518.01 518-1 SECTION 518 WATERSTOPS AND EXPANSION JOINTS DESCRIPTION
518.01 This work consists of furnishing and installing waterstops, expansion joints, and end dams
of the sizes and types required per these specifications and in conformity with the details shown on the plans, or as directed. This work consists of furnishing and placing a Polyester Concrete End Dam system , which includes Polyester -based P olymer Concrete (PPC) and High -Molecular -Weight Methacrylate (HMWM ) resin primer. The system shall be used for Portland Cement Concrete blockouts (PCC ) of bridge expansion devices on the concrete bridge deck, abutment backwalls, and approach slabs as shown on the plans. MATERIALS
518.02 Waterstops . Waterstops shall be manufactured either from neoprene or polyvinyl
chloride (PVC) meeting the requirements described in subsection 705.10. The Contractor will have the option of furnishing either material unless otherwise specified. The Contractor shall submit a certificate of compliance for each type of waterstop proposed for use on the project to the Engineer.
518.03 Asphaltic Expansion Devices . This device consists of an expansion joint system
composed of a blended polymer modified asphalt and special aggregate per these specifications and in conformity with the details shown on the plans or established. The joint system shall be installed in a prepared expansion joint blockout and shall be designed for a rated joint movement of 0 to 2 inches including rotations. The polymer modified asphalt, aggregate, backer rod, bridging plate, and joint binder shall conform to recommendations of the manufacturer of the approved joint system installed. Approved joint systems shall be those shown on the plans. The Contractor shall furnish manufacturer's certification that all materials furnished have been pre-tested and meet the requirements set forth in the specifications and conform to the materials listed in the latest product literature. No substitution of materials will be permitted.
518.04 Elastomeric Expansion Devices . This device consists of an elastomeric expansion joint
device and curb cover plates as shown on the plans and per these specifications. The expansion joint device shall seal the deck surface as indicated on the plans and prevent water from seeping through the superstructure slab. Seeping of water through the joint will be cause for rejection of the expansion device. The Contractor shall state at the Pre- construction Conference the specific manufacturer and model number of the device the Contractor int ends to furnish and install. The device shall consist of a continuous pre -molded elastomeric expansion joint seal, anchors and steel extrusions as shown on the plans, required by the manufacturer, or specified for attaching the elastomeric expansion joint seal to the steel armor. The expansion device shall have a rated movement of 0 to 4 inches including rotations. 518.05 518-2 The Contractor shall furnish manufacturer’s certification that the materials proposed for use on the project have been pre -tested and will meet the requirements as set forth in these specifications and the manufacturer’s current literature. The materials shall not be installed in the work before the Engineer’s approval. Structural steel sections shall conform to the specifications of AASHTO M 270 (ASTM A709 Grade 36). Fabrication of structural steel shall conform to the requirements of Section 509. All welding on elastomeric expansion devices shall conform to AWS D1.1. The material designations for all steel components shall be shown on the Contractor's working drawings. All structural steel elements of the bridge expansion device, including cover plates, shall be galvanized after fabrication per Section 509, whether or not they are in contact with the elastomeric seals.
518.05 Modular Expansion Devices . This device consists of a modular expansion joint
device and curb cover plates at the locations shown on the plans and per these specifications. The modular expansion joint device shall seal the deck surface, gutters, curbs, and walls as indicated on the plans, and prevent water from seeping through the bridge deck. Seeping of water through the joint will be cause for rejection of the expansion device. The Contractor shall state at the Pre- construction Conference the specific manufacturer and model nu mber of the device the Contractor intends to furnish and install. The expansion device shall have a rated movement greater than 4 inches but not exceeding 28 inches. The modular expansion joint device supplied shall be one of the approved devices as shown on the plans. The modular expansion device system shall be designed, fabricated, and delivered to the jobsite as a continuous unit, unless otherwise approved by the Engineer. Field splices shall not be located on the vehicle wheel path. The maximum length of completed expansion device assemblies shall be determined by practical shipping limitations. Handling and storage of the expansion joint device shall be per the manufacturer’s written recommendations and as approved by the Engineer. Only one type of modular joint device will be permitted to be installed at all locations. The installation of two different types at separate locations will not be permitted. The device shall consist of pre -molded elastomeric expansion joint seals (strip seals) mechanically held in place by steel center beams and edge beams. Each transverse center beam shall be individually supported by and connected by full penetration weld to an independent support bar. The device shall provide equal -distance control of the pre -molded elastomeric seals.
a.The center beam/support bar connection, field -splice, and other bolted and welded connection details in the joint shall be fatigue tested and designed following the guidelines provided in Appendix A19 of the latest edition of the AASHTO LRFD Bridge Construction Specification as well as the provisions included in Chapter 14 of the latest edition of the AASHTO LRFD Design Specification. The Contractor shall provide calculations electronically sealed by the Contractor’s Engineer to the Engineer.
