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NOTES
1. This manual does not claim or imply that it
addresses all safety-related issues, if any,
associated with its use. Manufacture of
concrete products may involve the use of
hazardous materials, operations and
equipment. It is the user’s responsibility to
determine appropriate safety, health and
Copyright 2006 by National Precast Concrete Association (NPCA)
environmental practices and applicable
Second Edition, 2005 All rights reserved.
regulatory requirements associated with
the use of this manual and the manufacture
No part of this manual may be reproduced in any form without permission in writing from
of concrete products.
the National Precast Concrete Association.
2. Use of this manual does not guarantee the
proper function or performance of any
product manufactured in accordance with
the requirements contained in the manual.
Routine conformance to the requirements
The association of the manufactured concrete products industry.
of this manual should result in products of
10333 North Meridian Street, Suite 272 | Indianapolis, Indiana 46290
an acceptable quality according to current
800-366-7731 | 317-571-0041 (fax) | www.precast.org
industry standards.
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INTRODUCTION
Precast concrete is ideally suited for utility, industrial and High-quality concrete products are important for many
communications structures. A properly manufactured and applications, most notably for underground structures
installed precast concrete structure can last almost that must resist soil pressures and sustain surface loads.
indefinitely. Precast concrete is inherently durable, highly The controlled manufacturing environment in a precast
impermeable and corrosion-resistant. concrete plant is ideal for the production of high-quality,
durable concrete products.
Utility, industrial and communications structures are an
important part of the manufactured concrete products This manual is intended to guide manufacturers in quality
industry, and we must continue to provide project owners production processes for manufacturing utility vaults. The
and end users with the best possible products at manual is not intended to be all inclusive and the
competitive prices. It is also important that those recommendations are not intended to exclude any
products contribute to the quality, timeliness and ease of materials or techniques that would help achieve the goal
installation of construction projects. The best practices of providing structurally sound, high quality products.
outlined in this manual are intended to help Attention to detail, quality materials, proper training and
manufacturers achieve these goals. a workforce dedicated to quality control will ensure that
the utility vault meets or exceeds the expectations of
When properly designed and manufactured, precast contractors and end users.
concrete is capable of maintenance-free performance
without the need for protective coatings, except in certain
circumstances such as highly-corrosive environments. The
“precast advantage” is further solidified through precast’s
ease of installation and strength. Because precast
concrete products typically are produced in a controlled
environment, they exhibit high quality and uniformity.
Adverse factors affecting quality which are typically
found on job sites – variable temperature, uneven curing
conditions, inconsistent material quality and
craftsmanship – are significantly reduced in a plant
environment.
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STRUCTURAL DESIGN
Loading Conditions The loading conditions illustrated in the diagram(s)
A properly designed precast concrete utility vault must should be analyzed and considered in the design of a
withstand a variety of loading conditions, which vary utility structure.
during manufacturing, installation, testing and service.
These structures are designed to withstand loading The following design characteristics have a critical impact
conditions through rational mathematical design on the performance of utility structures.
calculations, by proof-of-load testing or in accordance
with ASTM C 857 “Standard Practice for Minimum Concrete Thickness
Structural Design Loading for Underground Precast The concrete thickness must be sufficient to meet
Concrete Utility Structures.” minimum reinforcement cover requirements and withstand
design loading conditions.
Consider the following in the design:
• Surface surcharge loads Concrete Mix Design
• Concentrated wheel and other traffic loads Concrete must have a minimum compressive strength of
• Lateral loads 4,000 psi at 28 days. Consider methods to reduce
• Presumptive soil bearing capacity permeability, improve durability and increase strength.
• Buoyant forces Maintain a low water-cementitious ratio at or below 0.45.
• Connections and penetrations
• Point loads Reinforcement
Proper design and placement is critical to withstand the
Precast concrete utility vaults should be designed significant loads applied to utility vaults. Reinforcement
according to one or more of the following industry codes must be sufficient for required strength and service
and standards and as required by any regulatory groups conditions, including temperature and shrinkage effects.
with jurisdiction: Control cracking by using multiple small-diameter steel
• ACI 318 – Building Code Requirements for Structural bars rather than fewer large-diameter steel bars. Fiber
Concrete reinforcement also helps to reduce cracking and may add
• AASHTO – Specification for Highway Bridges some strength, but should not replace primary
• ASTM C 857 – Standard Practice for Minimum reinforcement. Welded-wire reinforcement can also be
Structural Design Loading for Underground Precast used, but particular attention should be paid to design
Concrete Utility Structures and location. All reinforcement should meet applicable
• ASTM C 858 – Standard Specification for Underground ASTM specifications.
