930MATERIALS FOR CONCRETE REPAIR

930-1Description

This Section covers cementitious materials used to repair concrete including defects or purposely placed openings in concrete elements. Materials containing organic compounds, such as bitumen and epoxy resin as the principal binder are not included. The re quirements for epoxy resin materials are covered in Section 926. Any depth larger than the manufacturer’s recommendation for the specific material shall be repaired with portland cement concrete meeting the requirements of Section 346.

930-2Product Acceptance on the Project

930-2.1Product Acceptance: Use only products listed on the Department’s Approved

Product List ( APL). Manufacturers seeking evaluation of products must submit an application in accordance with Section 6 and include independently certi fied test reports that the material meets the requirements of this Section. The application package must describe detailed quality control requirements for installation including, but not limited to: maximum water to cementitious material ratio, formulatio n for two or more component systems , special materials and/or equipment, recommendations for all surface preparation , and curing requirements. Provide the Engineer certification conforming to the requirements of Section 6 from the manufacturer confirming that the materials used meets the requirements of this Section and is the appropriate product for the intended use. When specified in the Contract Documents, submit a report of test results from an independent laboratory on samples taken from materials hipped. Ensure the test was performed within 45 days prior to the shipping date of the material.

930-2.2Material Supply, Storage, and Marking: The material shall be pre -

proportioned including aggregate. Deliver products in original, unopened containers w ith manufacturer’s name , date of manufacture , and clearly marked with all information described below. Store the material in an elevated dry and weather protected enclosure in full compliance with the manufacturer’s recommendations. Material must be used w ithin manufacturer’s recommended shelf life. The material from which the containers are made shall have water vapor transmission not greater than 100 g/m2 in 24 hours as determined in accordance with Procedure B of ASTM E96. All containers shall be mar ked with the following information:

repair material to the concrete or mortar being repaired.

be mixed with the package contents.

resting times in minutes.

recommended amount of liquid. 1021 FY 2023-24 Return to Table of Contents

by more than 2% from the weight stated in the declarations . The average weight of filled containers in a LOT shall be not less than the individual weight stated in the declarations .

cementitious material ratio.

930-2.3Sampling, Mixing, and Additional Testing: A LOT is the packaged repair

material normally placed on a pallet. A unit sample is a single container or package of material randomly selected from the LOT. Mix and install the materials in accordance with the manufacturer’s recommendations. Manufacturers will be required to provide field representation upon request by the Engineer. The Department reserves the right to conduct further field testing on any approved material.

930-2.4Rejection: All broken containers wi ll be rejected. Material that fails to meet any

of the requirements of this Specification will be rejected. Report all materials failing to meet this specification and state the reasons for rejection in writing to the Engineer and the producer or supplier. Material in local storage in the hands of a vendor for more than six months after testing will be retested before use, except for the scaling resistance test and length change immersed in sulfate solution test for magnesium ammonium phosphate concrete. Re tested material will be rejected if it fails to conform to any of the requirements of this Specification.

930-3Laboratory Specimen Preparation

930-3.1Mixing and Fabrication : Mechanically mix the dry packaged materials with

liquid components in accordance with the manufacturer ’s recommendations.

930-3.2Length Change: Make and cure the test specimens in accordance with

ASTM C157, except omit the curing period in Section 10.3; however both 11.1.1 and 11.1.2 shall apply for 28 day curing period.

930-3.3Manifestly Faulty Specimens: Visually examine each group of specimens

representing a given test or a given age of test, including tests of freshly mixed concrete, before or during the test, or both, whichever is appropriate. Discard any specimen found to be manifestly faulty by such examination without testing. Visually examine all specimens representing a given test at a given age after testing, and should any specimen be found to be manifestly faulty the test results thereof shall be disregarded. Shou ld more than one specimen representing a given test at a given age be found manifestly faulty either before or after testing, the entire test shall be disregarded and repeated. The test result reported shall be the average of the individual test results of the specimens tested or, in the event that one specimen or one result has been discarded, it shall be the average of the test results of the remaining specimens.

930-4Materials for Repair of Predominately Horizontal Surfaces

930-4.1General: This mater ial is intended to be used to repair concrete where the area to

be treated will be on a horizontal surface. Examples of the type of locations for these materials are bridge decks, portland cement concrete pavements and other locations required by the Contract Documents. Follow the manufacturer’s recommendations for preparing the surfaces , mixing, placing, and curing the repair material unless otherwise directed in the Contract Documents.

