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501001 PCC PAVEMENT, 8” SY

DE · 2025 Standard SpecificationsBook pages 160–167View official source ↗

PORTLAND AND CEMENT CONCRETE PAVEMENT SECTION 501 150 the plan pavement thickness as the maximum pavement thickness value used in this chart for a 1,000 square yard lot. 501.5.2 Pavement Smoothness Adjustments. The Department will apply incentive or disincentive pay adjustments as established by this specification and in accordance with the contract. 501.5.3 Low Strength Concrete Adjustments. The Department will consider concrete that fails to reach full 28 -day design strength (f' c) subject to remedial action. The Department will make prorated payment in accordance with Section 610. 5.D. Remove and replace concrete having compressive strength of 500 PSI or more below the designed (f'c) of the pavement. ITEM DESCRIPTION UNIT 501001 PCC PAVEMENT, 8” SY 501002 PCC PAVEMENT, 9” SY 501004 PCC PAVEMENT, 10” SY 501005 PCC PAVEMENT, 11” SY 501006 PCC PAVEMENT, 12” SY 5010 07 PCC PAVEMENT, 14” SY PATCHING PORTLAND CEMENT CONCRETE PAVEMENT SECTION 503 151 SECTION 503 — PATCHING PORTLAND CEMENT CONCRETE PAVEMENT

503.1Description.

This work consists of patching existing PCC pavement with high early strength concrete .

503.2Materials.

A.PCC, Class A Section 1022

B.Liquid Membrane -Forming Compo unds for Curing Section 10 45.7

C.Joint Sealants Section 1042 .1.B

D.Epoxy Grout Section 1047 .4

E.Wax -Based Bond Breaker with a Flash Po int not less than 200 Degrees F

F.Embedded Hardware:

1.Tie Bars Section 1037

2.Dowel Bars Section 1073

3.Tie Bolts – Hook Bolts or W -Bolts Section 1037

503.3Construction.

A.Provide a flatwork technician with an ACI or NRMCA certification or a certification from a program

pre-approved by the Department to supervise all finishing. Provide the flatwork certification to the engineer before placing concrete. 503.3.1 Patching Limits.

A.The contract or the engineer will designate pavement for patching. The engineer will paint the

patching limits on the existing pavement.

B.The Department will designate patches as either Type A or Type B. A Type A patch is 15 -feet or

less in length. A Type B patch is greater than 15 -feet and less than 100 -feet in length and contains load transfer assemblies consisting of dowel support baskets and dowel bars spaced at a maximum of 15 -feet.

C.Construct pavement replacement greater than 100 -feet in length under Section 501.

D.Patch limits in the direction of traffic shall either match or be offset by at least 2 -feet from the

existing concrete pavement joints, any cracks, or patch ends in the immediate adjacent lanes.

E.Submit requests to change patch limits due to poor existing concrete conditions at proposed tie -in

locations at least 5 -days before removal. The engineer will determine all patching limits

F.Ensure that the patches are at least the depth of the existing slab.

503.3.2 Saw Cutting.

A.Refer to and comply with all requirements listed in Section 762. Construct perimeter cuts plumb

and parallel to the roadway centerline. Minimize and seal over -cuts into the remaining slabs as directed by the engineer. Cut existing steel across the patch perimeter. Cut concret e no more than 2-days before removals. Remove and dispose of concrete slurry from saw cutting in accordance PATCHING PORTLAND CEMENT CONCRETE PAVEMENT SECTION 503 152 with Section 106.8. Clean all travel lanes to the satisfaction of the engineer before opening to traffic following the saw cutting operation. 503.3.3 Patch Removal.

A.Remove the patch and any remaining bituminous overlay in the patch area by the lift -out

technique without damaging the remaining concrete slabs or disturbing the base and subgrade. The lift -out technique entails drilling holes into the patch to insert l ifting hooks, pins, or chains. Repair damage to the remaining concrete slabs or the base and subgrade caused by improper patch removal using methods approved by the engineer.

B.When the lift -out technique is not feasible, break and remove the concrete in the patch area using

an approved mechanical pavement breaker or jackhammer. Remove the existing patch material with minimal disturbance to the remaining concrete or foundation .