Precast Concrete Utility Structures
Loading Diagram
*Manufacturer to specify the maximum depth of cover
Surcharge Surcharge
Grade line
Groundwater
Level
Mid-Seam
Top Seam Vault
Vault
+ +
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MATERIALS
The primary constituents of precast concrete are cement, Aggregates
fine and coarse aggregates, water and admixtures. The Ensure aggregates conform to the requirements of ASTM
following discussion covers relevant factors in the C33, “Standard Specification for Concrete Aggregates.”
selection and use of these fundamental materials. Evaluate the aggregates and maintain documention at the
plant for potential deleterious expansion due to alkali
Cement reactivity, unless the aggregates come from a state
The majority of cement used in the manufactured department of transportation-approved source. The
concrete products industry is governed by ASTM maximum size of coarse aggregate should be as large as
C 150,“Standard Specification for Portland Cement.” practical, but should not exceed 20 percent of the
The five primary types of ASTM C 150 cement are: minimum thickness of the precast concrete utility vault or
75 percent of the clear cover between reinforcement and
Type I Normal the surface of the vault. Larger maximum sizes of
Type II Moderate Sulfate Resistance aggregate may be used if evidence shows that
Type III High Early Strength satisfactory concrete products can be manufactured.
Type IV Low Heat of Hydration
Type V High Sulfate Resistance Aggregates are an important constituent of precast
concrete utility vaults. Nearly 75 percent of a precast
Select the cement type based on project specifications or concrete utility vault’s structure consist of coarse and
individual characteristics which best fit the operation and fine aggregates.
regional conditions of each manufacturer. Note that
certain types of cement may not be readily available in The selection of appropriate aggregates is largely a
certain regions. Store cement in a manner that will regional concern. The selection process is based on using
prevent exposure to moisture or other contamination. the best available clean, hard, durable aggregates and
Bulk cement should be stored in watertight bins or silos. proper gradations. Aggregates should conform to ASTM
If different types of cement are used at a facility, store C 33 – Standard Specification for Concrete Aggregates
each type in a separate bin or silo. Clearly identify and ACI 318 – Building Code Requirements for Structural
delivery locations. Concrete.
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If the only available aggregates in your area have been For good bond development, ensure aggregate surfaces
found to cause excessive expansion of mortar or are clean and free from excessive dust or clay particles.
concrete, appropriate precautionary measures should be Excessive dust or clay particles typically are defined as
taken during the mix design process. The use of mineral material passing a #200 sieve, the limit of which is no
admixtures, a low water-cement ratio or a low-alkali more than 3 percent. Friable aggregates may fracture in
cement can all aid in controlling such expansive the mixing and placement process, compromising the
reactions. When using mineral admixtures or a low-alkali integrity of the hardened concrete product.
cement, trial batches should be tested to establish their
viability in controlling the expansive reactions. Moisture Content of Aggregate
The measurement of aggregate moisture content is
Gradation of Aggregates important in the control of concrete workability, strength
Aggregate gradation influences both the economy and and quality. Aggregates – particularly fine aggregates
strength of a finished utility vault. The purpose of proper (sands) – can collect considerable amounts of moisture
gradation is to produce concrete with a maximum density on their surfaces. Fine aggregates can hold up to 10
along with good workability to achieve sufficient percent moisture by weight; coarse aggregates can hold
strength. up to 3 percent.
Well-graded aggregates help improve workability, Water on the surface of an aggregate that is not
durability and strength of the concrete. Poorly graded or calculated into the mixture proportions will increase the
gap-graded aggregates rely on the use of excess mortar water-cementitious ratio. The moisture content of
to fill voids between coarse aggregates, leading to aggregates will vary throughout a stockpile and will be
potential durability problems. Concrete mixes containing affected by changes in weather conditions. Therefore,
rounded coarse aggregates tend to be easier to place and adjust mixture proportions as necessary throughout the
consolidate. However, crushed aggregates clearly are production day to compensate for moisture content
acceptable. The use of elongated, flat and flaky changes in the aggregate.
aggregates is discouraged. Gap-graded aggregates
lacking intermediate sizes are also discouraged. The following methods will increase the likelihood of
uniform moisture content:
Figure 2 — Poorly graded mix vs. Well-graded mix design
• Enclose storage of daily production quantities
• Store aggregates in horizontal layers
• Have at least two stockpiles
• Allow aggregate piles to drain before use
• Avoid the use of the bottom 12 inches of a stockpile
• Continuously sprinkle aggregate stock piles (climate
dependent)
Porous concrete resulting from Inclusion of fine materials provides • Store entire stockpile indoors or under cover
absence of fine materials. Arrows filling for spaces between coarse
indicate water infiltration. aggregates. Careful monitoring of aggregate moisture content during
batching will reduce the need to add additional cement to
Aggregate Deleterious Substances offset excess water. This will maintain high-quality
Ensure all aggregates are free of deleterious substances, standards and save on expensive raw materials.
including:
The plant should have a program in place that manages
• Substances that cause an adverse chemical reaction in surface moisture content or accounts for moisture
fresh or hardened concrete variation during batching.