b.The following components shall meet the listed requirements: 518.06 518-3 Table 518 -1 EXPANSION JOINT COMPONENT REQUIREMENTS Structural Steel (except center beams, edge beams and support bars) AASHTO M 270 (ASTM A709) Grade 36 Center Beams, Edge Beams and Support Bars AASHTO M 270 (ASTM A709) Grade 50 or AASHTO M 270 (ASTM A709) Grade 50W Headed Studs ASTM A108 Pre-molded Seals, Lubricant Adhesive, and Sliding Surfaces Conforming to manufacturer’s current literature Stainless- steel Bearing Surfaces Subsection 705.06 The steel fabricator for modular expansion devices shall be certified under the AISC Quality Certification for Simple Steel Bridges category , as a minimum. All structural steel elements of the bridge expansion device, including cover plates, shall be galvanized after fabrication per 509, whether or not they are in contact with the elastomeric seals. All welding on modular expansion devices shall conform to AWS D1.1. The manufacturer shall furnish certification that the materials proposed for use on the project have been pre -tested and will meet the requirements as set forth in these specifications and the manufacturer's current literature. The material shall not be installed in the work before the Engineer’s approval. All components of the expansion joint device, including stiffening plates and anchorages, shall be supplied by the manufacturer. The material designations for all components shall be shown on the shop drawings.
518.06 Polyester Concrete End Dam .
a.Submittals. Fifteen days before the Polyester Concrete Pre-placement Conference the Contractor shall submit the following:
1.Polyester Concrete End Dam System. The Contractor shall submit to the Engineer two copies of the Manufacturer’s written instructions for the installation of the Polyester Concrete End Dam system. The literature shall contain pertinent materials and installation data for the PPC supplied on the project. The Contractor shall submit the proposed testing procedures, mix design, form installation, and criteria for all PPC materials.
2.Manufacturer Qualifications. The Contractor shall install a Polyester Concrete End Dam system with all components of PPC provided through a single manufacturer. The manufacturer shall have documented experience supplying five successful projects of similar size and scope within the past five years. The Contractor shall submit documentation of the manufacturer’s project experience including the following: 518.06 518-4 A. Project construction dates.
B.PPC quantities.
C.Reference names and contact information for owner representatives.
3.Contractor Qualifications. The Contractor shall submit documentation of at least 10 successful projects with one or more of the following: (1) Thin Bonded Overlay (Polyester Concrete), and (2) Polyester Concrete End Dam, to established grade lines using s imilar equipment as specified in subsection 518.11(c) below within the past five years. The documentation of Contractor qualifications shall include the following:
A.Project construction dates.
B.PPC quantities.
C.Reference names and contact information for owner representatives. If the Contractor does not have at least 10 documented successful projects of experience with placing PPC systems, the Contractor shall arrange for a qualified Manufacturer’s Technical Representative with at least five documented successful projects of exp erience with PPC system placements within the past five years to be on-site throughout the duration of the project to provide technical support for the material mixing and placement. If the Contractor has at least 10 documented successful projects of experience with placing PPC systems, the qualified Manufacturer’s Technical Representative with at least five documented successful projects of experience with PPC system placements within the past five years shall, at a minimum, be on -site the first day of PPC placements, and shall be available as requested by the Engineer if necessary.
4.Manufacturer’s Technical Representative Qualifications. The Manufacturer’s Technical Representative shall have at least five documented successful projects of experience of similar size and scope with PPC system placements using similar equipment as specified , within the past five years, and be competent in all aspects of the work including all materials to install the PPC systems. This includes, but is not limited to, surface preparation, PPC application and PPC curing. The Technical Representative shal l be available on -site for the first day of PPC placement to facilitate the installation. The Contractor shall submit documentation of the Technical Representative’s experience including the following:
A.Years of experience with PPC systems.
B.Project construction dates.
C.PPC quantities.
D.Reference names and contact information for owner representatives.
5.Certified Test Report. The Contractor shall furnish a Certified Test Report, per subsection 106.13, confirming that all materials required for a Polyester Concrete End Dam system have been pre -tested , and meet all requirements.
6.Placement Plan. The Contractor shall submit a Polyester Concrete Placement Plan that includes the following:
A.Schedule of work and required testing.
B.Placement sequence and procedure.
C.Description of all equipment used.
D.Method for preventing leakages of HMWM primer and Polyester Concrete.
E.Method for measuring and maintaining thickness and profile for each lift. 518.06 518-5 F. Finishing surface method including sequence and repair of damaged sections.
G.Cure time for Polyester Concrete.
H.Storage and handling of resin and PPC components.
I.Procedure for disposal of excess resin, PPC and containers.