930-4.2Classification: The materials to be considered under this cla ssification shall

meet the following requirements: 1022 FY 2023-24 Return to Table of Contents 930-4.2.1 Rapid Hardening: Moderate compressive strength for repairing concrete with an in -place compressive strength less than or equal to 4,000 psi. 930-4.2.2 Very Rapid Hardening: High compressives trength for repairing concrete with an in -place compressive strength greater than 4,000 psi. This material may be used in lieu of rapid hardening materials.

930-4.3Physical Properties: The repair material shall meet or exceed the physical

properties stated in Table 930-1 as determined by the specified test methods. 1023 FY 2023-24 Return to Table of Contents

930-4.4Specimen Preparation:

930-4.4.1 Flow/Slump : Testing for flow/slump will be completed in 15 minutes, plus or minus 1/2 minute, after the start of mixing liquid with the rapid hardening materials or 5 minutes, plus or minus 1/2 minute, after mixing the liquid with the very rapid hardening materials. Table 930-1 Physical Properties of Repair Materials for Horizontal Surfaces Requirement Test Method Rapid Hardening Very Rapid Hardening Minimum Compressive Strength, psi 3 hours ASTM C39* or ASTM C109* N/A 2,000 24 hours 2,000 4,000 7 days 4,000 6,000 28 days Greater than or equal to strength at 7 days. Maximum Length Change, % Allowable expansion at 28 days when water cured compared to length at one day ASTM C157** 0.12 0.12 Allowable shrinkage at 28 days when air cured compared to length at one day -0.12 -0.12 Allowable difference between increase in water and decrease in air 0.20 0.20 Minimum Slump (Concrete), inches ASTM C143*** 3 3 Minimum Flow (Mortar), % ASTM C1437*** 100 80 Time of Setting (Initial), minutes ASTM C191* or ASTM C403* Minimum 30 10 to 29 Coefficient of Thermal Expansion, in/in/°F ASTM C531* or AASHTO T 336 3.0x 10-6 to 9.0 x 10-6 3.0 x 10-6 to 9.0 x 10-6 Minimum Bond Strength by Slant Shear, psi 24 hours FM 5-587 400 450 7 days Greater than or equal to strength at 24 hours. Maximum Allowable Total Chlorides lb/yd3 FM 5-516 0.40 * as applicable ** Make and cure the test specimens in accordance with ASTM C157, except omit the curing period in *** Testing for flow/slump will be completed in 15 plus or minus 1/2 minute after the start of mixing liquid with the rapid hardening materials or 5 plus or minus 1/2 minute after mixing the liquid with the very rapid hardening materials. 1024 FY 2023-24 Return to Table of Contents

930-5Materials for Repair of Predominately Vertical Surfaces

930-5.1General: This material is intended to be used to repair concrete where the area

exposed in the field to be treated will be on a vertical surface. If an element has both horizontal and vertical surfaces, then the repair used will be for vertical surfaces. If it is not apparent which material is to be used, the vertical application will prevail. Examples of the type of locations for these materials are columns, caps, beams, piles, incidental concrete products, drainage structures and other locations required by the Contract Documents. Follow the manufacturer’s recommendations for preparing the surfaces and for mixing, placing and curing the repair material.

930-5.2Classification: The materials to be considered under this classification shall

meet the following requirements: 930-5.2.1 High Performance: Moderate compressive strength for repairing concrete with a designed compressive strength greater than or equal to 5,000 psi. 930-5.2.2 Ultra -high Performance: High compressive strength for repairing concrete with a designed compressive strength greater than 5,000 psi. These materials may be used in lieu of high performance vertical materials.

930-5.3Physical Properties: The repair material shall meet or exceed the physical

properties state d in Table 930-2 as determined by the specified test methods. 1025 FY 2023-24 Return to Table of Contents Table 930-2 Physical Properties of Repair Materials for Vertical Surfaces* Requirement Test Method High Performance Ultra-high Performance Minimum Compressive Strength, psi 24 hours ASTM C39** or ASTM C109** 1,000 2,000 7 days N/A 5,000 28 days 5,000 Greater than or equal to strength at 7 days Maximum Length Change, % Allowable expansion at 28 days when water cured compared to length at one day ASTM C157 ** 0.12 0.12 Allowable shrinkage at 28 days when air cured compared to length at one day -0.08 -0.08 Maximum Slump (Concrete), inches ASTM C143 3**** 3**** Maximum Flow (Mortar), % ASTM C1437 100**** 100**** Time of Setting (Initial), minutes ASTM C191** or ASTM C403** 10 to 180**** 10 to 180**** Coefficient of Thermal Expansion, in/in/°F ASTM C531 *** or AASHTO T 336*** 3.0 x 10-6 to 9.0 x 10-6 Minimum Bond Strength by Slant Shear, psi, 24 hours FM 5-587 450 750 7 days 750. 750 Minimum Flexural Strength (at 7 days), psi ASTM C580 500 700 Maximum Absorption (Mortar at 7 days), % ASTM C413 4 4 Minimum Surface Resistivity (Concrete at 28 days), kohm-cm AASHTO T 358 N/A 22 Maximum Allowable Total Chlorides lb/yd3 FM 5-516 0.40

