435Rapid Setting Cement Concrete End Dams and Patches

435.1 General Description

This work includes constructing bridge joint end dams and partial or full depth patches in concrete structures. Use rapid-setting cement concrete under these conditions: • Quick traffic return is required. • The required minimum depth is 1 in. (25 mm)

435.1.01 Definitions

General Provisions 101 through 150.

435.1.02 Related References

A. Standard Specifications Section 461—Sealing Roadway and Bridge Joints and Cracks Section 500—Concrete Structures Section 504—Twenty-Four Hour Accelerated Strength Concrete Section 833—Joint Fillers and Sealers Section 886—Epoxy Resin Adhesives Section 934—Rapid Setting Patching Materials for Portland Cement Concrete B. Referenced Documents General Provisions 101 through 150.

435.1.03 Submittals

A. Mix Design Submit rapid-setting cement concrete mix designs and materials to the Office of Materials and Research for verification and approval at least 35 days before use.

435.2 Materials

Use these materials to construct bridge joint end dams or repair concrete: Material Section Rapid-setting Cement Material 934 Epoxy Adhesive, Type II 886 Silicone Sealant 461.3.05.C.2 and 833.2.06 Preformed Foam Joint Filler 833.2.10

435.2.01 Delivery, Storage, and Handling

General Provisions 101 through 150.

435.3 Construction Requirements

435.3.01 Personnel

General Provisions 101 through 150.

435.3.02 Equipment

General Provisions 101 through 150.

435.3.03 Preparation

Prepare the surfaces for construction as follows: 1. Scarify the surface within the repair area using a concrete scabbler to remove unsound concrete and concrete laitance down to sound coarse aggregate. 2. After scarifying the surface, sandblast it to remove loose or unsound concrete or other contaminates. 3. Clean the prepared area with compressed air. 4. Completely coat the bottom and vertical side walls of the prepared area with a film of Type II epoxy approximately 10 to 20 mils (0.25 to 0.50 mm) thick.

435.3.04 Fabrication

General Provisions 101 through 150.

435.3.05 Construction

Repair the bridge joint end dams in the locations or areas indicated on the Plans or as designated by the Engineer. Remove asphaltic concrete from the end dams areas according to Figure 1 (Figure 1 metric). FIGURE 1 B.F.P.R. 1 ft W 1 f t Approach s lab Make saw cut f ull depth of overlay forver ti cal fac e, typ. PC C end dam Temporary joint filler (Recess 6 mm ± below fi nished gr ade) . Typ. end bent W 1 ft A sphalt overlay Surf aces to be coated with type II epoxy, TYP. S ee contract plans for Dimension “W” Typ. interm. bent S ilicone Sealant 1 ft W PCC end dam 1/ 2 inm in . Asphalt Overlay 1/2 inmin . 3/ 8 in min. 1/ 2 in min. 1/ 4 in radius, each side of opening Backer rod FIGURE 1 (METRIC) A. Weather Limitations Place rapid-setting cement concrete within the temperature range of 40 ºF to 100 ºF (4 ºC to 38 ºC). Do not apply epoxy bonding adhesive to a damp substrate. B. Mix Design Do not use aggregate that is larger than one-quarter the depth of the repair. C. General Instructions Handle, mix, place, and finish rapid-setting cement concrete according to the manufacturer’s instructions. Ensure that the finished rapid-setting cement concrete surface is the same elevation and cross slope as the adjacent pavement. B.F.P.R. 300 mm W 300 mm Approach slab Make saw cut f ull depth of overlay forver ti cal fac e, typ. PC C end dam Temporary joint filler (Recess 6 mm ± below fi nished gr ade) . Typ. end bent W 300 mm A sphalt overlay Surf aces to be coated with type II epoxy, TYP. Typ. interm. bent S ilicone Sealant 300 mm W PCC end dam 13 mmm in . 10 mm min . 13 mm min . 6 mm radius, each side of opening Backer rod D. Placement Place the rapid-setting cement concrete as follows: 1. Deposit it in the area while the epoxy is still tacky. 2. Vibrate it to completely fill the area of the end dam or patch. 3. Finish the concrete to the proper grade; do not disturb it until the water sheen disappears from the surface. E. Curing Cure the rapid-setting cement concrete according to Subsection 500.3.05.Z, Cure Concrete, and as follows: 1. Cure it long enough to develop the concrete strength in place as required in Subsection 435.3.05.G, Compressive Strength. 2. Use the compressive strength test procedures in Subsection 504.3.06.A, Compressive Strength Testing, except the Laboratory may reduce the number of test cylinders. F. Joint Reestablishment Reestablish the joint as follows: 1. Place temporary joint material that conforms to Subsection 833.2.10 in the joint so to place and screed the full width of the end dams or patches and to bridge the temporary joint material with the screeding apparatus. 2. If patching a joint, reestablish the joint opening to match the existing joint; if constructing an end dam, match the plan details. 3. Remove the temporary joint material. Sandblast the vertical faces of the joint opening to remove loose material and to produce a coarse texture conducive to bonding sealant. 4. Immediately after sandblasting, seal the opening according to Figure 1 (metric) and Subsection 461.3.05.C.2. G. Compressive Strength Do not allow traffic on end dams or patches until the rapid-setting cement concrete obtains a minimum compressive strength of 2,500 psi (15 MPa).

435.3.06 Quality Acceptance

A. Correction of Defects Remove and replace, at the Contractor’s expense, completed end dams or patches that contain cracks, are disbonded from asphalt or slab, or are damaged from construction or traffic before Final Acceptance. Replace, at the Contractor’s expense, silicone joint sealant that fails or that is not within the depth tolerances of Figure 1 (Figure 1metric).

435.3.07 Contractor Warranty and Maintenance

General Provisions 101 through 150.

435.4 Measurement

The area measured for payment is the rapid-setting cement concrete in cubic feet (meters) used in bridge joint end dams or patches completed in place and accepted.

435.4.01 Limits

General Provisions 101 through 150.

435.5 Payment

The joints measured will be paid for at the Contract Unit Price per cubic foot (meter) for bridge joint and end dams, and per cubic foot (meter) for patches. Payment is full compensation for: • Sawing as required • Removing the asphaltic concrete material or spalled, broken, or damaged Portland Cement Concrete • Cleaning the substrate by sandblasting or abrading and planning • Mixing, placing, finishing, and curing the concrete • Providing equipment, tools, and labor • Performing incidentals to complete the work, including sealing the joints Payment will be made under: Item No. 435 Rapid-setting cement concrete bridge joint end dams Per cubic foot (meter) Item No. 435 Rapid-setting cement concrete patching Portland cement concrete Per cubic foot (meter)

435.5.01 Adjustments

General Provisions 101 through 150.