J.Procedure for cleanup of mixing and placement equipment.
7.Equipment . The Contractor shall submit documentation of certification of scales that will be used to calibrate the mobile mixing truck. The certification shall be dated within the last month. A new certification shall be done if any adjustments are made to the scales.
8.Material Samples. Representative material samples used for the project shall be submitted to the Engineer a minimum of 30 days before the PPC application. The exact samples of materials from the same lots used for the project, for all components of the PPC system shall be submitted by the manufacturer, if requested, a minimum of 15 days before the PPC application. The quantities of the material samples shall consist of one 4-liter sample for each liquid with corresponding amounts of catalysts and acceler ators, and a 50 -pound sample for each dry component.
b.Material Requirements. Materials for the Polyester Concrete End Dam shall be as follows:
1.PPC. The PPC shall consist of Polyester Resin Binder, catalysts and dry aggregate specified in Table 518 -4. It shall also include a compatible primer applied on the prepared concrete areas, which when mixed with other specified materials and applied as specified, shall produce a PPC meeting the requirements of this specification. Accelerators may be required to speed up the chemical reaction and achieve proper Set Time of the PPC. They shall be used as recommended by the PPC Manufacturer.
2.Polyester Resin Binder. Polyester Resin Binder shall have the following properties:
A.Be an unsaturated Isophthalic Polyester -styrene Co -polymer. The Polyester Resin content shall be 12 percent + 1 percent of the weight of the dry aggregate.
B.Contain at least 1.0 percent by weight Gamma- methacryloxypropyltrimethoxysilane, an Organosilane Ester Silane coupler.
C.Be used with a promoter that is compatible with suitable Methyl Ethyl Ketone Peroxide and Cumene Hydroperoxide initiators.
D.Have the values for the material properties shown in Table 518 -2. Table 518 -2 POLYESTER RESIN BINDER PROPERTIES (Tested each lot sent to the job) Property Test Method Value Viscosity* ASTM D2196 0.1x10-5 to 2.9x10-5 psi-sec (0.075 to 0.20 Pa -s) RVT No.1 Spindle, 20 RPM at 77 °F Specific Gravity* ASTM D1475 1.05 to 1.10 at 77 °F Elongation ASTM D638 35% minimum Type I specimen, thickness 0.25 ± 0.03” at Rate = 0.45 inch/minute. Elongation ASTM D618 Sample Conditioning: 18/25/50+5/70 Tensile Strength ASTM D638 2,500 psi, minimum Type I specimen, thickness 0.25 ± 0.03” at Rate = 0.45 inch/minute. Tensile Strength ASTM D618 Sample Conditioning: 18/25/50+5/70 Table 518 -2 Notes: * Test shall be performed before adding initiator.
3.Primer . Primer for the concrete blockout surfaces shall be a wax -free low odor, High - molecular -weight Methacrylate primer (HMWM), and consist of a resin, initiator, and promoter. 518.06 518-6 When initiators and promotors are required to achieve proper modifications for working under different temperature conditions and applications of the primer, they shall be used as recommended by the PPC Manufacturer. HMWM primer shall be applied to bond in PCC surfaces and promote adhesion to the PPC materials. The primer shall be tested for the Bond Strength per CP-L4302. The primer shall have a maximum volatile content of 30 percent before adding the initiator, when tested per ASTM D2369, and conform to Table 518 -3. Initiators for the Methacrylate Resin shall consist of a metal drier and Peroxide. If supplied separately from the resin, the metal drier shall not be mixed with the Peroxide directly. The containers shall not be stored in a manner that allows leakage or spilling to contact the containers or materials of the other. Table 518 -3 HIGH MOLECULAR WEIGHT METHACRYLATE RESIN PROPERTIES (Tested yearly) Property Test Method Value Viscosity* ASTM D2196 4.0x10-5 psi-sec (0.025 Pa -s) maximum (Brookfield RVT with UL adapter, 50 RPM at 77 °F) Volatile Content* ASTM D2369 30% maximum Specific Gravity* ASTM D1475 0.90 minimum at 77 °F Flash Point* ASTM D3278 180 °F minimum Vapor Pressure* ASTM D323 0.04 inch Hg, maximum at 77 °F PCC Saturated Surface -Dry Bond Strength (Adhesive) CP-L4302 700 psi, minimum at 24 hours and 70 + 1 °F (with Polyester Concrete at 12 % resin content by weight of the dry aggregate) Table 518 -3 Notes: * Test shall be performed before initiator is added
4.Aggregate . Aggregate for Polyester Concrete shall:
A.Have not more than 45 percent crushed particles retained on the No. 8 sieve when tested per AASHTO Test Method T335.
B.Provide fine aggregate consisting of natural sand.
C.Have a weighted -average aggregate absorption of no more than 1.0 percent when tested under AASHTO Test Methods T84 and T85.