• Clay, dust and other surface-coating contaminants
• Structurally soft or weak particles
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Handling and Storage of Aggregate temperature extremes. Ensure they are accessible for visual
Aggregate handling is an important operation. Handle and observation and periodic maintenance. Perform periodic
store aggregates to prevent contamination and minimize recalibration of the batching system as recommended by
segregation and degradation. Accurately graded coarse the manufacturer or as required by local regulations.
aggregate can segregate during a single improper Chemical admixture performance can vary. Exercise
stockpiling operation, so handling should be minimized to caution, especially when using new products. Test some
reduce the risk of particle size segregation. Also trial batches and document the results before using a
minimize the number of handling operations and material new admixture for production. Follow manufacturers’
drop heights to avoid breakage. recommendations exactly. Carefully check admixtures for
The following methods can prevent segregation: compatibility with the cement and any other admixtures
• Store aggregates on a clean, hard, well-drained base to used. Do not mix similar admixtures from different
prevent contamination. Bin separation walls should manufacturers without the manufacturer’s agreement or
extend high enough to prevent overlapping and cross- testing to verify compatibility.
contamination of different-sized aggregates. Additional guidelines for the use of admixtures are included
• Avoid steep slopes in fine aggregate stockpiles. Fine in ACI 212.3, “Guide for Use of Admixtures in Concrete.”
aggregate stockpiles should not have slopes greater Avoid accelerating admixtures that contain chlorides in
than the sand’s angle of repose (i.e., natural slope, order to prevent possible corrosion of reinforcing steel
typically 1:1.5) to prevent unwanted segregation. elements and other embedded metal objects.
• Remove aggregates from a stockpile by working
horizontally across the face of the pile. Avoid taking Supplementary Cementitious
aggregate from the exact same location each time. Materials (SCMs)
Supplementary Cementitious Materials are often
Water incorporated into a concrete mix to reduce cement
Water used in mixing concrete should meet the contents, improve workability, increase strength and
requirements of ASTM C 1602, “Standard Specification for enhance durability. The most common types of SCMs are
Mixing Water Used in the Production of Hydraulic fly ash, silica fume and ground granulated blast furnace
Cement Concrete.” Avoid water containing deleterious slag (GGBFS) as know simply as slag. More than one
amounts of oils, acids, alkalis, salts, organic material or SCM may be incorporated into a mix while various types
other substances that may adversely affect the properties of blended cements are also available. The following
of fresh or hardened concrete. standards establish the minimum requirements for some
of the common SCMs and blended cements.
Chemical Admixtures • ASTM C595: Standard Specification for Blended
Commonly used chemical admixtures in precast concrete Hydraulic Cements
manufacturing include: • ASTM C618: Standard Specification for Coal Fly Ash and
• Accelerating admixtures (ASTM C494, “Specification for Raw or Calcined Natural Pozzolan for Use in Concrete
Chemical Admixtures for Concrete”) • ASTM C989: Standard Specification for Ground
• Air entrainment admixtures (ASTM C260, “Specification Granulated Blast-Furnace Slag for Use in Concrete and
for Air-Entraining Admixtures for Concrete”) Mortars
• Water-reducing admixtures (ASTM C494, “Specification • ASTM C1240: Standard Specification for Use of Silica
for Chemical Admixtures for Concrete”) Fume Used in Cementitious Mixtures
• High-range water-reducing admixtures or
superplasticizers (ASTM C1017, “Chemical Admixtures Ready-Mixed Concrete
for Use in Producing Flowing Concrete”) Verify that the ready-mixed concrete supplier is operating
in accordance with ASTM C94, “Standard Specification
Store admixtures in a manner that avoids contamination,
for Ready-Mixed Concrete.” Perform plastic concrete tests
evaporation and damage. Protect liquid admixtures from
(slump, temperature, air content and density) at the plant
freezing and extreme temperature changes, which could
prior to casting products. Record any added water on the
adversely affect their performance. It is also important to
delivery batch ticket for each truck and keep it on file.
protect admixture batching components from dust and
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CONCRETE MIXTURE
PROPORTIONING
Concrete mix design, also known as mix proportioning, is concrete must be sufficiently plastic (flowable or
a broad subject – one that is specific to concrete in deformable) to be properly placed, consolidated and
general and not necessarily to utility vaults in particular. finished. The size, shape and grading of aggregates,
This discussion will focus only on critical factors that cement content, water-cement ratio and admixtures affect
pertain to high-quality precast concrete that is the workability of a mix.
recommended when casting utility vaults.
Water-reducing admixtures and superplasticizers can
Mix designs are selected based upon several necessary greatly increase the workability of fresh concrete without
factors including permeability, consistency, workability, changing the water-cement ratio. Experience has shown
strength and durability. The elements necessary to that concrete with low water-cement ratios (less than
achieve high-quality precast concrete include: 0.45) can be properly placed and consolidated with the
• Low water-cement ratio (less than 0.45) proper use of admixtures. However, air entrainment
• Minimum compressive strength of 4,000 psi at 28 days should be limited to keep the air content at a maximum
• Use of quality aggregates of 7 percent.