C.Where the patch is next to the shoulder and removal of the concrete results in a clean, uniform

shoulder edge, the engineer may allow the contractor to use the shoulder edge as the form for the new concrete. If the shoulder is not designated for replacement, repair all areas of the shoulder pavement structure removed or disturbed by the patching operation. If the bituminous shoulder is damaged during concrete removal, place a side form to provide a vertical edge for the concrete patch. 503.3.4 Patch Preparation.

A.If the base material appears unsuitable or washed out after removing the concrete, remove the

unsuitable material to a maximum depth of 6 -inches, or less as directed by the engineer. Fill the excavated area with concrete when placing the patch. Clean out the repair area with hand tools and protect the patch subgrade from water intrusion. Excessive moisture remaining after excavation may requ ire construction of a pipe underdrain system as directed by the engineer or as shown in the contract.

B.In areas of composite pavements consisting of bituminous concrete over PCC pavement, the

contractor may pour the concrete patch flush with existing bituminous concrete pavement to eliminate grade differential. Place the additional concrete depth, not to exceed 6 -inches, as directed by the engineer.

C.Pay particular attention to existing longitudinal joint areas where loose concrete may have

cracked away from the plumb line during patch removal. Clean all vertical faces before placing concrete.

D.Just before placing the concrete patch, spray a coating of wax -based bond breaker on the

longitudinal and transverse vertical faces of existing concrete pavement adjacent to the patch. 503.3.5 Dowel and Tie Bar Installation.

A.Provide and install dowel support baskets and dowel bars conforming to the requirements of the

contract for internal crack control joints at Type B patches . Cut the shipping or tie wires on the dowel bar support basket after placement within the proposed pavement box.

B.Equipment.

Use a drill support system to maintain proper hole alignment. Use gang drills on contracts requiring multiple patches. Saw out all damaged pavement adjacent to the patch if damaged by the drilling operation and replace the damaged sections.

C.Placement.

PATCHING PORTLAND CEMENT CONCRETE PAVEMENT SECTION 503 153 1. Place dowel bars in accordance with the Standard Construction Details. Tie bars are to be provided and installed for Type B patches that are placed adjacent to concrete. Do not install tie bars on Type A patches .

2.Drill the dowel bar and tie bar holes parallel to the pavement profile and centerline to a depth

of half the dowel bar or tie bar length. When using epoxy adhesive , drill holes 1/16 -inch greater than the dowel bar or tie bar diameter. When using non -shrink grout, drill hole 1/4 -inch greater than the dowel bar or tie bar diameter. Use epoxy adhesive conforming to ASTM C881 Type IV, Grade 2 or 3, Class A, B, and C, or use fast setting non -shrink grout conforming to ASTM C1107. Use compressed air that is dr y and oil free at a continuous pressure of at least 100 pounds per square inch, measured at the source, to clean the holes before placing grout or epoxy.

3.Place the anchoring grout or epoxy using a nozzle or wand that will deposit the material to the

back of the hole. Do not push or pour the anchoring material into the holes. Install the dowel bar or tie bar into the grout using a twisting motion to completely coat the dowel bar or tie bar surface. Install a plastic grout retention disk around each dowel bar or tie bar to prevent grout loss and to help center the dowel bar or tie bar in the hole. Support the dowel bars and tie bar s in proper alignment unti l the grout has cured. Align the dowel bars and tie bars not to exceed the tolerances indicated in the contract. Fill any unused hole with epoxy grout. 503.3.6 Placing Concrete.

A.Wet the base course just before placing concrete. The water application rate should not cause any

pooling on the grade.

B.Place patching concrete directly on the moist subgrade and uniformly distribute and spread it over

the entire patch area. Place the concrete in each patch area in a continuous operation. Consolidate the concrete using a standard spud -type vibrator capable of visibly affecting the concrete a distance of 1 -foot from the vibrator head. Insert the vibrator vertically into the concrete without dragging it through the mix.

C.Place the concrete when the ambient air temperature is at least 35 degrees F and rising, unless

otherwise allowed by the engineer.

D.Do not place plastic concrete if the temperature reaches 95 degrees F, unless otherwise allowed

by the engineer. 503.3.7 Concrete Strength Requirements.

A.Place Class A concrete, having a minimum compressive strength of 2,000 pounds per square inch,

or full design strength as noted in the contract, within 6 -hours of concrete placement. Provide Sure -Cure mold test cylinders and all associated equipment for the engineer’s use. The engineer will sample and test the concrete. The engineer may also use the concrete maturity meter, in accordance with AASHTO T325, t o determine compressive strength.

