453PRESSURE GROUTING AND REPAIR OF PORTLAND CEMENT CONCRETE PAVEMENT

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may be extended if approved by the Engineer. The test rolling equipment shall be rubber-tired and of sufficient weight {mass} to give a 20,000 pounds {90 kN} single axle load with a minimum of 10,000 pounds {45 kN} per side (a properly loaded dump truck may be used). Each slab shall be tested by making one or more passes over it with the test roller. The rolling shall be slow enough to allow an observer to measure the movement and mark the slab if regrouting is needed. If the slab moves 0.03 of an inch {0.8 mm} or more during the test rolling, new holes shall be drilled and the slab regrouted. All slabs which have been regrouted shall be retested as outlined above for the initial testing. After two returns for regrouting, should the slab fail the test rolling, the Engineer will make the decision to leave the slab as is, continue regrouting, or remove and replace the slab. Payment will be made under the appropriate pay items for the additional drill holes and grout used in the regrouting operation. The cost of test rolling shall be absorbed in other items of work. The construction methods outlined above may be modified by the Engineer as field conditions indicate. Pressure grouting operations shall cease at least three hours before sundown, except that on cloudy days pressure grouting operations shall cease earlier as necessary to permit grout to harden at least three hours prior to allowing traffic back on the grouted slab before first darkness. First darkness shall be defined as that time of day the average traveling public vehicle would first begin to use its headlights.

The extent of removal shall be as shown on the plans or directed by the Engineer. The slab section designated for removal shall be sawed as shown on the plans. The Contractor shall not oversaw the slab within 2 feet {600 mm} of another oversaw or within 2 feet {600 mm} of any type of joint. Transverse cuts for removal and the placing of new steel tie bars shall be performed as shown by plan details. The sections of pavement to be removed may be removed in any manner approved by the Engineer which does not damage the underlying base layer, adjacent concrete slabs, or the joint steel. Any damage to the underlying base or adjacent slabs shall be repaired to the satisfaction of the Engineer. Joint steel shall be cleaned and reconditioned to provide the same load transfer and/or tie as in the original pavement design. Any damaged or destroyed steel, which in the opinion of the Engineer would not function properly, shall be replaced in kind and retied to the old pavement by drilling an appropriate size hole of the proper depth and anchoring the new bar with an approved adhesive material. This replacement also includes steel damaged or destroyed previous to the removal operation. All tie bars and dowel bars tied to the old pavement shall be anchored into place with an approved adhesive material in such a manner as to meet a 7200 pound {32 kN}, minimum, pull-out requirement. The Department will perform the pull-out tests in accordance with ALDOT-366. The Contractor shall supply the equipment necessary to perform the pull-out test. Slabs shall be removed and replaced during the same day. Preparation for removal, including sawing the slab into smaller pieces, may be done the day prior to removal, but traffic shall be maintained on the slab the night before removal.

After completion of removal operation, the joint steel and/or reinforcing steel shall be reconditioned or replaced (reconditioned means the cleaning and straightening of the steel bars and the cleaning, painting, greasing, replacement, etc. of the dowels), new tie bars placed as detailed by the plans, and the base cleaned and repaired as directed, and then the slab shall be poured. The Contractor shall provide gang drills or templates that will provide the proper alignment for holes drilled for dowels or tie bars. The size of the drilled hole shall be 1/8 of an inch {3 mm} greater in diameter than the diameter of the dowel or tie bar being installed therein. The drill used shall not cause any spalling of the existing concrete around the face of the drill hole. The Contractor shall provide a device that will place the adhesive in the back of the drilled hole first and then proceed toward the front. After the dowels or tie bars are anchored in place, the Contractor shall allow time for the adhesive to set and then allow sufficient time for any required pull-out tests to be performed prior to pouring the replacement slab. The concrete paving slab shall be poured in accordance with the provisions of Section 450 except that Structural Portland Cement Concrete meeting the requirements of Section 501 for a PRESSURE GROUTING AND REPAIR OF PORTLAND CEMENT CONCRETE PAVEMENT 275

Class A concrete utilizing either Type III cement or Type I, Type IL, Type IP or Type IS cement with a non-chloride accelerator, shall be used and a full paving train will not be required. Unless shown otherwise by the plans, the surface finish and slope of the new pavement shall be the same as the adjoining pavement slabs. If the pavement is to be covered by a bituminous overlay, a wood float finish and straight slope will be acceptable. All joints, except expansion joints, with adjacent pavement shall be butt type tied construction joints. Expansion joints shall be reconstructed so that the continuity of existing expansion joints are retained utilizing similar joint filler and sealed with the type sealer specified on the plans. Other reconstructed joints which require sealing shall be sealed with the specified type sealer. When a joint is completely removed, new materials shall be used throughout the joint. All materials necessary to repair or reconstruct the joints in or adjacent to the concrete pavement replacement is considered incidental to said replacement. All joints shall be constructed in accordance with the provisions of Subarticle 450.03(j) except as noted herein. Due to the requirement for the use of either an accelerator or Type III cement in the concrete mix, extreme care shall be taken to see that joints are saw cut before uncontrolled shrinkage cracking begins. Slabs that have been removed shall be replaced the same day they are removed. The Contractor shall use such approved methods as necessary to keep all pavement surfaces adjacent to this operation reasonably clean of excess grout or other materials at all times.