• Appropriate concrete consistency (concrete that can be
readily placed by traditional methods; this is typically The use of chemical admixtures for wet-cast concrete
measured by slump) (such as air-entraining admixtures, water-reducing
admixtures and superplasticizers) helps to attain
High water-cement ratios lead to undesirable increased workable concrete with a low water-cement ratio. Their
capillary porosity within the concrete. Capillary pores are use is particularly important, since most utility vaults
voids resulting from the consumption and evaporation of require heavier reinforcing and have large penetrations
water during the hydration or curing process. Enlarged that require special attention to ensure full consolidation.
and interconnected capillary voids serve as pathways for In certain circumstances, and where local regulations
water and other contaminates to infiltrate the concrete allow, properly designed and tested self-consolidating
system. Lower water-cement ratios result in smaller and concrete (SCC) can be used to improve the likelihood of
fewer pores, reducing the concrete’s permeability. proper bond between concrete and reinforcement.
Aggregate quality and gradation have a tremendous Air-entraining admixtures are designed to disperse
impact on the concrete’s overall quality. Mix designs with microscopic air bubbles throughout the concrete’s matrix
well-graded aggregates and sufficient quantities of fine to function as small “shock absorbers” during freeze-
aggregate have reduced water demands (i.e., lower thaw cycles. The required air content for frost-resistant
water-cement ratios) while maintaining adequate concrete is determined by the maximum aggregate size
workability and ease of placement. and severity of in-service exposure conditions (ACI 318).
Air entrainment improves workability and reduces
Proper consistency of fresh concrete is a critical element bleeding and segregation of fresh concrete while greatly
in producing high-quality precast concrete. Fresh improving the durability of hardened concrete.
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LIFTING INSERTS
Commercially manufactured lifting devices come
furnished with documented and tested load ratings. Use
the devices as prescribed by the manufacturer’s
specification sheets. Lifting devices should meet the
minimum requirements of ASTM C857, “Standard Practice
for Minimum Structural Design Loading for Underground
Precast Concrete Utility Structures.
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COATINGS
Good concrete with a water-cement ratio less than 0.45
and a compressive strength greater than 4,000 psi is
sufficient for utility vaults. Under normal conditions,
there is no need for additional applications of asphalt,
bituminous, epoxy or cementitious coatings. However, a
protective exterior coating may be specified when a soil
analysis indicates a potential for chemical attack.
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PRODUCTION PRACTICES
Quality Control
All plants must have a quality control program and
manual, including but not limited to the following:
Forms
Forms must be in good condition. Frequent inspection
intervals and regular maintenance ensure that forms are
free of any damage that could cause concrete placement
difficulties or dimensional problems with the finished
product.
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REINFORCEMENT
Fabrication drawings must be a part of every QC Conventional reinforcement (ASTM A615, “Specification
program. Fabrication drawings should detail the for Deformed and Plain Billet-Steel Bars for Concrete
Reinforcement”) is produced from recycled metals that
reinforcement requirements and all necessary information
pertaining to the product prior to casting. have higher carbon contents and are likely to become
brittle if improperly welded. A brittle weld is a weak link,
Conventional Reinforcement which can compromise the structural integrity of the
Fabricate reinforcing steel cages by tying or welding the finished product. ASTM A615/615M states: “Welding of
bars, wires or welded wire reinforcement into rigid material in this specification should be approached with
structures. The reinforcing steel cages should conform to caution since no specific provisions have been included
the tolerances defined on the fabrication drawings. If not to enhance the weldability. When the reinforcing steel is
stated, minimum bend diameters on reinforcement to be welded, a welding procedure suitable for the
should meet the requirements set forth in ACI 318, as chemical composition and intended use or service should
defined in Table 1. Make all bends while the be used.”
reinforcement is cold. The minimum bend diameter for
concrete reinforcing welded wire reinforcement is 4db. Ensure lap splices for steel reinforcement (rebar and
welded-wire reinforcement) meet the requirements of ACI
318. Adequate development length is required to develop
Table 1: Concrete Reinforcing Steel the design strength of the reinforcement at a critical
section. A qualified engineer should determine
development length and clearly indicate it on shop
ASTM A615 and A706 Minimum Bend ASTM A615 and A706
drawings.
Inch-Pound Bar Sizes Diameter Soft Metric Bar Sizes
# 3 through # 8 6db # 10 through # 25 Reinforcement steel should be free of loose rust, dirt and
# 9, # 10 and # 11 8db # 29, # 32 and # 36 form release agent. Cut, bend and splice reinforcing steel
# 14 and # 18 10db # 43 and # 57 in accordance with fabrication drawings and applicable
industry standards. Inspect reinforcing cages for size,
db = nominal diameter (inch or mm) of bar spacing, proper bends and length. Secure the reinforcing
cage in the form so that shifting will not occur during
Weld reinforcement (including tack welding) in casting. Use only chairs, wheels and spacers made of
accordance with AWS D1.4, “Structural Welding Code, noncorrosive materials.