B.To accomplish the designed compressive strength in 6 -hours, establish the actual combination of

weights and proportion of admixtures as required due to field conditions, ambient temperature, humidity, and wind conditions. If unfavorable weather conditions prevent the concrete from reaching the desired streng th in 6 hours, reschedule the patching work subject to approval by the engineer. The Department may consider the concrete defective if it fails to meet the compressive strength within 6 -hours.

C.Remove and replace concrete the engineer determines to be structurally inadequate. The

Department will allow concrete determined to be structurally adequate by the engineer, but not PATCHING PORTLAND CEMENT CONCRETE PAVEMENT SECTION 503 154 meeting 2,000 pounds per square inch in 6 -hours, to remain in place at a prorated payment in accordance with Section 503.5.1. If the contractor does not want to accept the prorated payment, the contractor may remove and replace the concrete in an attempt to achieve full compensation. 503.3.8 Finishing Concrete.

A.Strike off the concrete surface flush with the existing pavement. For patches up to 10 feet long,

place the screed parallel to the centerline of the roadway. For longer patches, the contractor may place the screed perpendicular to the centerline of the roadway.

B.Provide a tined finish on the concrete patch with the texture applied in a direction perpendicular

to the traffic flow when a bituminous concrete overly will cover the patch surface. Match the adjacent pavement surface cross slope and profile. The Depar tment will consider the patch unacceptable if the profile in the finished patch area contains excessive surface deviations. The maximum allowable longitudinal and transverse deviation is 1/4 -inch in 10 -feet. Provide a 10 -foot straight edge for testing. Whe n the concrete patch is the final roadway surface, match the texture of the adjacent pavement. Match the patch surface cross section with the preceding and following pavement surfaces. The Department will not allow use of steel trowels for finishing surfaces. The engineer may test for excessive surface deviations with a straightedge, a profilometer, or other surface measuring device.

C.Repair damaged concrete or the bituminous shoulder before opening the patch area to traffic.

503.3.9 Curing.

A.Use one of the methods listed below:

1.White Membrane Curing Compound

a.Spray the curing material on the pavement surface and all exposed edges immediately

following concrete texturing.

b.Continuously agitate the curing material during application to keep it thoroughly mixed.

2.Polyethylene Sheeting

Place polyethylene sheeting over the concrete and beyond the slab edges a distance that equals double the pavement thickness. Add weight to secure the material against wind and weather.

3.Insulating Blankets

Secure edges and seams of insulating blankets to prevent dislodging due to wind, rain, or adjoining traffic. Use insulating blankets in accordance with Section 610.3.5.C.6. 503.3.10 Joints.

A.Install in accordance with the Standard Construction Details.

B.Clean and seal all joints with hot -poured sealant material after the specified strength has been

achieved, if no overlay is planned in accordance with Section 504.

C.Form or saw transverse and longitudinal joints as shown in the contract. Saw transverse joints in

Type B patches matching existing within the patch area in accordance with Section 501.3.9. Clean and seal the joints around the entire patch perimeter, and all transverse joints in larger patches, with hot -poured sealant material within 5 days after concrete placement, if no overlay is planned. Refer to and comply with all Section 504 requirements. PATCHING PORTLAND CEMENT CONCRETE PAVEMENT SECTION 503 155 D. If the pavement will receive an overlay, the contractor may tool the transverse joints at the ends of the patch. The Department will not require a sealant reservoir in this case. Widen and seal the sawed transverse joints for crack control within Type B patches for both finished surface and overlay conditions. 503.3.11 Performance Measures. Repair or remove and replace uncontrolled random cracks before Final Acceptance and payment. Submit repair or replacement procedures to the engineer for approval.

503.4Method of Measurement.

A.Patching PCC Pavement, 6 feet to 15 feet, Type A and Patching PCC Pavement Greater than 15

feet to 100 feet, Type B.

1.The Department will measure concrete patches placed and accepted by the square yard. The

Department will measure the width from outside of the completed patches as constructed and will measure parallel to the transverse saw cuts. The Department will measure parallel to the centerline of the pavement, along the center of the patch. The Department will not measure additional patch areas made necessary due to improper concrete removal or saw cutting.

