506.1 General Description
This work consists of making and placing expanded mortar composed of a special Portland cement concrete and an aluminum powder additive.
506.1.01 Definitions
General Provisions 101 through 150.
506.1.02 Related References
A. Standard Specifications Section 800—Coarse Aggregate Section 801—Fine Aggregate Section 830—Portland Cement Section 835—Aluminum Powder Section 880—Water B. Referenced Documents General Provisions 101 through 150.
506.1.03 Submittals
General Provisions 101 through 150.
506.2 Materials
All materials shall meet the requirements of the following Specifications: Material Section Portland Cement, Type I 830.2.01 Coarse Aggregate, Class A or B Stone, Size No. 89 800.2.01 Fine Aggregate, Size No. 10 801.2.02 Water 880.2.01 Aluminum Powder 835.2.01
506.2.01 Delivery, Storage, and Handling
General Provisions 101 through 150.
506.3 Construction Requirements
506.3.01 Personnel
General Provisions 101 through 150.
506.3.02 Equipment
General Provisions 101 through 150.
506.3.03 Preparation
A. Using Expanded Mortar for Shear Keys When using expanded mortar for shear keys on precast bridge decks, thoroughly clean and saturate the recesses in the precast decks with clean water before placing the mortar.
506.3.04 Fabrication
General Provisions 101 through 150.
506.3.05 Construction
Mix and use expanded mortar according to the following: A. Proportion Expanded Mortar Ensure that the expanded mortar consists of a fresh mixture of the composition given in the following table: Proportions for Expanded Mortar Pounds (kilograms) of Portland Cement Lbs(kgs) of Saturated Surface Dry Aggregate per Bag of Cement Maximum Water per Bag of Cement Quantity of Aluminum Powder Fine Coarse 94 (42.6) 140 (63.5) 140 (63.5) 6 gal (22.7 L) 1 level tsp. (5 mL) B. Mix Expanded Mortar Mix the materials as follows: 1. Mix the materials dry, either in a clean mixer or in a clean, tight box until a uniform mixture is produced. 2. Add enough water to produce the desired consistency, but do not add more water than specified in the Proportions for Expanded Mortar table in Subsection 506.3.05.A. C. Use Expanded Mortar Begin using the expanded mortar according to the temperature requirements in the following table: Temperature Required Action > 90 °F (> 32 °C) Use mortar within 15 minutes after mixing. 70 °F to 90 °F (21 °C to 32 °C) Use mortar within 30 minutes after mixing. 40 °F to 70 °F (4 °C to 21 °C) Use mortar within 30 minutes after mixing. * *Mortar may require additional aluminum powder to secure the required expansion. Additional amounts shall range from 0% at 70 °F (21 °C) to 100% at 40 °F (4 °C) in a straight-line proportion. D. Place Expanded Mortar Place the expanded mortar as follows: 1. Expanded Mortar for Shear Keys a. Completely fill the shear key with mortar. b. Rod the mortar into a dense, homogenous mass. c. Float the mortar off flush with the surface of the precast decks. d. Moist cure the mortar continuously for a minimum of three days. 2. Placement Restrictions Do not place the mortar until after the entire bridge has been erected and all units are in final alignment. Do not allow traffic on the bridge decks until 5 days after the expanded mortar is placed.
506.3.06 Quality Acceptance
General Provisions 101 through 150.
506.3.07 Contractor Warranty and Maintenance
General Provisions 101 through 150.
506.4 Measurement
Expanded mortar is not measured for separate payment.
506.4.01 Limits
General Provisions 101 through 150.
506.5 Payment
Expanded mortar will be paid for at the Contract Price for concrete of the same Class as the concrete the mortar comes in contact with, and the Contractor shall include the cost of expanded mortar in the Contract Price for such concrete.
506.5.01 Adjustments
General Provisions 101 through 150.
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