Edition 2 / Revision 1 TRANSPORT FOR NSW

June 2020

TRANSPORT FOR NSW (TfNSW)

TfNSW SPECIFICATION D&C B349

PRECAST CONCRETE NOISE WALL MEMBERS

(NOT PRETENSIONED)

NOTICE

This document is a Transport for NSW D&C Specification. It has been developed for use with Design

& Construct roadworks and bridgeworks contracts let by Transport for NSW. It is not suitable for any

other purpose and must not be used for any other purpose or in any other context.

Copyright in this document belongs to Transport for NSW.

REVISION REGISTER

Ed/Rev

Number

Clause

Number Description of Revision

Authorised

By Date

Ed 1/Rev 0 First issue. GM, IC 10.07.12

Ed 1/Rev 1 Updated to accord with base (non-D&C)

Specification B349 Ed 1/Rev 1.

MCQ 27.09.18

Ed 2/Rev0 Updated to accord with base (non-D&C)

Specification B349 Ed 2/Rev 0.

MCQ 22.02.19

Ed 2/Rev 1 Global References to “Roads and Maritime

Services” or “RMS” changed to “Transport

for NSW” or “TfNSW” respectively.

DCS 22.06.20

References to “RMS Representative”

changed to “Principal”.

Edition 2 / Revision 1 TRANSPORT FOR NSW

June 2020

SPECIFICATION D&C B349

PRECAST CONCRETE NOISE WALL

MEMBERS (NOT PRETENSIONED

Copyright – Transport for NSW

IC-DC-B349

VERSION FOR:

DATE:

Precast Concrete Noise Wall Members (Not Pretensioned) D&C B349

Ed 2 / Rev 1 i

CONTENTS

CLAUSE PAGE

FOREWORD ............................................................................................................................................... II TfNSW Copyright and Use of this Document ............................................................................... ii Base Specification .......................................................................................................................... ii

1 GENERAL ........................................................................................................................................ 1 1.1 Scope .............................................................................................................................. 1 1.2 Structure of the Specification ......................................................................................... 1 1.3 Definitions ...................................................................................................................... 2

2 MATERIALS .................................................................................................................................... 2 2.1 Concrete .......................................................................................................................... 2 2.2 Reinforcement ................................................................................................................ 2 2.3 Colouring Additives ....................................................................................................... 2

3 MANUFACTURE .............................................................................................................................. 2 3.1 Formwork ....................................................................................................................... 2 3.2 Concreting ...................................................................................................................... 2 3.3 Exposed Aggregate Finish .............................................................................................. 3 3.4 Marking of Members ...................................................................................................... 3

4 CONFORMITY ................................................................................................................................. 3 4.1 Member Dimensional Tolerances ................................................................................... 3 4.2 Production of Subsequent Members ............................................................................... 4 4.3 Member Strength ............................................................................................................ 5 4.4 Inspection and Nonconformity ....................................................................................... 5

5 HANDLING, STORAGE AND TRANSPORT OF MEMBERS .................................................................. 6 5.1 General ........................................................................................................................... 6 5.2 Lifting ............................................................................................................................. 6 5.3 Stacking .......................................................................................................................... 6 5.4 Certification of Stacking Arrangement ........................................................................... 6 5.5 Transport......................................................................................................................... 7

6 INCORPORATION IN THE WORKS .................................................................................................... 7 6.1 Certification of Conformity ............................................................................................ 7 6.2 Warranty ......................................................................................................................... 7

ANNEXURES B349/A AND B349/B – (NOT USED) ................................................................................... 8

ANNEXURE B349/C – SCHEDULES OF HOLD POINTS AND IDENTIFIED RECORDS .................................... 8 C1 Schedule of Hold Points ................................................................................................. 8 C2 Schedule of Identified Records....................................................................................... 8

ANNEXURE B349/D – PLANNING DOCUMENTS ....................................................................................... 8

ANNEXURES B349/E TO B349/L – (NOT USED) ....................................................................................... 9

ANNEXURE B349/M – REFERENCED DOCUMENTS ................................................................................ 10

LAST PAGE OF THIS DOCUMENT IS .......................................................................................................... 10

D&C B349 Precast Concrete Noise Wall Members (Not Pretensioned)

ii Ed 2 / Rev 1

FOREWORD

TFNSW COPYRIGHT AND USE OF THIS DOCUMENT

Copyright in this document belongs to Transport for NSW.

When this document forms part of a deed

This document should be read with all the documents forming the Project Deed.

When this document does not form part of a contract

This copy is not a controlled document. Observe the Notice that appears on the first page of the copy

controlled by TfNSW. A full copy of the latest version of the document is available on the TfNSW

Internet website: http://www.rms.nsw.gov.au/business-industry/partners-

suppliers/specifications/index.html

BASE SPECIFICATION

This document is based on Specification TfNSW B349 Edition 2 Revision 1.