No traffic, including construction equipment, will be permitted on the grouted slabs until at least three hours after the grouting has been completed. No traffic, including construction equipment will be permitted on the replaced slab until at least six hours after the slab has been poured. Traffic shall be placed on grouted slabs before first darkness of the same day that the slabs were grouted; traffic shall be placed on replaced slabs no later than the morning following the day the slabs were replaced.

453.04Method of Measurement

Each drill hole through the concrete paving slab ordered by the Engineer and placed in accordance with the requirements noted herein in this Section and properly filled after satisfactory use will be measured for payment. Portland cement concrete grout will be measured for payment by the bag (94 pounds {42 kg}) of Portland cement used in the grout; all other ingredients required in the grout will not be measured for payment. Concrete pavement removed will be measured in square yards {square meters} computed from surface measurements taken to the nearest 0.1 foot {0.1 meter}. Concrete pavement replacement slabs will be measured by computing the theoretical cubic yards {cubic meters} of concrete necessary to replace the removed slab. The thickness used in computing the theoretical cubic yards {cubic meters} will be the average thickness necessary to replace the slab and to fill any voids, except those caused by the Contractor, underneath the slab.

453.05Basis of Payment

Drill holes for stabilizing the concrete pavement, measured as noted above, will be paid for at the contract unit price bid per each which shall be full compensation for the drilling of the holes and the sealing of the holes after the satisfactory use thereof, and includes the furnishing of equipment, tools, labor, and incidentals necessary to complete this item of work.

Portland cement pressure grout, measured as noted above, will be paid for at the contract unit price bid per bag of cement used in the grout, which shall be full compensation for furnishing the grout, including all ingredients for the type mix designated, for the mixing, for pumping of the grout, and for all equipment, tools, labor, and incidentals necessary to complete this item of work.

Removal of concrete pavement slabs, measured as noted above, will be paid for at the contract unit price bid per square yard {square meter}, which shall be full compensation for the sawing and CLEANING AND SEALING JOINTS AND CRACKS IN CONCRETE PAVEMENT 276

satisfactory removal and disposal of the old concrete, for the reconditioning or replacement of all steel and the concrete joint including all equipment, tools, labor, and other incidentals necessary to complete this item of work.

Concrete pavement replacement slabs, measured as noted above, will be paid for at the contract unit price bid per cubic yard {cubic meter} which shall be full compensation for the furnishing of the concrete mix, the hauling of the mix, the forming, placing, including any new steel, sawing and sealing of joints, finishing and curing of the slab and for all equipment, tools, labor, and incidentals necessary to complete this item of work.

After the grouting operation, all surfaces shall receive grinding in accordance with Section 455 and shall meet the smoothness requirements of Subarticle 455.03e.

453-A Drill Holes (Max. bid limited to $6.00 per Hole) - per each 453-B Portland Cement Pressure Grout - per bag (94 pounds {42 kg}) 453-C Removal of Concrete Pavement Slab - per square yard {square meter} 453-D Concrete Pavement Replacement Slab - per cubic yard {cubic meter} CLEANING AND SEALING JOINTS AND CRACKS IN CONCRETE PAVEMENT

454.01Description

This Section shall cover the work of cleaning and sealing joints and cracks in existing concrete pavement. The shape of the joints shall be restored by sawing the concrete to allow the proper sealing of the joints. Cracks shall be sealed by the routing of a groove at the crack for the placement of sealant. The cleaning and sealing of joints and cracks will be classified by "Type" in accordance with the following: Type I: Cleaning and sealing of joints and cracks that will not be covered by a bituminous overlay. Type II: Cleaning and sealing of joints and cracks that will be covered by a bituminous overlay.

454.02Materials

The sealant shall be either a Hot Applied Joint Sealant or a Cold Applied Joint Sealant as shown on the plans. Joint sealants shall meet the requirements given in Section 832 for joint and crack sealants.

454.03Construction Requirements

The Contractor shall submit descriptions of all equipment proposed for use in sawing the joints, routing the cracks, cleaning the joints and cracks and placing the sealant. The submittal shall also consist of the operational guidelines from the equipment manufacturer. The Contractor shall deliver the submittal to the Engineer for review. The Engineer will not approve the submittal but will review it for completeness. The Engineer will prohibit the use of equipment that may damage the pavement or result in a joint or crack that cannot be sealed. Equipment shall not be brought to the worksite until the Engineer informs the Contractor that the submittal is complete.

The old joint sealant material and other debris shall be removed from the joint. Material placed to form an expansion joint during the original construction of the pavement shall not be removed. The joint shall then be cut with a concrete saw to provide the shape and size of joint shown on the plans. The concrete saw shall be a saw that is designed for cutting concrete. If water is used to facilitate cutting, the resulting slurry shall be completely removed from the joint and the pavement surfaces before it dries. Removal of the slurry shall be by flushing the joint and pavement surface with a jet of water under pressure and by the use of other tools as required by the Engineer. After the sawing, and flushing if necessary, the joint shall then be cleaned of loose material by the use of compressed air.