Reinforcing Steel.” This code requires either special
preheat requirements (when required) or weldable grade It is important to place and hold reinforcement in position
reinforcement as defined by ASTM A706, “Specification as shown in the fabrication drawings. A maximum
for Low-Alloy Steel Deformed and Plain Bars for Concrete recommended placement tolerance for the depth of
Reinforcement,” for any welding of reinforcing steel, reinforcement is +1/4 inch (ACI 318). As a general rule the
including tack welds. Take special care to avoid variation in spacing between bars should not exceed
undercutting or burning through the reinforcing steel. more than 1/12 of the designed bar spacing nor exceed
1.5 inch in variation, except for welded wire mesh
conforming to Specifications A185 or A497. The
recommended minimum concrete cover over reinforcing
steel is 3/4 inch (ASTM C858).
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N AT I O N A L P R E C A S T C O N C R E T E A S S O C AT I O N
PRE-POUR CHECKLIST
REMARKS: ______________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
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CASTING CONCRETE
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CURING PROCEDURES
Two critical elements in curing concrete are maintaining Choose the method(s) that best suit the particular
correct moisture content and maintaining correct concrete production operation. All three are permissible, but
temperature. Proper curing is important in developing preventing the loss of water (method 2) may be the
strength, durability and chemical resistance and simplest choice for utility vaults. Maintaining moisture
watertightness – all important considerations for requires constant wetting, which is labor intensive.
underground utility vaults. Alternate wetting and drying can lead to problems with
cracking. Steam curing can also be effective. Concrete
Note: Concrete temperature discussed in this manual temperatures should never exceed 150 F. Both of these
refers to the temperature of the concrete itself, not the techniques are described in ACI 308, “Standard Practice
ambient temperature. for Curing Concrete,” and the PCA publication “Design
and Control of Concrete Mixtures.” Plastic coverings or
The nature of precast operations poses unique challenges membrane-forming curing compounds require less labor
to proper curing. To ensure cost-effective use of forms, efforts and allow form stripping the next work day. There
precasters often strip the forms at the beginning of the are some special considerations for both:
next workday. That is an acceptable standard, according
to ACI 308, “Standard Practice for Curing Concrete.” The 1. Plastic sheeting must comply with ASTM C171,
time necessary to develop enough strength to strip the “Standard Specification for Sheet Materials for Curing
forms is highly dependent on ambient temperature in the Concrete,” which specifies a minimum thickness of 4
casting area. The Portland Concrete Association (PCA) mm and be either white or opaque in color. PCA states
lists three methods of curing: that other colors can be used depending on sun
conditions and temperature. When using multiple
1. Maintaining water moisture by wetting (fogging, sheets, overlap them by approximately 18 inches to
spraying, wet coverings, etc.) prevent moisture loss.
2. Preventing the loss of water by sealing (plastic 2. Curing compounds can be applied when bleed water is
coverings or applying curing compounds) no longer present on the surface. As with plastic,
3. Applying heat (often in conjunction with moisture, with white-colored compounds might reflect sunlight better
heaters or live steam) and limit temperature gain. Follow the manufacturer’s
recommendations.
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N AT I O N A L P R E C A S T C O N C R E T E A S S O C AT I O N
POST-POUR OPERATIONS
Post-Pour Inspections
A post-pour inspection checklist, as illustrated, provides a
method of identifying and communicating quality
problems as they occur. It serves as a method of
gathering data for identification of any trends that may
be evident. After a utility vault is stripped from the form,
it should be inspected for conformance with the
fabrication drawings and any necessary repairs should be
made. All products should be clearly labeled with the
date of manufacturing and marked in accordance with
ASTM C 858.
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POST-POUR CHECKLIST
REMARKS: ______________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
______________________________________________________________________________
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N AT I O N A L P R E C A S T C O N C R E T E A S S O C AT I O N
FINISHING AND
REPAIRING CONCRETE
Finished Formed Surfaces – Formed surfaces must be Cold Joints
relatively smooth and free of significant honeycombed Cold joints require special care and, as a minimum,
areas, air voids and “bugholes.” should include a high-quality water stop, bonding agent
and continuation of reinforcing between pours.
Repairing Minor Defects – Defects that do not impair the
use or life of the product are considered minor or Final Product Inspection
cosmetic and may be repaired in any manner that does Utility vaults should be visually checked for required
not impair the product. supplementary items, embedded items and quality at the
plant prior to shipping.