* Use cement-based materials modified with polymers and silica fume for extremely aggressive environments

** Make and cure the test specimens in accordance with ASTM C157, except omit the curing period in

Section 10.3; however both 11.1.1 and 11.1.2 shall apply for 28 day curing period.

*** As applicable

**** For pump and pour applications, the maximum flow, slump and time of setting can be adjusted according to

the manufacturer’s recommendation.

930-6Material for Repair of Concrete in High Stress Concentration Areas

930-6.1General: This material is intended to be used to repair block-outs and voids in

post-tensioned elements, load bearing area of a beam, and other locations required by the

Contract Documents. This material may be used for the repair of horizontal or vertical surfaces.

Follow the manufacturer’s recommendations for preparing the surfaces and for mixing, placing

and curing the concrete. This material shall be a magnesium ammonium phosphate based

concrete (MAPC) or a magnesium potassium phosphate based concrete (MPPC). 1026FY 2023-24Return to Table of Contents

930-6.2Physical Properties: The MAPC and MPPC materials shall meet or exceed

physical properties stated in Table 930-3 as determined by the specified standard test methods.

Table 930-3

Physical Properties of Repair Material in High Stress Areas

Requirement Test Method Test Value

Minimum Compressive Strength (at 28 days), psi ASTM C109* 8,500

Minimum Flexural Strength (at 28 days), psi ASTM C348* 600

Minimum Slant Shear Bond (at 14 days), psi FM 5-587* 2,500

Time of Setting (Initial), minutes ASTM C191** 15 to 60

Maximum Scaling Resistance ASTM C672 No scaling

Maximum Length Change, %

Allowable expansion at 28 days when water cured

compared to length at one day ASTM C157***

0.03

Allowable shrinkage at 28 days when air cured

compared to length at one day -0.03

Maximum Allowable Total Chlorides lb/yd FM 5-516 0.40

* The test methods for compressive strength (ASTM C109), flexural strength (ASTM C348), and Slant Shear Bond

(FM 5-587) shall be modified so that the specimens are air cured instead of moist cured. All of these samples shall

be air cured until the time of testing.

** Initial time of set for MAPC or MPPC will be tested in accordance with ASTM C191 with the following

modification. The initial time of set shall be tested at 95° plus or minus 5°F.

*** Make and cure the test specimens in accordance with ASTM C157, except omit the curing period in

Section 10.3; however both 11.1.1 and 11.1.2 shall apply for 28 day curing period.

930-6.3Curing of Compressive Strength, Flexural Strength and Slant Shear Bond

Specimens: The test methods for compressive strength (ASTM C109), flexural strength

(ASTM C348), and Slant Shear Bond (FM 5-587) shall be modified so that the specimens are air

cured instead of moist cured. All of these samples shall be air cured until the time of testing.

930-7Special Fillers

930-7.1General: This material is intended to be used as filler material and for rapid

repairs to pile jacket structures and other locations specified in the Plans. Meet the requirements

of the contract documents for preparing the surfaces, placing, sampling, testing, and curing the

concrete. Mix the material in accordance with the manufacturer’s recommendations.

930-7.2Classification: The materials to be considered under this classification shall

meet the following requirements:

930-7.2.1 Cathodic Protection (CP) Filler: Provide cementitious based materials

with a minimum cement content of 900 pounds of cement per cubic yard of mix. Material

formulation must not contain fly ash, slag, silica fume or other mineral admixtures which may

produce increased electrical resistance. The material shall not contain any substances corrosive

to metals. 1027FY 2023-24Return to Table of Contents

930-7.2.2 Non-Cathodic Protection (Non-CP) Filler: Provide cementitious

based materials with a minimum cement content of 650 pounds of cement per cubic yard of mix.

The material shall not contain any substances corrosive to metals.

