/10139 Issued 03/04/2023

828.06 GENERAL

1. Manufacture and acceptance of precast concrete members shall be in

accordance with this specification, the Drawings and any other
requirements of the Contract.

2. Casting methods shall be designed to ensure that no damage occurs to the

precast concrete members. All precast concrete members shall be free
from any grout or slurry loss, honeycombing, cracking or spalling. Precast
concrete members with defects of this nature shall be rejected. For crack
width limits refer to Specification 820.

3. Some beams are required to have holes located in the webs for subsequent
attachment of formwork during bridge construction. The location and size of
these holes and the number of beams requiring these holes are detailed on
the Drawings.

828.07 FORMWORK

1. The provisions of Specification 821 FORMWORK shall apply to the

manufacture of precast concrete members and in addition:

a. Formwork shall be fabricated from steel with a minimum thickness of

3mm.

b. Unformed surfaces of concrete shall be roughened and shall be free

from laitance and loose material which may be deleterious to the
bond with the in situ deck concrete. This shall be achieved after
curing by scabbling or any other suitable method.

828.08 REINFORCEMENT

1. The provisions of Specification 822 STEEL REINFORCEMENT shall apply

to all reinforcement utilised in precast concrete members, except that the
tolerance on the minimum clear cover specified shall be -0mm + 10mm in
all cases. Any lengths of reinforcement which are left exposed after
manufacture shall be coated with cement grout to prevent rusting.

828.09 PRESTRESS

1. The provisions of Specification 824 PRESTRESSING OF CONCRETE shall

apply in relation to prestressing of precast concrete members, with
additional provisions as specified in this clause 828.09.

2. The stressing bed shall have the capacity to safely accommodate the forces
involved for the pretensioned member being manufactured.

3. The structural adequacy of a temporary stressing bed shall be certified by

an appropriate Engineer eligible for Corporate Membership of the Institution
of Engineers, Australia. Such certification shall be made available to the
Superintendent prior to the commencement of any stressing.

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4. Pressure gauges shall comply with the requirements of AS 1349. The

diameter of the gauge shall not be less than 150mm or shall be of such a
type which will allow visual reading to the nearest 0.5MPa. The maximum
jacking force shall correspond to a gauge pressure between 50 and 90
percent of the gauge capacity. A device shall be fitted to the gauge to
protect it against a sudden loss of pressure. Provision shall be made for the
attachment of a second gauge.

5. Calculations to determine the nominated jacking force, nominated

elongations, and corresponding gauge pressure shall be carried out for the
coils in each lot, using the representative test certificates.

6. All calculations shall be certified by an appropriate Engineer who is eligible

for Corporate Membership of the Institution of Engineers, Australia.

7. Where prestressing strand is to be deflected at tie down points as shown on

the Drawings then the steelwork which is cast into the beam to hold the
deflected strand shall be hot dipped galvanised in accordance with AS/NZS
4680 and shall be rebated 15mm from the surface of the concrete. The
void so formed shall be filled with a compatible colour matching epoxy
mortar and brought to a smooth, even finish.

8. At least five (5) Business Days prior to the proposed pretensioning of HOLD POINT
each member or line of members, the Contractor shall submit to the
Superintendent stressing calculations, Engineer's certification and the
representative test certificates for each member.

9. The Superintendent will consider the submitted documents for compliance

with the Specification, and any other requirement of the Contract, prior to
authorising the release of the Hold Point, for each member or line of
members.

10. Strands at the ends of units shall be cut off flush or left protruding as
detailed on the drawings. Strands cut off flush shall be coated with epoxy
resin to prevent rusting. Strands left protruding shall be coated with cement
grout.

11. Where debonding of strands is shown in the drawings, PVC sheathing tubes
with external diameter not exceeding the strand diameter plus 3mm must be
utilised. Rigid electrical conduits must not be utilised as sheathing. The
sheathing tube must be extended beyond the end of the member and
sealed sufficiently to prevent ingress of mortar.

828.10 CONCRETE

1. The provisions of Specification 820 CONCRETE FOR STRUCTURES shall

apply to all concrete utilised in the manufacture of precast concrete
members. In addition:

a. If the Contractor proposes to use external type vibrators for concrete Compaction
compaction then evidence shall be provided to show that the same
level of compaction as achieved by immersion vibrators.

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b. Where steam curing is proposed to be used then it shall be low Curing

pressure wet steaming and in accordance with Specification 820
CONCRETE FOR STRUCTURES. Any other form of accelerated
curing will not be permitted. Steaming shall not commence until at
least two hours after the last batch of concrete has been placed.
Subsequent curing shall be in accordance with Specification 820.