(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)

Ed 2 / Rev 1 1

TfNSW SPECIFICATION D&C B349

PRECAST CONCRETE NOISE WALL MEMBERS

(NOT PRETENSIONED)

1 GENERAL

1.1 SCOPE

This Specification sets out the requirements for the manufacture and delivery of reinforced precast

concrete panels and concrete posts, where applicable, for noise walls.

This Specification is not applicable to pretensioned precast concrete, which is covered by

Specification B110, or tilt-up concrete panels.

This Specification is used in conjunction with Specification TfNSW D&C R271, which sets out other

requirements, including design and construction, for noise walls. Where the requirements in this

Specification conflict with those in TfNSW D&C R271, the requirements in this Specification

override those in TfNSW D&C R271.

1.2 STRUCTURE OF THE SPECIFICATION

This Specification includes a series of annexures that detail additional requirements.

1.2.1 (Not Used)

1.2.2 (Not Used)

1.2.3 Schedules of HOLD POINTS and Identified Records

The schedules in Annexure B349/C list the HOLD POINTS that must be observed. Refer to

Specification TfNSW D&C Q6 for the definition of HOLD POINTS.

The records listed in Annexure B349/C are Identified Records for the purposes of TfNSW D&C Q6

Annexure Q/E.

1.2.4 Planning Documents

The PROJECT QUALITY PLAN must include each of the documents and requirements listed in

Annexure B349/D and must be implemented.

1.2.5 (Not Used)

1.2.6 Referenced Documents

Standards, specifications and test methods are referred to in abbreviated form (e.g. AS 1234). For

convenience, the full titles are given in Annexure B349/M.

(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)

D&C B349 Precast Concrete Noise Wall Members (Not Pretensioned)

2 Ed 2 / Rev 1

1.3 DEFINITIONS

The following definitions apply to this Specification:

Engineer Engineer(s) eligible for Corporate Membership of the Engineers Australia and with

appropriate qualifications and experience for the relevant type of engineering work.

2 MATERIALS

2.1 CONCRETE

Concrete must conform to the requirements of:

(a) for members with design life of fifty years or less

AS 3600

(b) for members with design life of more than fifty years

AS 5100 and Specification TfNSW D&C B80

2.2 REINFORCEMENT

Reinforcement must conform to the requirements of:

(a) for members with design life of fifty years or less

AS 3600

(b) for members with design life of more than fifty years

AS 5100 and Specification TfNSW D&C B80

2.3 COLOURING ADDITIVES

Where colouring additives are used, they must first be approved by the Principal.

3 MANUFACTURE

3.1 FORMWORK

Formwork must conform to the requirements of TfNSW D&C B80 applicable to precast concrete

members, and to this Specification.

Assemble and check the formwork before each major production run and after any major

modifications. Carry out a dimensional check of the formwork to verify that the member tolerances of

Clause 4.1 will be achieved.

3.2 CONCRETING

Placing, finishing and curing of concrete for panels and posts must conform to the requirements of:

(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)

Precast Concrete Noise Wall Members (Not Pretensioned) D&C B349

Ed 2 / Rev 1 3

(a) for members with design life of fifty years or less

AS 3600

(b) for members with design life of more than fifty years

TfNSW D&C B80, with Clause 7.5 of TfNSW D&C B80 “Certification Prior to Concreting”

modified as follows:

Give the Project Verifier at least 2 working hours’ notice of placing concrete for the first

member of a line of members. No Hold Point applies. Prepare verification checklists for

formwork, reinforcement, embedments and any other items before placing concrete. If required,

submit a copy of these checklists to the Project Verifier.

3.3 EXPOSED AGGREGATE FINISH

Where an exposed aggregate finish on wall panels is specified, produce test panels (test members) for

the Principal’s inspection.

Obtain the Principal’s approval before commencing manufacture of the wall panels.

The finish on all manufactured panels must match that of the test panel.

Remove all residues on the surfaces arising from the process to produce the exposed aggregate finish.

3.4 MARKING OF MEMBERS

3.4.1 Temporary Identification

Provide temporary identification of each member until permanent marking has been carried out.

3.4.2 Permanent Markings – Panels

Provide a permanent panel identification number on the top surface of the panel adjacent to one of the

panel's lifting devices.

3.4.3 Permanent Markings – Posts

Permanently mark each post with the date of casting and identification number in the fresh concrete, at

a part of the post that will be embedded within the ground after installation.