D.At the time of mixing with resin, have moisture content of not more than one -half of the weighted -average aggregate absorption when tested under AASHTO Test Method T255.
E.Comply with the requirements for the aggregate gradation shown in Table 518 -4. 518.06 518-7 Table 518 -4 AGGREGATE GRADATION (Tested yearly)
5.Sand. Sand for abrasive sand finish shall:
A.Be commercial- quality blast sand.
B.Have not less than 95 percent pass the No. 8 sieve, and not less than 95 percent retained on the No. 20 sieve when tested under AASHTO Test Method T27.
C.Have an average absorption of not more than 1.0 percent when tested under AASHTO Test Method T85.
6.Composite System Properties . Polyester Concrete End Dam system shall have the values for the composite system properties shown in Table 518 -5: Table 518 -5 COMPOSITE SYSTEM PROPERTIES (Tested every 2 years) Property Test Method Values Abrasion Resistance CP-L4301 < 2g weight loss (at 12% resin content by weight of the dry aggregate) Modulus of Elasticity ASTM C469 1,000,000 psi to 2,000,000 psi (at 12% resin content by weight of the dry aggregate) PPC (Bond Strength) CP-L4302 500 psi minimum at minimum of 24 hours and 70 °F (without Primer, at 12% resin content by weight of the dry aggregate, and saturated surface dry specimen) Compressive Strength at Final Set Time ASTM C805 3,000 psi at minimum of 4 hours Compressive Strength at Cure Time ASTM C39 4,500 psi at minimum of 24 hours Sieve Size Percent Passing 3/8” 100 No. 4 62 - 85 No. 8 45 - 67 No. 16 29 - 50 No. 30 16 - 36 No. 50 5 - 20 No. 100 0 - 7 No. 200 0 - 3 518.07 518-8 CONSTRUCTION REQUIREMENTS
518.07 Waterstops. Waterstops shall be furnished full length for each straight portion of
the joint, without field splices. Field splices shall have a full- size tensile strength of 100 pounds per inch of width. Waterstops, when being installed, shall be cut and spliced at changes in direction as may be necessary to avoid buckling or distortion of the web or flange. If, after placing concrete, waterstops are substantially out of position or shape, the surrounding concrete shall be removed, the waterstop reset or replaced if damaged, and the concrete replaced at the Contractor’s expense.
518.08 Asphaltic Expansion Devices The joint system shall be installed according to the
manufacturer's recommendation and specifications and according to the details on the plans. The backer rod shall be secured and sealed in the joint opening according to the manufacturer's directions. The bridging plate shall be centered and secured over the joint opening according to the manufacturer's directions. The joint binder, polymer modified asphalt, and aggregate shall be placed in the sequence and by the methods recommended by the manufacturer. The completed joint shall be compacted by the methods recommended by the manufacturer. The final grade of the joint after compaction shall match the finished grade of the deck. The final thickness of the joint shall be 2.5 inches minimum. A representative of the joint manufacturer shall be on site during the installation of each of the joint components. The representative shall certify that the joint was installed per manufacturer's recommended procedures and per the attached details. If a joint fails to meet the manufacturer's specifications, it shall be removed and replaced with a properly installed joint at the expense of the Contractor. Two copies of the manufacturer's product literature, specifications and installation instructions shall be provided to the Engineer.
518.09 Elastomeric Expansion Devices. The Contractor shall submit working drawings as
specified in subsection 105.02. The manufacturer’s instructions for proper installation of the expansion joint device shall be included in the working drawings. Working drawings that lack manufacturer’s installation instructions shall be returned for resubmittal. Where applicable according to the plans, details of the expansion device through the curb, and details of the curb cover plates and connections, shall be shown on the working drawings. At the discretion of the Engineer , the manufacturer may be required to furnish facilities for testing and inspecting of the completed device or a representative sample in the plant or at an independent test facility. The inspectors shall be allowed free access to the necessary parts of the manufacturer’s plant and test facility. The manufacturer shall provide a technical representative to be present at all times while the expansion device is being installed. The expansion device shall be installed in strict accordance with the manufacturer's written instructions and these specifi cations. 518-9 The expansion device shall be anchored as shown on the plans. Curb cover plates, where called for by the plans, shall be anchored to the concrete with cast -in-place inserts. Bolts shall be zinc or cadmium plated. The expansion device shall be accurately set and securely supported at the correct grade and elevation and the correct joint opening as shown on the plans and on the working drawings. If portland cement concrete end dams are specified on the plans, the area beneath the expansion device angles shall be pressure injected by approved methods with an approved epoxy grout until all voids beneath the angles are eliminated. This shall be perf ormed before the installation of the elastomeric expansion joint seal and after the concrete end dams have cured for a minimum of 120 hours. Epoxy grout shall not be placed when the ambient temperature is 35 °F or below, or when temperatures are expected to fall to or below 35 °F at any time during the period of 12 hours following placement, unless the entire expansion device is protected from freezing by a heating enclosure. Before the pre -molded elastomeric expansion joint seal is installed, the contact