828.11 TRANSFER OF PRESTRESS

1. The Contractor shall use methods that minimise the shock transfer of stress
during the release of tendons. Examples of non-complying methods include
cutting through with a disk grinder, and severing the tendons directly and
quickly with a naked flame.

2. The transfer of the prestressing force from the stressing bed to the member
shall not occur until the concrete has reached the minimum transfer
strength specified in the Drawings.

3. Prior to transfer all tendons shall be checked to ensure all tendons are tight.

4. The slippage of each tendon into the concrete at transfer shall be visually
inspected. Localised spalling around fully bonded strands at transfer as a
result of excessive slippage shall be identified as a nonconformance and
treated in accordance with Specification 201 – QUALITY MANAGEMENT.

828.12 RECORDS

1. The Contractor shall enter all transfer information on a record sheet.

Information shall include, but not be limited to, concrete compressive
strength, verification of the transfer method and order of release of tendons,
and any defects in the member.

828.13 MEMBER TOLERANCES

1. Precast pretensioned concrete I beams shall conform to the dimensions Beams

and details given on the Drawings.

2. Precast pretensioned concrete planks shall conform to the dimensions and Planks
details given on the Drawings.

828.14 MARKING OF MEMBERS

1. Each precast concrete member shall be clearly marked using distinguishing Identification
numbers or letters consistent with those shown on the Drawings.

828.15 – 828.25 NOT USED

TRANSPORT, HANDLING AND STORAGE

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828.26 GENERAL

1. Temporary storage areas for precast concrete members shall be carefully

cleared and levelled. The beams and planks shall be supported over their
full width at the lifting points only. Temporary supports shall be of timber of
a minimum size 150mm wide, 100mm thick and 1m long. The supports
shall be on firm foundations and every precaution must be taken to prevent
subsidence from occurring and to prevent the units bearing other than at the
specified support positions.

2. Any precast concrete member damaged or distorted in excess of the

specified tolerances prior to or during installation shall be replaced at no
cost to the Principal.

828.27 LIFTING

1. Precast concrete members shall be kept in the upright position at all times
and shall only be lifted from the specified lifting points. Precast concrete
members shall be lifted using either a full length steel lifting beam or two
cranes to ensure the force at the lifting points is in accordance with the
Drawings.

828.28 TRANSPORT

1. Precast concrete members shall be transported to the Site in a manner

which does not damage the precast concrete members. Precast concrete
members shall not be transported until they are at least 7 days old and the
concrete shall have reached its 28 day nominated strength.

828.29 STACKING

1. Precast concrete members may be stacked on top of each other. Each

layer shall be separated from the next layer by at least 75mm, by temporary
supports placed in line vertically at the support points. No superimposed
loads shall be placed on the units.

2. Where stacking of girders is required by the Contractor, the design of the

stacking arrangement shall be carried out by an appropriate Engineer
eligible for Corporate Membership of the Institution of Engineers, Australia.
A certificate from the Engineer shall be provided to the Superintendent,
prior to stacking the girders, stating that the proposed stacking arrangement
will not overstress or damage any girder so stacked. Consideration shall be
given to the relief of temperature, shrinkage, creep and any other effects on
the stacking arrangements.

828.30 – 828.40 NOT USED

INSTALLATION
828.41 GENERAL

1. No precast concrete member shall be installed until the supporting

substructure has gained 75% of its design strength. Precast concrete
members shall be installed to a tolerance of ±3mm.

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828.42 WELDING OF POSITIVE MOMENT CONNECTION

REINFORCEMENT AT BEAM ENDS

1. The Contractor shall observe the rules and procedures of welding laid down
in AS/NZS 1554.3.

828.43 PLANK JOINTS

1. Plank locating dowels shall be fully installed and grouted before placing any
shear key concrete.

2. The shear keys between planks shall be adequately sealed at their lower
section as detailed on the Drawings before placing the shear key concrete.

3. The shear key concrete shall be placed in a continuous operation for each
shear key for each plank length. Concrete shall be compacted using a
25mm maximum diameter pencil vibrator in accordance with Specification
820 CONCRETE FOR STRUCTURES.

4. Joints between plank ends over the piers shall be filled with a cement
mortar with a water/cement ratio by mass not exceeding 0.42 and a
sand/cement ratio by mass of 3.0. The mortar shall be rodded into the joint
to achieve maximum compaction.

828.44 DECK CONCRETE OVERLAY

1. The deck concrete overlay shall not be placed earlier than 3 days after the
completion of all plank shear key joints.

2. Before the deck concrete overlay is placed the top surface of the precast
concrete units shall be thoroughly cleaned with a water jet to remove dust
and chips and any other foreign matter.