4 CONFORMITY

4.1 MEMBER DIMENSIONAL TOLERANCES

4.1.1 Panels

Unless shown otherwise on the Design Documentation drawings, dimensions of panels as measured at

the age of 28 days must conform to the tolerances given in Table B349.1.

(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)

D&C B349 Precast Concrete Noise Wall Members (Not Pretensioned)

4 Ed 2 / Rev 1

Table B349.1 – Dimensional Tolerances for Panels

Description Tolerance (1)

Overall dimensions

Any linear side dimension in cross section:

2 m 4 mm

2 m 7 mm

Overall length, L Greater of 0.06% L or 10 mm

Squareness of corners

Any diagonal dimension (2, 3):

2 m 4 mm

2 m, 4 m 5 mm

4 m 7 mm

Twist

Angular rotation ½ over length of panel

Profile

Bow in horizontal plane Greater of 0.06% L or 8 mm

Deviation from design profile in vertical plane Greater of 0.06% L or 8 mm

Flatness of Panel Sides

Deviation from straight 3 mm

Cored holes and openings

Location 7 mm

Diameter or side dimensions 4 mm

Note: (1) Measurements for checking tolerances must be carried out at a time of day (e.g. early morning) when

differential temperature effects will not be significant. (2) Applies to any diagonal dimension, whether in cross section or plan. (3) Tolerances shown for squareness of corners are the permitted deviations between the measured and

design diagonal dimensions.

4.1.2 Posts

The dimensions of any cross section must not deviate from that in the design by more than 3 mm.

The sides of posts must not deviate from a straight line by more than 10 mm over the post height.

4.2 PRODUCTION OF SUBSEQUENT MEMBERS

4.2.1 Certification of First Member Produced

Upon removal of the first member from each mould or line of members from a long-line mould,

measure and record the dimensions of the member.

(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)

Precast Concrete Noise Wall Members (Not Pretensioned) D&C B349

Ed 2 / Rev 1 5

Submit to the Project Verifier a diagram showing the actual dimensions achieved for the first member

compared to the specified dimensions and tolerances, prior to any further member being cast in the

mould. The diagram must be accompanied with a certificate stating that:

“The member dimensions, as anticipated at the age of 28 days, will be as shown on the Design

Documentation drawings and will be within the tolerances specified in Specification TfNSW

D&C B349”.

4.2.2 Casting of Further Members

If any dimensions of the first member anticipated at the age of 28 days do not conform to the specified

tolerances, deal with the nonconformity in accordance with TfNSW D&C Q6, and the following Hold

Point applies:

HOLD POINT (Applies only if dimensions of first member do not conform)

Process Held: Casting of any further members in that mould.

Submission Details: A certificate with supporting checklists verifying that the amended

formwork will produce members conforming to the tolerances in Clause 4.1.

Release of Hold Point: The Nominated Authority will consider the submitted details and may carry

out further surveillance and audit, prior to authorising the release of the Hold

Point.

For members other than the first member from each mould, maintain records verifying that the

specified tolerances for overall length, overall height and overall width at each end face have not been

exceeded.

4.3 MEMBER STRENGTH

The manufactured concrete members must achieve the 28-day compressive strength shown on the

Design Documentation drawings.

4.4 INSPECTION AND NONCONFORMITY

4.4.1 Inspection by Engineer

The Engineer must visually inspect all concrete members for cracks or damage, and verify that

permanent identification numbers have been marked on the members in accordance with Clause 3.4.

4.4.2 Nonconformity

Replace any member that is cracked or damaged, or has not meet the specified 28-day compressive

strength.

You may propose to the Principal a method of repair for cracked or damaged members, but the

Principal is not obliged to accept your proposal.

(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)

D&C B349 Precast Concrete Noise Wall Members (Not Pretensioned)

6 Ed 2 / Rev 1

5 HANDLING, STORAGE AND TRANSPORT OF MEMBERS

5.1 GENERAL

Support precast concrete members in a horizontal or vertical position, at a minimum distance of

100 mm above the ground surface.

Support members at the positions as shown on the Design Documentation drawings, or as certified by

an Engineer.

Support the members over the full width of their bottom surface.

5.2 LIFTING

5.2.1 General

Include in the PROJECT QUALITY PLAN the following details of the method of lifting of members:

(a) Location of lifting points, unless these are as shown on the Design Documentation drawings.

(b) Lifting devices, comprising inserts which are cast into the concrete, and associated lifting

clutches.

(c) A certificate from an Engineer stating that the capacity of the lifting devices is adequate.

5.2.2 Lifting Devices

Lifting inserts which are cast into the concrete must be made of stainless steel or be galvanized, and

recessed such that they do not project above the surface of panels.

Lifting devices must be designed by an Engineer, using a minimum factor of safety of 4 for shear,

tension and flexure for the load cases when lifting the largest size panels from a horizontal position

and tilting it to a vertical position, and when lifting the panel from a vertical position.

