for Highway Construction Page 380 of 715 SECTION 511 – CONCRETE WATERPROOFING SYSTEMS
511.01 Description.
Provide concrete waterproofing systems and install on bridge deck s or other designated surfaces.
A.System Types . Use one of the following system types :
1.Type C Penetrating Water System. Sealant that penetrates the bridge deck surface and forms a water -repellant layer within the co ncrete .
2.Type D Precoated, Preformed Membrane Sheet System. Prefabricated sheets that are self - adhesive or require a separate bonding agent.
3.Type E Spray -Applied Waterproofing System. Suitable for concrete or miscellaneous metal surfaces to prevent corrosion from soluble salts on the bridge deck and approach slabs that are to be overlaid with asphalt .
B.Qualifications.
1.Manufacturer Representative. Provide the services of a manufacturer' s representative authorized to observe the installation of each membrane system, including the asphalt concrete wearing course . The manufacturer's representative must be an employee of the membrane system manufacturer. Do not begin membrane work until the manufacturer's representative is onsite and authorizes the work to begin. Follow the manufacturer's written instructions when installing the spray membrane system, as provided in this specification. Instruct th e manufacturer's representative to alert the Contractor and the Engineer of anything that could affect the performance of the spray waterproofing membrane or the warranty. Submit a daily written report that has been prepared by the manufacturer's represe ntative and details all membrane- related activities, test results, observations, repairs , postspray survey results, tack coat timing issues, and contaminated tack repairs. Submit the daily written report by th e end of each day until the work is complete.
2.Applicator Qualifications. Provide a manufacturer -authorized applicator. Applicators must be re- certified annually by the manufacturer.
3.Submittals. Begin work no earlier than 1 week after the following items are approved:
a.The manufacturer must provide independent laboratory test illustrating each component’s accordance to the physical property requirements listed in Tables 511.02- 1, 511.02- 2, and
511.02 3. All testing must be current (i.e., conducted within the past 3 years).
b.The manufacturer’s safety data sheet (SDS) for each of the components.
c.The manufacturer’s current product data sheets and installation details for the product. Provide all membranes and primers f rom the same manufacturer.
d.Two sample coupons (3”x6”) that are representative of the finished membrane surface, texture, and color. Approved samples will serve as a basis for acceptance of the work for the duration of the contract . for Highway Construction Page 381 of 71 5 e. Service record showing that the membrane has a satisfactory record of at least 10 years, before the date of submission, for similar applications with names of specific structures and owner contact information.
f.List of projec ts similar in nature and complexity completed in the last 10 years.
511.02 Materials.
A.Precoated Preformed Membrane Sheet Type D.
1.Tapecoat M860.
2.Phillips Petrotac.
3.Polyguard nw -75.
4.PavePrep GeoTac.
B.Penetrating Water Repellent Type C System. Provide penetrating water repellent that is an emulsion, solution of silane, siloxane, or approved generic equivalent that when applied, does not stain, discolor, darken the concrete surface, or form a coating on concrete surfaces. Ensure the repellent material complies with the following minimum testing requirements:
1.Maximum Water Absorption.
a.Water immersion : ASTM C642.
b.Duration: 48 hours.
c.Maximum absorption: 1 per cent by weight.
2.Percent Reduction of Water Weight Gain.
a.Water immersion/(15% NaCl): NCHRP Rep. #244 Series II.
b.Duration: 21 Days.
c.Minimum percent reduction of water weight gain versus control: 75 percent.
3.Chloride Ion Penetration.
a.Test No. 1.
1.Chloride ion absorbed at 1 inch depth: NCHRP Rep. #244 Series II.
2.Duratio n: 21 days.
3.Minimum percent reduction based on untreated 75 percent.
b.Test No. 2
1.Chloride ion absorbed @ 1 inch depth: NCHRP Rep #244 Series IV.
2.Duration: 24 weeks.
3.Minimum percent reduction based on untreated: 90 percent.
4.Penetration Depth (Department Test): 5/32 inch minimum.
5.Alberta Transportation Waterproofing Test BT001. for Highway Construction Page 382 of 71 5 a. Waterproofing before sandblast: 82.5 percent minimum.
b.Waterproofing after sandblast: 75.0 percent minimum. Use an independent testing laboratory for tests 2, 3, and 5 at no cost to the Department. Submit certified laboratory reports for tests 2, 3, and 5 at least 30 calendar days before intended product application. Submit a certificati on statement the sealer used has the same formulation as t he material previously tested by laboratory reports. Tests 1 and 4 are the Department’s responsibility and may be waived based on previous testing or product ac ceptance by other states. Project samples may be taken to verify the certification .
C.Spray -Applied Waterproofing System Type E System. The coating system must be a spray -applied, 100% solids, fast -cure, high- build polymer system. Primer is required. The membrane must pass ASTM C836- 00. ASTM C836 -00 must be conducted on the neat membrane and aggregated top coat.
1.Base Membrane. The thickness to be tested must be at least 80 mils or the minimum thicknes s required to pass ASTM C836- 00. The thickness used to pass the test must be the minimum thickness required for all field base membrane application.
2.Composite Base Membrane and Aggregated Top Coat. In addition to the base membrane, the complete composite base membrane and aggregated top coat system must be subjected to ASTM C836- 00. Use part “1” above to determine minimum thickness of the base membrane. The top coat material must be 30 to 40 mils with aggregate broadcast at a rate of 0.33 to 0.50 pounds per square foot to achieve a minimum 95 percent coverage rate.