Repairing Honeycombed Areas – Remove all loose
material from the damaged area. Cut back the damaged Product Shipment
zone in horizontal or vertical planes deep enough to All vehicles used to transport products must be in good
remove the damaged concrete. Coarse aggregate particles condition and capable of handling the product without
should break rather than merely dislodge when chipped. causing damage. Utility vaults should be adequately
Use only materials that are specifically developed for cured as specified prior to shipment to a job site or
concrete repair, and make repairs according to the distant storage areas. All products must be properly
manufacturers’ specifications. secured with appropriate blockage and either nylon
straps or chains with guards as to avoid product damage
Repairing Major Defects – Major defects are defined as during shipment. NPCA’s publication Cargo Securement
those that impair the intended use or structural integrity for the Precast Concrete Industry outlines proper
of the product. If possible, repair products with major methods for securing product. It is recommended that the
defects by using established repair and curing final inspection include checking these items.
procedures only after a qualified person evaluates the
feasibility of the repair.
Secondary Pours
For products that require secondary pours, establish
procedures to assure that the new concrete bonds
adequately to the product and becomes an integral part
of it. The surfaces of the product against which the
secondary pour is to be made should be free of laitance,
dirt, dust, grease or any other material that will tend to
weaken the bond between the original and new
concretes. If the surface is very smooth, roughen it to
help promote a good bond. As a minimum, use a high-
quality water stop, keyway and continuation of
reinforcing between pours to ensure a watertight joint.
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SEALS, FITTINGS
AND JOINTS
Careful attention to joint details, sealing materials and It is important that all joints be properly cleaned and
penetration fittings are important to ensure quality utility prepared, according to the sealant manufacturer’s
vaults. Systems in areas of high water tables may require recommendations. Preformed flexible joint sealants must
special methods for joint and penetration seal designs. be sufficiently pliable to compress a minimum of 50
percent at the temperature during assembly. Utility vault
Joint Designs sections sealed on site should not be backfilled until the
The most common joint designs are tongue-and-groove sealant has settled.
or lap joints.
Properly splice the sealant by one of the following
For the manufacture of utility vaults, it is recommended methods:
that only interlocking joints be used. In cases of • Overlap splice – Place one piece on top of the other
potentially significant frost heave, differential settlement and carefully mold together
and groundwater exposure, greater attention to joint • Side-by-side – Place in parallel and carefully mold the
design detail is needed. Mechanical fasteners or two pieces together
secondary pours for lids on bases may be necessary in
areas with severe site conditions. The key to preventing Sealant Size
most differential settlement is proper bedding preparation A critical factor when evaluating the sealing potential of a
(especially compaction) of the site. sealant is cross-sectional area. Cross-sectional area is
defined as the geometric shape of the sealant (i.e., 0.75
inches high by 1.0 inches wide). Industry experience has
shown that a sealant’s cross-sectional height must be
compressed a minimum of 30 percent to create a good
seal; 50 percent compression is desirable.
The characteristics of a high-quality sealant include: Pulling irons should be structurally engineered to resist
• Workability over a wide temperature range the anticipated cable pulling loads. Additionally, the
• Adhesion to clean, dry surfaces pulling load placed upon the wall of the utility vault
• Good performance over time (must not shrink, harden should be considered in the structural design calculations
or oxidize) for the vault. Pulling irons should not be used for lifting
and handling product.
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INSTALLATION
Proper installation is absolutely critical for maintaining Sites with silty soils, high water tables or other “poor”
the inherent quality of plant-manufactured concrete bearing characteristics must have specially designed
products and should be performed in accordance with bedding and bearing surfaces. In the presence of high
ASTM C 891 – Standard Practice for Installation of water tables, structures should be properly designed to
Underground Precast Concrete Utility Structures. Many of resist flotation.
the problems experienced with troublesome utility vaults
can be attributed to incorrect procedures during Proper compaction of the underlying soil and bedding is
installation. In addition to damaging the structure, critical to ensure there is no differential settlement.
improper installation techniques can lead to safety
hazards. Placement
Prior to placement in the excavation, the structure’s
Site Conditions orientation should be confirmed. Inlet penetrations should
The installation site must be accessible to large, heavy be aligned in the proper direction and the bedding
trucks or cranes weighing up to 80,000 pounds. The material should be checked. After placement, check to
construction area should be free of trees, branches, ensure that the structure is level.
overhead wires or parts of buildings that could interfere
with the delivery and installation of the utility vault. Most
trucks require access within 3 to 8 feet of the excavation
to be unloaded. Product Notes:
1) After Placement, Check That the Structure is Level
2) Backfill Shall be Placed in Uniform, Properly
Excavation
Compacted Layers Not to Exceed 24" Thick.