Provide waterproof caps to cover the lifting inserts after the panels are permanently placed.

5.3 STACKING

Precast concrete members may be stored stacked on top of one another.

Separate each layer of stacked members from the next layer by minimum 75 mm high bearers. Place

temporary supports in line vertically at the specified support points.

Timber bearers used must be made of sound timber and must be of a size appropriate to the weight of

the supported members, but not be less than 100 mm wide and 75 mm height.

Posts may be stacked up to a maximum of six layers.

5.4 CERTIFICATION OF STACKING ARRANGEMENT

At all times, secure members in a stable condition to prevent them from toppling over.

Where stacking of members is required, design or otherwise check stability of the stacking

arrangement using an Engineer.

(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)

Precast Concrete Noise Wall Members (Not Pretensioned) D&C B349

Ed 2 / Rev 1 7

Consider temperature, shrinkage, creep and any other effects on the stability of the stacking

arrangement.

Provide to the Project Verifier a certificate by the Engineer, prior to stacking the members, stating that

the proposed stacking arrangement will not overstress or damage any member, and that the stacked

members will be stable.

5.5 TRANSPORT

Transport members in a manner which does not damage the members.

Do not transport any member to the Site which:

(a) have not reached the specified 28-day strength;

(b) have not been cured according to this Specification;

(c) are cracked or otherwise damaged, and have not been repaired to the satisfaction of the

Principal;

(d) are not matching in colour contrast;

(e) does not meet the strength, serviceability and other requirements in TfNSW D&C R271.

If members are required to be supported on a delivery vehicle in a manner other than as stated on the

Design Documentation drawings or this Specification, prior to transport, submit to the Project Verifier

a certificate by the Engineer stating that the proposed method of support will be stable and will not

overstress the member.

6 INCORPORATION IN THE WORKS

6.1 CERTIFICATION OF CONFORMITY

Prior to any member being incorporated in the Works, submit to the Project Verifier a certificate for

each member stating that it conforms to Specification TfNSW D&C B349 and that all nonconformities

have been rectified. The certificate must be accompanied by a checklist and associated records for

each member, verifying conformity.

6.2 WARRANTY

Provide to the Principal a warranty that the materials and components used in the manufacture of the

noise wall panels and posts will achieve the design life without maintenance.

(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)

D&C B349 Precast Concrete Noise Wall Members (Not Pretensioned)

8 Ed 2 / Rev 1

ANNEXURES B349/A AND B349/B – (NOT USED)

ANNEXURE B349/C – SCHEDULES OF HOLD POINTS AND

IDENTIFIED RECORDS

Refer to Clause 1.2.3.

C1 SCHEDULE OF HOLD POINTS

Clause Description of Hold Point

4.2.2 Casting of any further members in that mould (applies only if dimensions of first member

do not conform).

C2 SCHEDULE OF IDENTIFIED RECORDS

The records listed below are Identified Records for the purposes of TfNSW D&C Q6 Annexure Q/E.

Clause Description of Identified Record

4.2.1 Diagram showing actual dimensions of first member compared with design dimensions.

5.2 Certification that lifting devices for members is adequate.

5.4, 5.5 Certification of stacking arrangement in storage and during transport.

6.1 Certificate of conformity for each member.

ANNEXURE B349/D – PLANNING DOCUMENTS

Refer to Clause 1.2.4.

The following documents are a summary of documents that must be included in the PROJECT

QUALITY PLAN. Review the requirements of this Specification and other contract documents to

determine any additional documentation requirements.

Clause Description

2.3, 3.3 Method of achieving the required surface textures and colours.

4.1 Method for verification of the member dimensions.

4.4 Procedures and materials for localised repairs to member.

5.2 Method of lifting of members.

5.4, 5.5 Certified design of temporary support and stacking arrangements of members.

(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)

Precast Concrete Noise Wall Members (Not Pretensioned) D&C B349

Ed 2 / Rev 1 9

ANNEXURES B349/E TO B349/L – (NOT USED)

(TfNSW COPYRIGHT AND USE OF THIS DOCUMENT - Refer to the Foreword after the Table of Contents)

D&C B349 Precast Concrete Noise Wall Members (Not Pretensioned)

10 Ed 2 / Rev 1

ANNEXURE B349/M – REFERENCED DOCUMENTS

Refer to Clause 1.2.6.

TfNSW Specifications

TfNSW D&C Q6 Quality Management System

TfNSW D&C B80 Concrete Work For Bridges

TfNSW D&C R271 Design and Construction of Noise Walls

Australian Standards

AS 3600 Concrete structures

AS 5100 (Set) Bridge design