surfaces of the adjacent steel shall be thoroughly cleaned of mill scale and foreign material that will affect the installation or the sealing capabilities of the elastomeric expansion joint seal. The cleaned metal surfaces shall be protected from rusting until the pre -molded elastomeric expansion seal and lubricant adhesive are placed against the metal surface. All cleaned metal surface where rusting appears shall be re -cleaned at no additional expense to the State. After the expansion joint device has been permanently installed the Contractor shall test the full length of the device for watertight integrity. The Contractor shall employ a method satisfactory to the Engineer. The entire joint system shall be covered with water, either ponded or flowing, for a minimum duration of 15 minutes. The concrete surfaces under the joint shall be inspected, during this 15 -minute period and also for a minimum of 45 minutes after the supply of water has stopped, for any evidence of dripping water or moisture. Watertightness shall be interpreted to be no free dripping water on any surface on the underside of the joint. Patches of moisture shall not be cause for non -acceptance. If the joint system exhibits evidence of water leakage at any place whatsoever, the Contractor shall locate the leakage and correct the leakage as approved by the Engineer. Subsequent to corrective measures, the watertight integrity test shall be performed subject to the same conditions as the original test. This work and subsequent tests shall be done at the Contractor’s expense. The watertight integrity test is not required for joints at the ends of approach slabs. The words “permanently installed” as used above include completion of the portions of the curb and deck that cannot be constructed until after the expansion device is installed. This applies even though this work is to be paid for under other items of the Contract. The Contractor shall provide written certification to the Engineer that the expansion joint device was installed per the manufacturer's instructions, the advice of their technical representative, and these specifications. Any certification from the joint manufacturer's technical representative, provided by the Contractor to the Engineer, shall be in writing. 518-10
518.10 Modular Expansion Device.
a.The Contractor shall submit shop drawings as specified in subsection 105.02. The manufacturer's instructions for proper installation of the expansion joint device shall be included in the shop drawings. Details of the expansion device through the curb, and details of the curb cover plates and connections, shall be shown on the shop drawings. At the discretion of the Engineer , the manufacturer may be required to allow inspection of the completed device in the plant. The inspectors shall be allowed full access to the parts of the manufacturer’s plant necessary for the fabrication and assembly of the expansion joint device. The Contractor and Engineer shall ensure that the time of inspection does not result in a delay in fabrication. The manufacturer shall provide a technical representative to be present at all times while the expansion device is being installed. The Contractor shall notify the expansion device manufacturer of the scheduled installation a minimum of two weeks before the installation date. The modular expansion joint device shall be installed in strict accordance with the manufacturer's written instructions, the advice of the manufacturer's technical representative, and these specifications. The permanently installed expansion joint device shall match exactly the finished roadway profile and grade, and specified recesses as shown on the plans. Immediately before installation, the expansion joint device shall be inspected by the Engineer for proper alignment, and complete bond between the pre -molded elastomeric seals and the steel, and proper stud placement and effectiveness. Pre -molded elastomeric seals not fully bonded to the steel shall be made fully bonded at the expense of the Contractor. All bolted connections shall be checked and tightened if found to be loose. Bends or kinks in the expansion joint device steel will not be allowed (except as necessary to follow the roadway grades). Straightening of bends or kinks will not be allowed. If an expansion joint device exhibits bends or kinks, it shall be removed from the work site, and replaced by a new expansion joint device, at the expense of the Contractor. The expansion joint device shall be preset by the manufacturer before shipment. Presetting shall be done per the joint opening at 70 ºF as indicated on the Contract Plans. Mechanical devices, supplied to set the expansion joint device to the proper width shall be disposed of by the Contractor following final adjustment for temperature. Anchorages shall be inspected visually and shall be given a light blow with a 4 -pound hammer. If an anchorage does not have a complete weld or does not emit a ringing sound when struck with a light blow of a hammer, it shall be replaced. All anchorage replacements shall be at the expense of the Contractor. Stainless- steel sheet shall be welded to the support member. Adhesive will not be permitted. 518.10 518-11 The expansion device shall be anchored as shown on the plans. Curb cover plates shall be anchored to the concrete with cast- in-place inserts. Bolts shall be zinc or cadmium plated. The expansion device shall be accurately set for the correct joint opening and field conditions before placement in the blockout, and then secured at the correct grade and elevation and the correct joint opening as shown on the plans and on the shop drawings.
b.The structure temperature shall be measured by recording the surface temperature of the concrete, steel, or both with a surface thermometer as described below.