B.Undercut Excavation, Patching.

1.The Department will measure material removed below the bottom of the original concrete

pavement the contractor patched by the cubic yard. Refer to Section 202.3.7.

C.Patching Concrete.

1.The Department will measure concrete placed in undercut areas below the bottom of the

original pavement requiring the patch, or additional thickness above in order to eliminate grade differential in finished pavements by the square yard -inch.

D.Saw Cutting .

1.Refer to Section 762 for the method of measurement.

E.Dowel Bars.

1.The Department will measure the dowel bars installed and accepted at the ends of a patch as

each. The Department will not measure dowel bars and dowel support baskets (load transfer assemblies) installed at internal crack control joints in Type B patches. The Department will consider dowel bars and dowel support baskets installed at internal crack control joints in Type B patches as incidental to the contract unit price per square yard for item 503002 – Patching PCC Pavement, Greater Than 15 feet to 100 feet, Type B.

F.Crack and Joint Sealing Less than 3/4 -Inch Wide.

1.Refer to Section 504 for crack and joint sealing methods of measurement.

G.Tie Bars.

1.The Department will not measure tie bars placed in Type B patches.

2.Do not place tie bars in Type A patches.

503.5Basis of Payment.

PATCHING PORTLAND CEMENT CONCRETE PAVEMENT SECTION 503 156 A. If the contract calls for replacing a bituminous overlay, the Department will pay for the overlay using the applicable bituminous concrete pay item.

B.Type A Patches.

1.Square yard payment will constitute full compensation for:

a.Providing , placing , finishing, texturing, and curing concrete;

b.Sure -Cure test molds and curing materials;

c.removing and disposing of existing concrete and any bituminous overlay remaining on the

patch area at the time of removal;

d.preparing the foundation;

e.tooling, finishing, curing, texturing, sealing of over -cuts in non -overlay areas, and protecting

the new concrete; and

f.disposing of excess material resulting from necessary undercutting.

2.Type B Patches.

a.The square yard payment includes everything listed under basis of payment for Type A

patches and the following:

i.Providing and installing load transfer assemblies consisting of dowel bars and dowel support

baskets at all transverse joint locations except at either end of the patch; ii. providing and installing tie bars in accordance with the Standard Construction Details ; and iii. transverse saw cutting and sealing in accordance with the Standard Construction Details.

C.Undercut Excavation , Patching.

1.The Department will pay this item separately in accordance with Section 202.3.7.

D.Patching Concrete.

1.The square yard -inch payment includes providing and placing concrete to depths not to exceed

6-inches resulting from the undercut excavation, patching item, or to eliminate the grade differential of finished pavements.

E.Saw Cutting Concrete, Full Depth.

1.The Department will pay this item separately in accordance with Section 762.

2.The Department will consider the following as incidental to the item of work and will make no

separate payment for this work:

a.Cutting existing bituminous overlays up to 8 -inches thick over the concrete unless otherwise

noted in the contract;

b.cutting existing steel across the patch perimeter; and

c.additional cuts to facilitate patch removal.

F.Dowel Bars.

1.Payment for each dowel bar includes:

a.Drilling the dowel holes;

PATCHING PORTLAND CEMENT CONCRETE PAVEMENT SECTION 503 157 b. providing and placing dowel bars;

c.anchoring grout;

d.grouting retainer disks; and

e.providing and placing temporary dowel supports to maintain alignment.

G.Crack and Joint Sealing Less Than 3/4 -Inch Wide.

1.The Department will pay for this item separately in accordance with Section 504.

503.5.1 Price Adjustment for Low Strength Concrete. The Department will calculate the prorated payment for concrete, as referenced in Section 503.3.7, as shown in the following equation:

ITEM DESCRIPTION UNIT 503001 PATCHING PCC PAVEMENT, 6’ TO 15’, TYPE A SY 503002 PATCHING PCC PAVEMENT, 15’ TO 100’, TYPE B SY 503004 PATCHING PCC PAVEMENT (UNDERCUTTING) SY-IN 503006 DOWEL BARS EA

Source: Delaware Standard Specifications for Road and Bridge Construction, 2025 Edition. Pages 160–167 of 779.

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141 Department considers a roll of concrete covering approximately half of the distributing augers

50300 1 PATCHING PCC PAVEMENT, 6’ TO 15’, TYPE A SY