930-7.2.3 Extended Materials: Where concrete filler materials are specified,

approved mortar materials may be extended using size number 89 gradation aggregates from a

certified FDOT approved source.

930-7.3Physical Properties: The repair material shall meet or exceed the physical

properties stated in Table 930-4 as determined by the specified standard test methods. If

extended, materials shall meet the minimum requirements of Table 930-4.

930-7.4Constructability: Submit to the Engineer for approval shop drawing as may be

required to complete repairs in compliance with the design shown in the Plans and the

manufacturer’s recommended repair system.

Table 930-4

Physical Properties of Special Fillers

Requirement Test Method Cathodic

Protection

Non-

Cathodic

Protection

Minimum Compressive Strength, psi

24 hours ASTM C39* or

ASTM C109*

1,500 2,000

28 days 5,000 5,000

Maximum Length Change, %

Allowable expansion at 28 days when water

cured compared to length at one day

ASTM C157**

0.12 0.12

Allowable shrinkage at 28 days when air

cured compared to length at one day -0.12 -0.12

Allowable difference between increase in

water and decrease in air 0.20 0.20

Slump (Concrete), inches ASTM C143 7-9 7-9

Minimum Flow (Mortar), % ASTM C1437 100 100

Time of Setting (Initial), minutes ASTM C191* or

ASTM C403* 200 to 400 200 to 400

Minimum Bond Strength by Slant Shear (at

7 days), psi FM 5-587 450 450

Minimum Flexural Strength (at 7 days), psi ASTM C580 700 700

Minimum Tensile Strength (at 7 days), psi ASTM C307 200 200

Surface Resistivity (at 28 days), kohm-cm AASHTO T 358 15 or less 22 or greater

Maximum Allowable Total Chlorides lb/yd FM 5-516 0.40

* as applicable

** Make and cure the test specimens in accordance with ASTM C157, except omit the curing period in

Section 10.3; however both 11.1.1 and 11.1.2 shall apply for 28 day curing period. 1028FY 2023-24Return to Table of Contents

ACCESSORY MATERIALS FOR

CONCRETE PAVEMENT AND CONCRETE STRUCTURES METAL ACCESSORY MATERIALS FOR CONCRETE PAVEMENT AND CONCRETE STRUCTURES

931-1Reinforcement Steel (for Pavement and Structures)

931-1.1Steel Bars:

931-1.1.1 Carbon Steel Bars: Carbon steel bars for concrete reinforcement shall conform to the requirements of ASTM A615 Grades 60 or 80. 931-1.1.2 Stainless Steel Bars: Stainless steel bars for concrete reinforcement shall conform to the requirements of ASTM A955, Grades 60 or 75; or ASTM A276, UNS S31653 or S31803. 931-1.1.3 Low -Carbon Chromium Steel Bars: Low-carbon chromium steel bars for concrete reinforcement shall conform to the requirements of ASTM A1035 Grade 100. 931-1.1.4 Special Requiremen ts: The following special requirements shall apply:

No. 3 and larger shall be deformed bars.

taken to mean the Department. 931-1.1.5 Acceptance of Steel Bars: Acceptance of reinforcing steel shall be based on the manufacturer being on the National Transportation Product Evaluation Program

certified mill analysis . The test results shall meet the specification limits of the ASTM or AASHTO designation for the size, grade and any additional requirements. The manufacturer’s certified m ill analysis for each heat, size, and grade per shipment of reinforcing steel shall be provided to the Engineer prior to use. The Engineer will select samples representing each LOT of reinforcing steel. A sample is defined as the reinforcing steel and t he certified mill analysis corresponding to the sample. A LOT is defined as the weight of all bars, regardless of size, grade or pay item in consecutive shipments of 100 tons or less. Samples shall be cut from bundled steel that is shipped to the jobsite. Projects with less than two tons of bars do not require Department sampling.

931-1.2Wire Reinforcement:

931-1.2.1 Carbon Steel Wire Reinforcement: Plain and deformed carbon steel wire reinforcement shall meet the requirements of ASTM A1064. Deformed carbon steel wire shall be Grade 75. 931-1.2.2 Stainless Steel Wire Reinforcement: Plain and deformed stainless steel wire reinforcement shall meet the requirements of ASTM A276, UNS S30400. 931-1.2.3 Acceptance of Wire Reinforcement: Acceptance of wire reinforcement shall be based on the manufacturer’s certified mill analysis certifying that the test results meet the specification limits of the ASTM designation for the sizes and any additional 1029 FY 2023-24 Return to Table of Contents