Bedding Underground Utilities to be Located Prior to Excavation in Accordance to OSHA Regulations Backfilling
long service life of the utility vault. Engineered bedding 4" Sand or Granular Bedding (Minimum)
material should be used as necessary to provide a Properly Compacted Base to Prevent Settling
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Lifting Devices All lifting devices and apparatus should meet OSHA
Verify lifting apparatus such as slings, lift bars, chains requirements documented in “Code of Federal
and hooks for capacity, and ensure an adequate safety Regulations” Title 29 Part 1926. Other applicable codes
factor for lifting and handling products. The capacity of and standards are ANSI A10.9 and ASTM C857, C890 and
commercial lifting devices must be marked on the C913.
devices.
A factor of safety of at least 4 is recommended for lifting
devices. Manufacturers of standard lifting devices should
provide test data to allow selection of appropriate
loading.
Backfilling
Backfill should be placed in uniform, mechanically
compacted layers less than 24 inches thick. This fill
should be equally and uniformly placed around the vault.
Backfill should be free of any large stones (greater than
3 inches in diameter) or other debris. Each layer should
be adequately compacted.
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REFERENCES
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GLOSSARY
air void – a space in cement paste, mortar or concrete
admixture – a material other than water, aggregates, filled with air; an entrapped air void is
cement and fiber reinforcement, used as an ingredient characteristically 1 mm or more in width and irregular
of concrete, and added to the batch immediately before in shape; an entrained air void is typically between 10
or during its mixing. Typically are liquid in Ìm and 1,000 Ìm in diameter and spherical in shape.
composition.
alkali-aggregate reactivity (AAR) – a chemical reaction
admixture, accelerating – an admixture that accelerates that occurs between the alkalies (sodium and
the setting and early strength development of concrete. potassium) from portland cement or other sources and
certain constituents of some aggregates; under certain
admixture, air-entraining – an admixture that causes the conditions resulting in deleterious expansion of
development of a system of microscopic air bubbles in concrete or mortar; often known as alkali-silica
concrete, mortar or cement paste during mixing. reaction (ASR). Cement manufacturers often test
aggregates for AAR as a service to their customers.
admixture, mineral – finely divided, powdered or
pulverized materials added to concrete to improve or ASTM – ASTM International is a not-for-profit
alter the properties of the plastic or hardened concrete. organization that provides a forum for producers,
users, ultimate consumers and those having a general
admixture, water-reducing – admixture that either interest (government and academia) to meet and write
increases the slump of freshly mixed concrete without standards for materials, products, systems and
increasing the water content or that maintains the services.
slump with a reduced amount of water due to factors
other than air entrainment. bedding material – gravel, soil , sand or other material
that serves as a bearing surface on which a structure
aggregate – granular material, such as sand, gravel, rests and which carries the load transmitted to it.
crushed stone or iron blast-furnace slag used with a
cement medium to form hydraulic-cement concrete or bleeding – the separation of mixing water or its
mortar. emergence from the surface of newly placed concrete,
caused by the settlement of the solid materials.
aggregate, coarse – generally pea-sized to 2 inches;
aggregate of sufficient size to be predominately bonding agent – a substance applied to a suitable
retained on a No. 4 sieve (4.75 mm). substrate to create a bond between it and a succeeding
layer, such as between a layer of hardened concrete
aggregate, fine – general coarse sand to very fine; and a layer of fresh concrete.
aggregate passing the 3/8 inch sieve (9.5 mm) and
almost entirely passing a No. 4 sieve (4.75 mm) and cement, hydraulic – a cement that sets and hardens by
predominately retained on the No. 200 sieve (75 mm). chemical interaction with water and is capable of doing
so under water.
air content – the volume of air voids in cement paste,
mortar, or concrete, exclusive of pore space in cementitious material – an inorganic material or mixture
aggregate particles, usually expressed as a percentage of inorganic materials that set and develop strength by
of total volume of the paste, mortar or concrete. chemical reaction with water by formation of hydrates.
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concrete – a composite material that consists essentially dead load – a constant load that in structures is due to
of a binding medium within which are embedded the mass of the members, the supported structure, and
particles of fragments of aggregate, usually a permanent attachments or accessories.
combination of fine aggregate and coarse aggregate; in
portland-cement concrete, the binder is a mixture of delayed ettringite formation (DEF) – occurs at later
portland cement and water. ages (months to years) and the related heterogeneous
expansion in hardened concrete can produce cracking
concrete, fresh – concrete that possesses enough of its and spalling. DEF is related to environmental or
original workability so that it can be placed and internal sulfate attack.
consolidated by the intended methods.
deleterious substances – materials present within or on
compressive strength – measured maximum resistance aggregates that are harmful to hardened concrete,
of a concrete or mortar specimen to axial compressive often in a subtle or unexpected way. More
loading; expressed as a force per unit cross-sectional specifically, this may refer to one or more of the
area; or the specified resistance used in design following: materials that may be detrimentally reactive
calculations. with the alkalis in the cement (see alkali aggregate
reactivity); clay lumps and friable particles; coal and
consistency – the relative mobility or ability of freshly lignite; etc.
mixed concrete to flow; it is usually measured by the
slump test. dry-cast (no-slump concrete) – concrete of stiff or
extremely dry consistency showing no measurable
consolidation – the process of inducing a closer slump after removal of the slump cone.
arrangement of the solid particles in freshly mixed
concrete during placement by the reduction of voids, differential settlement – the uneven sinking of material
usually accomplished by vibration, centrifugation, (usually gravel or sand) after placement.
rodding, tamping or some combination of these actions.