1.Concrete Bridges : Record the temperature of the underside of the concrete slab at each end of the superstructure element adjacent to the expansion joint. Take the average of the readings to use with the temperature chart shown on the plans. In lieu of surface readings, in ternal slab readings may be taken by drilling a 1/4- inch diameter hole 3 inches into the concrete slab, filling the hole with water, and inserting a probe thermometer.
2.Steel Bridges: Record the concrete slab temperature as described above. In addition, record the surface temperature of the shaded portion of the girder web at each location. Average the readings of the steel and concrete to use with the temperature chart.
c.All non -galvanized metal surfaces to come in contact with the pre -molded elastomeric seal shall be blast cleaned per the requirements of Steel Structures Painting Council Surface Preparation Specification N o. 6 (SSPC -SP6, Commercial Blast Cleaning). After cleaning, all cleaned surfaces shall exhibit a clean quality of CSA2, or better, as defined by Steel Structures Painting Council Standard SSPC -VIS l. The cleaned metal surfaces shall be protected from rusting until the pre -molded elastomeric seal and lubricant adhesive are placed against the metal surface. Any cleaned metal surface where rusting appears shall be recleaned per the foregoing, at no additional expense to the State. In order to perform the work of installing the expansion joint device in a proper manner, some portions of the curb and bridge deck cannot be constructed until after the expansion device is installed. After the modular expansion joint device has been set to its final line and grade, recess openings in the deck and curb shall be filled with deck concrete or as shown in the plans . Grout shall be required below the support bar boxes where clearance will not allow proper consolidation of deck concrete. In su ch cases, grout shall be placed before pouring concrete, and techniques utilized will assure full support of the support bar boxes. This shall be verified by visual inspection. The grout shall be a CDOT -approved grout, and strict adherence to the grout manufacturer’s instructions shall be followed. The uppermost surface of the concrete placement shall have a broom finish. The cost of this work including grout placement shall be included in the unit price bid for deck concrete.
d.After the expansion joint device has been permanently installed the Contractor shall test the full length of the device for watertight integrity. The Contractor shall employ a method satisfactory to the Engineer. The entire joint system shall be covered with water , either ponded or flowing, for a minimum duration of 15 minutes. The concrete surfaces under the joint shall be inspected, during this 15 -minute period and also for a minimum of 45 minutes after the supp ly of water has stopped, for any evidence of dripping water or moisture. Watertightness shall be interpreted to be no free dripping water on any surface on the underside of the joint. Patches of moisture shall not be cause for non -acceptance. 518.11 518-12 If the joint system exhibits evidence of water leakage at any place whatsoever, the Contractor shall locate the leakage and take measures to correct the leakage as approved by the Engineer. Subsequent to corrective measures, the watertight integrity test shall be performed subject to the same conditions as the original test. This work shall be done at the Contractor’s expense. The words “permanently installed” as used above include completion of the portions of the curb and deck that cannot be constructed until after the expansion device is installed. This applies even though this work is to be paid for under other items of the Contract.
e.The Contractor shall provide written certification to the Engineer that the expansion joint device was installed per the manufacturer’s instructions, the advice of their technical representative, and these specifications. Any certification from the joint manufacturer’s technical representative, provided by the Contractor to the Engineer, shall be in writing.
518.11 Polyester Concrete End Dam.
a.Pre-placement Conference. A Polyester Concrete Pre- placement Conference shall be held at least 15 days before any PPC placement operation begins. Attendees shall include all parties involved in the work.
b.Trial Application. The Contractor shall construct a test box for a test pour. The test box shall be at least 2 feet long, the depth of the Polyester Concrete End Dams, and the maximum width of the End Dams, or as approved by the Engineer. Before constructing the Polyester Concrete End Dams, one or more trial applications shall be placed in the test box to determine the Initial Set Time (Gel Time), Final Set Time, and Cure Time and to demonstrate the effectiveness of the mixing, placing, and finishing equ ipment proposed. The Final Set Time can be determined when the in -place PPC cannot be deformed by pressing with a finger, indicating the resin binder is no longer in a liquid state. The trial application shall replicate field conditions and be constructed using the same installer and equipment as the production work. The location of the trial application shall be as approved by the Engineer. Trial applications shall be properly disp osed of off -site by the Contractor. The number of trial applications required shall be as many as necessary for the Contractor to demonstrate the ability to construct an acceptable trial end dam section and competency in ability to perform the work. All Set Times are based on anticipated application temperatures, conditions, and lane closure timing. The Contractor shall adjust the mix design, and construct a test box , and demonstrate that the adjusted mix consolidates and sets properly. The methods, installer, or the PPC system may be reje cted after three trial applications if not shown to be adequate or in compliance with this specification as directed by the Engineer. Acceptable test results shall be achieved on a trial application before installation may proceed.
c.Equipment. All equipment for cleaning the existing concrete surface and mixing and applying the PPC system shall be per the Material Manufacturer’s recommendations as approved by the Engineer before commencement of any work. 518.11 518-13
1.Measuring Equipment. The following equipment shall be provided:
A.Certified Scales used to calibrate the mobile truck mixing equipment.