3. Immediately prior to commencing of concreting the top surface of the

precast units shall be thoroughly wetted.

4. All other work for the deck concrete overlay shall be in accordance with
Specification 820 CONCRETE FOR STRUCTURES.

828.45 – 828.80 NOT USED

AS BUILT AND HANDOVER REQUIREMENTS

828.81 – 828.90 NOT USED

CONTRACT SPECIFIC REQUIREMENTS

828.91 – 828.99 NOT USED

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GUIDANCE NOTES
FOR REFERENCE ONLY – DELETE GUIDANCE NOTES FROM FINAL DOCUMENT

1. All edits to downloaded Specifications shall be made using Track Changes, to clearly show
added/deleted text.

2. If all information relating to a clause is deleted, the clause number should be retained and the
words “NOT USED” should be inserted.

3. The proposed documents with tracked changes shall be submitted to the Project Manager for
review, prior to printing the final batch of documents. When this final printing is carried out, the
tracked changes option is to be turned off.

4. Before printing accept all changes in the document, turn off Track Changes and refresh the
Table of Contents.

5. The Custodian of this specification is the Structures Design and Standards Engineer.

1. SUPPLY BY PRINCIPAL (Clause 828.91)

1.1 If the Principal will pre-supply precast concrete members, include Clause 828.91 in the
CONTRACT SPECIFIC REQUIREMENTS Section, complete and incorporate Annexure
828A into the Specification document.

1.2 Annexure 828A is provided for listing Principal supplied items such as precast concrete
beams and planks, in which case any Clauses relating to manufacture should be deleted
and marked as “Not Used”. The description to be entered in Annexure 828A should
include identification with items shown on the Drawings, and the location for pick-up of
precast members.

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Specification 828 Precast Concrete Members – 04/10139 Issued 03/04/2023

CONTRACT SPECIFIC REQUIREMENTS

The following clauses are to be placed under the CONTRACT SPECIFIC REQUIREMENTS, as
required. After inserting the clause, change the clause number and heading to style “H2 SP” so it
appears in the Table of Contents.

828.91 PRECAST MEMBERS SUPPLIED BY THE PRINCIPAL

828.91.01 GENERAL

1. The number and type of precast concrete members which will be supplied
by the Principal free of charge to the Contractor is given in Annexure 828A.
These will conform to the dimensions specified on the Drawings within the
tolerances specified in the Specifications. All units have been precast
under factory conditions.

2. Holes are provided on the beam webs for the attachment of falsework. The
drilling of other holes in the beam will not be permitted.

828.91.02 SUPPLY

1. The precast concrete members will be stored in the Perth metropolitan area
and will be available to the Contractor at the times and locations shown in
Annexure 828A. The Contractor shall provide all equipment, plant and
labour necessary for the transportation of the beams and planks to the Site.

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ANNEXURE 828A

SUPPLY OF PRECAST MEMBERS BY PRINCIPAL

Type Number Location Time Of Availability

(Weeks after
Commencement of
Contract)
Beam Type A

Beam Type B

Plank Type A

Plank Type B

(NOTE: This Annexure is used in conjunction with Clause 828.91 and should be varied as required to suit.)

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AMENDMENT CHECKLIST

Specification No. 828 Title: PRECAST CONCRETE MEMBERS Revision No:

Project Manager: Signature: Date:

Checked by: Signature: Date:

Contract No: Contract Description:

ITEM DESCRIPTION SIGN OFF

Note: All changes/amendments must be shown in Tracked Changes mode until approved.
1. Project Manager has reviewed Specification and identified Additions and
Amendments.
2. CONTRACT SPECIFIC REQUIREMENTS addressed? Contract specific
materials, products, clauses added? (Refer Specification Guidance Notes for
guidance).
3. Any unlisted materials/products proposed and approved by the Project
Manager? If “Yes” provide details at 16.
4. Standard clauses amended? MUST SEEK approval from Manager
Commercial.
5. Clause deletes shows as “NOT USED”.
6. Appropriate INSPECTION AND TESTING parameters included in Spec 201
(Text Methods, Minimum Testing Frequencies verified).
7. ANNEXURES completed (refer Specification Guidance Notes).
8. HANDOVER and AS BUILT requirements addressed.
9. Main Roads QS has approved changes to SMM.
10. Project Manager certifies completed Specification reflects intent of the
design.
11. Completed Specification – independent verification arranged by Project
Manager.
12. Project Manager’s review completed.
13. SPECIFICATION GUIDANCE NOTES deleted.
14. TABLE OF CONTENTS updated.
15. FOOTER updated with Document No., Contract No. and Contract Name.
16. Supporting information prepared and submitted to Project Manager.
Further action necessary:

Signed: (Project Manager) Date:

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