Consolidation facilitates the release of entrapped air; as elongated aggregate – a particle of aggregate where its
concrete subsides, large air voids between coarse length is significantly greater than its width.
aggregate particles are filled with mortar.
entrained air – see air void; microscopic air bubbles
curing – action taken to maintain moisture and intentionally incorporated in mortar or concrete during
temperature conditions in a freshly placed cementitious mixing, typically between 10 Ìm and 1,000 Ìm (1 mm) in
mixture to allow hydraulic cement hydration and (if diameter and spherical or nearly so.
applicable) pozzolanic reactions to occur so that the
potential properties of the mixture may devlop. entrapped air – see air void; air voids in concrete that
are not purposely entrained and that are larger, mainly
curing compound – a liquid that can be applied as a irregular in shape, and less useful than those of
coating to the surface of newly placed concrete to entrained air; typically greater than 1 mm in diameter
retard the loss of water or to reflect heat so as to and may be of various shapes.
provide an opportunity for the concrete to develop its
properties in a favorable temperature and moisture ettringite – a mineral, high-sulfate calcium
environment. sulfoaluminate occurring in nature or formed by sulfate
attack on mortar and concrete.
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gradation – the particle-size distribution as determined portland cement clinker – a partially fused ceramic
by a sieve analysis (i.e., ASTM C 136); usually material consisting primarily of hydraulic calcium
expressed in terms of cumulative percentages larger or silicates and calcium aluminates.
smaller than each of a series of sizes (sieve openings)
or the percentages between certain ranges of sizes pozzolan – a siliceous or siliceous and aluminous
(sieve openings). material that in itself possesses little or no
cementitious value but will, in finely divided form and
hydration – formation of a compound by the combining in the presence of moisture, chemically react with
of water with some other substance; in concrete, the calcium hydroxide at ordinary temperatures to form
chemical process between hydraulic cement and water. compounds possessing cementitious properties.
infiltration – to cause (as a liquid) to permeate psf – pounds per square foot
something by penetrating its pores or interstices.
psi – pounds per square inch
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secondary pour – a situation when a succeeding layer of specification – an explicit set of requirements to be
concrete is placed on previously-placed hardened satisfied by a material, product, system or service that
concrete. also indicates the procedures for determining whether
each of the requirements is satisfied.
segregation – the unintentional separation of the
constituents of concrete or particles of an aggregate, standard – as defined by ASTM, a document that has
resulting in nonuniform proportions in the mass. been developed and established within the consensus
principles of the Society.
set – the condition reached by a cement paste, mortar or
concrete when it has lost plasticity to an arbitrary superplasticizer – see admixture, water-reducing.
degree, usually measured in terms of resistance to Superplasticizers are also known as high-range water-
penetration or deformation; initial set refers to first reducing admixtures.
stiffening; final set refers to attainment of significant
rigidity. surcharge – a surface load applied to the structure,
transferred through the surrounding soil.
silica fume – very fine non-crystalline silica produced in
electric arc furnaces as a byproduct of the production trowelling – smoothing and compacting the unformed
of elemental silicon or alloys containing silicon; also surface of fresh concrete by strokes of a trowel.
known as condensed silica fume and micro-silica. It is
often used as an additive to concrete and can greatly water-cement ratio – the ratio of the mass of water,
increase the strength of a concrete mix. exclusive only of that absorbed by the aggregates, to
the mass of portland cement in concrete, mortar or
slump – a measurement indicative of the consistency of grout; stated as a decimal and abbreviated as w/c.
fresh concrete. A sample of freshly mixed concrete is
placed and compacted by rodding in a mold shaped as waterstop – a thin sheet of metal, rubber, plastic or
the frustum of a cone. The mold is raised, and the other material inserted across a joint to obstruct the
concrete is allowed to subside. The distance between seepage of water through the joint.
the original and displaced position of the center of the
top surface of the concrete is measured and reported water table – the upper limit of the portion of the
as the slump of the concrete. Under laboratory ground wholly saturated with water.
conditions, with strict control of all concrete materials,
the slump is generally found to increase proportionally workability of concrete – that property of freshly mixed
with the water content of a given concrete mixture, concrete or mortar that determines the ease with which
and thus to be inversely related to concrete strength. it can be mixed, placed, consolidated and finished to a
Under field conditions, however, such a strength homogenous condition.
relationship is not clearly and consistently shown.
Care should therefore be taken in relating slump
results obtained under field conditions to strength.
(ASTM C 143)
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