B.Means to measure the resin levels in the tank of the mobile truck mixer during PPC placement operations and access to the resin tank.
2.Mixing Equipment. A continuous mixer shall be used for all PPC applications. The continuous mixer shall:
A.Employ an auger screw/chute device.
B.Be equipped with an automatic metering device that measures and records aggregate and resin volumes. Record volumes at least every five minutes, including time and date. Submit recorded volumes at the end of the work shift.
C.Have a visible readout gauge that displays volumes of aggregate and resin being recorded.
D.Produce a satisfactory mix consistently during the entire placement.
E.Be calibrated by certified scales provided by the Contractor. Calibration shall be demonstrated by comparing the computer tickets to three consecutive batches of aggregate verified to be within 2 percent of one another. The process shall be repeated for three consecutive batches of resin, also verified to be within 2 percent of one another. This calibration process shall be witnessed by the Engineer, and the calibration shall be done every 90 days. A portable mechanical mixer of appropriate size for proposed batches, as recommended by the manufacturer and approved by the Engineer, may be used for all PPC applications and for smaller area applications of less than 2 ,000 cubic feet per contract.
3.Finishing Equipment: PPC materials shall be placed using hand tools such that the finish shall match the adjacent deck or pavement surfaces and meet the requirements of the project.
d.Surface Preparation. Before HMWM primer and PPC applications, the concrete surfaces to be treated shall be cleaned by shot -blasting, scarifying, chipping, or sandblasting until all unsound materials and contaminants that may interfere with the primer and PPC have been removed from the concrete blockouts. Exposed concrete surfaces shall be protected from precipitation and heavy dew during and after the application of the primer.
e.Forms . Forms of the concrete blockouts shall be tight, and sufficiently rigid to prevent distortion due to the pressure of the PPC and other loads incidental to the PPC. The formwork shall be inspected by the Engineer before the PPC placements. The forms shall be sealed watertight so that there is no leakage.
f.HMWM Primer Application. Before placing HMWM primer in the concrete blockouts, the exposed surfaces of the existing concrete shall be completely dry and blown clean with oil - free compressed air. However, the primer shall be placed after 28 -day curing time of new concrete. After the exposed concrete surfaces have been prepared and cleaned, the primer shall be applied per the Manufacturer's recommendations. The primer shall be applied within five minutes of mixing at a spread rate of approximately 90 square feet per gallon, and uniformly spread to completely cover any surfaces where PPC materials will bond. The primer shall be reapplied to any areas that appear dry after 15 minutes of absorbing the materials. The concrete surface temperature shall be at 40 °F and rising to 95 °F maximum, and the relative humidity shall be not more than 85 percent. 518.11 518-14 (g) Polyester Concrete Application. The Polyester Concrete shall be applied in the concrete blockouts within two hours after the primer has been applied. Before PPC placement, the surface temperature of the concrete blockouts to receive PPC shall be at 40 °F and rising to 95 °F maximum. The PPC shall be placed before the Initial Set Time and 15 minutes following addition of an initiator, whichever occurs first, or within a more restrictive temperature range if recommended by the manufacturer. After placing PPC in the concrete blockouts, if the Initial Set time of the PPC has exceeded 120 minutes, the materials shall be removed and replaced at the Contractor’s expense. Two-unit weight tests shall be performed on site for each lift and each day’s production of PPC material using 4 inch x 8 inch cylinders. The average of the two test results shall be within 135 +/- 5 pounds per cubic foot. If the average of the unit weight tests is not within this specified range, adjustments shall be made to the PPC, and the tests performed again. Any material placed that is outside the specified range shall be removed and replaced at the Contractor’s expense. After a minimum of four hours and before opening to traffic, the Compressive Strength Test for Polyester Concrete End Dams shall be performed per the Rebound Hammer of Hardness Concrete, ASTM C805. The test results shall achieve the Compressive Strength of 3,000- psi minimum before opening traffic. In addition, one -unit weight test cylinder shall be stripped after 90 minutes and examined for evidence of poor consolidation. If uncured or unconsolidated material is determined to be present, the in -place end dam material shall be rem oved and replaced at the Contractor’s expense. If the depth of the Polyester Concrete End Dams exceeds 6 inches, the PPC materials shall be placed in lifts. The maximum thickness of each lift shall be recommended by the manufacturer or approved by the Engineer. Each lift of the PPC shall be consolidated and achieve a relative compaction in the concrete blockouts to the satisfaction of the Engineer. A minimum of two 4 -inch x 8-inch test cylinders shall be made for each day’s production of PPC for expansion joint end dams. The test cylinders shall be broken at intervals as directed by the Engineer to verify a minimum compressive strength of 4,500 psi has been achieved. If the mater ial has not reached 4,500 psi at 28 days, the Engineer has the option of price reducing the material or remove and replace per subsection 601.17.
h.Surface Finishing. The proposed surface of Polyester Concrete End Dams shall be consolidated and finished to the required grade and cross slope using finishing equipment as approved by the Engineer. Sand finish shall be applied by either mechanical means or hand broadcasting onto the glossy surface at a minimum rate of 2.2 lbs. per square yard immediately after finishing and before the Initial Set Time occurs. The smoothness of the PPC surface shall be tested with a 10 -foot straightedge transversely and longitudinally. Deviations greater than 3/8 of an inch shall be diamond ground to the proposed finish grade. The thickness of the PPC shall not be reduced by more than 3/8 of an inch. Where there is a low spot reduced by more than 3/8 of an inch on the PPC surface, the low area shall be removed at least 3/4” and replaced with new PPC system to the proposed finish grade as directed by the Engineer. If there is a damaged surface on the PPC, the Contractor shall remove unsound PPC surface and replace it with new PPC system per the Finishing Surface Method. 518.12 518-15 After final surface finishing, traffic or equipment shall not be allowed on the treated surface until the PPC has achieved the Final Set Time. The Polyester Concrete End Dams shall be protected from moisture until Final Set Time has been obtained. The Co ntractor shall follow all Manufacturer’s recommendations including surface preparation and all Set Times before opening treated surfaces to traffic or completing the work. METHOD OF MEASUREMENT
518.12 Waterstop will be measured by the number of linear feet installed and accepted.
Asphaltic expansion devices will be measured by the number of linear feet from curb face to curb face along the joint installed and accepted. Elastomeric expansion device will be measured by the linear foot between faces of curbs, parallel to the expansion device, completely installed, tested, and accepted. Portions of devices required in faces of curbs, including cover plates and hardware, wil l not be measured for payment. Polyester Concrete End Dam will not be measured but will be the quantity designated on the plans. Exceptions for each structure will be:
1.when field changes are ordered, OR
2.when it is determined that there are discrepancies on the plans in an amount plus or minus 2 percent of the plan quantity for the structure. Polyester Concrete End Dam will be measured by the number of cubic feet completed in place and accepted. The pay volume for each discrete location (a contiguous treated area not touching other treated areas) shall be rounded up to the next whole cubic foot. BASIS OF PAYMENT
518.13 The accepted quantities of waterstop will be paid for at the contract unit price per
linear foot. The accepted quantity of asphaltic expansion joint will be paid for at the contract unit price per linear foot and shall include all preparation materials, installation, compacting and final treatments associated with the particular joint provided. The accepted quantity of elastomeric expansion device will be paid for at the contract unit price per linear foot and shall include all work necessary to complete the item, including furnishing and installing steel extrusions, steel angles, steel anchors, cover plates and hardware, bolts, inserts, epoxy grout, lubricant adhesive, pre -molded elastomeric joint seal and all miscellaneous hardware required. The accepted quantity of modular expansion device will be paid for at the contract unit price per linear foot and shall include all work necessary to complete the items, including furnishing and installing modular expansion device, steel angles, concrete a nchorages, cover plates and hardware, bolts, inserts, lubricant adhesive and all miscellaneous hardware required. 518.13 518-16 The accepted quantity of Polyester Concrete End Dam will be paid for at the contract unit price per cubic foot and shall include all work and materials necessary to complete the item including surface preparation, HMWM primer application, PPC application, surface finishing, trial application test boxes, testing, the on -site Technical Representative and all miscellaneo us work required. Payment will be made under: Pay Item Pay Unit Waterstop (Inch) Linear Foot Bridge Expansion Device (2 Inch) Linear Foot Bridge Expansion Device (0 - 4 Inch) Linear Foot Bridge Expansion Device (0 - __Inch) Linear Foot Polyester Concrete End Dam Cubic Foot 601.01 601-1
Division 600
MISCELLANEOUS CONSTRUCTION SECTION 601 STRUCTURAL CONCRETE DESCRIPTION
601.01 This work consists of furnishing and placing hydraulic cement concrete per these
specifications and in conformity with the lines, grades , and dimensions as shown on the plans or established. This work includes preparing concrete surfaces designated in the Contract and applying an approved color ed Structural Concrete Coating .
601.02 Classification. The classes of concrete shown in Table 601 -1 shall be used when
specified in the Contract.
Source: Colorado Standard Specifications for Road and Bridge Construction, 2023 Edition. Pages 533–548 of 943.