3.Primer. Provide a multi -component, polymer primer that is fast -setting with the mater ial properties shown in Table 511.02- 1. Table 511.02- 1 – Multi -Component Primer Physical Property Test Method Valu e Gel Time — > 5 minutes Tack -Free Time, max @ 77°F — < 2.5 hours Mixing Ratio — In accordance with the manufacturer ’s written instructions Adhesion to Concrete ASTM D7234 > 150 psi
4.Spray -Applied Waterproofing Membrane (Base Coat). Provide a spray -applied base membrane that is solvent -less, fast -setting, and 100 percent solids coating formulated to be used for applications requiring a seamless, flexible, waterproof, abrasion, and impact resistant surface that may be applied on multiple substrates in low temperature and high humidity. The membrane must have the material properties specified in Table 511.02- 2. for Highway Construction Page 383 of 71 5 Toning pigments must be laminar silicates, titanium dioxide, and inorganic oxides only. There must be no settling or color variation. Tinting must occur at the factory at the time of manufacture and placement in containers, before initial shipment. Use of vegetable or marine oils, paraffin materials, stearates, or organic pigments in any part of coating fo rmulation is not allowed. Submit a 1- quart wet sample, a drawdown color sample, and spectrophotometer or colorimeter readings taken in accordance with ASTM D2244, for each batch and corresponding standard color card. Table 511.02-2 – Spray-Applied Waterproofing Membrane (Base Membrane) Physical Property Test Method Value Solids Content — 100% Gel Time — < 10 seconds Cure Time — < 30 seconds Tack -Free Time — < 30 minutes Shore Hardness ASTM D2 240 > 40D Water Vapor Transmission ASTM E96 < 0.94 perms (wet cup) Adhesion to Concrete ASTM D7234 > 150 psi Tensile Strength ASTM D638 > 2,000 psi Elongation at Break ASTM D638 > 150% Crack Bridging Ability (80 Mils Neat – 1/8” Openi ng @ -15° F, 10 c ycles) ASTM C836 Pass @ 10 cycles
5.Spray -Applied Waterproofing Membrane (Aggregated Top Coat): Provide a spray -applied top coat membrane that is 100 percent solids, rapid curing, and specially formulated to accept and hold broadcast aggregate with the material properties specified in Table 511.02- 3. Table 511.02- 3 – Spray -Applied Waterproofing Membrane (Aggregated Top Coat Membrane) Physical Property Test Method Value Solids Con tent — 100% Gel Time — > 30 seconds Tack -Free Time — > 5 minutes Open to Traffic — 1 Hour Shore Hardness ASTM D2240 > 40D Tensile Strength ASTM D638 > 2,000 psi Tear Strength (pli; Die C) ASTM D638 > 350 Elongation at Break ASTM D638 > 150% at break Crack Bridging Ability (80 Mils Neat + 40 Mils with Aggregate – 1/8” Opening @ -15° F, 10 cycles) ASTM C836 Pass @ 10 cycles for Highway Construction Page 384 of 71 5 6. Tack Coat .
a.Emulsified Tack Coat . Provide a tack coat that is a polymer modified emulsion that is a CRS 2P product.
b.Manufacturer -Recommended Tack Coat. Waterproofing manufacturer may recommend an alternative tack coat. If an alternative tack coat is recommended, waterpro ofing manufacturer must also provide test results from an independent AASHTO -accredited laboratory illustrating that the proposed tack coat provides adequate shear and tensile adhesion between the waterproofing membrane and asphalt overlay.
511.03 Construction R equirements.
A.Surface Preparation . For new construction, clean, dry, fully cure, and finish the concrete surface as specified in 502.03.I.3. Sandblast new concrete surfaces where penetrating water repellent is to be applied. The Contractor may clean the surface with a hydroblast unit using water with a minimum nozzle pressure of 7,000 psi as an alternative to sandblasting. For rehabilitation of a structure, ensure the concrete surface to receive the membrane application is without foreign materials, sharp concrete edges are corrected to the Engineer’s satisfaction, and repairs and patches are fully cured. Sandblast the entire surface and the sides of curbs for a height of 1 inch above the thickness of the overlay before application of the membrane.
B.System Application Requirements.
1.Type C Application of Penetrating Water Repellent System. Type C, penetrating water repellent consists of a sealant that penetrates the deck surface and forms a water repellent layer within the concrete . Uniformly apply the penetrating water repellent material over surfaces to receive this treatment. Apply the penetrating water repellent compound on a completely cleaned and sandblasted surface. Ensure concrete moisture is as recommended by the manufacturer of the water repellent material. Apply the repellent using equipment and application pressure recommended by the manufacturer. Treat bridge deck and horizontal surfaces using a spray bar system approved by the manufacturer. Apply and use the sealing penetrant in accordance with the manufacturer’s written instructions, except do not apply the material when ambient or surface temperature is below 40°F or above 100°F or when wind exceeds 15 mph. On surfaces exposed to foot or vehicle traffic, ensure the application rate is not lighter than that used to pass the Alberta sandblast test. On other surfaces, the Contractor may use the manufacturer’s normal recommended application rate.
2.Type D Application of Precoated Pre- formed Membrane Sheet System. Type D, precoated pre- formed membrane consists of prefabricated sheets that may be self -adhesive or may require a separate bonding agent. Apply precoated, pre- formed membrane sheets to the surface receiving the membrane. Ensure application, surface preparation, and if required, primer is in accordance with the manufacturer’s written instructions. Lap joints between sheets of the membrane at least 2 inches. Ensure the membrane sheet system does not have wrinkles. for Highway Construction Page 385 of 71 5 3. Type E Spray -Applied Waterproofing System. Type E, spray -applied waterproofing system suit able for concrete or miscellaneous metal surfaces to prevent corrosion from soluble salts on the bridge deck and approach slabs that are to be overlaid with asphalt . The manufacturer’s representative must be on the project site at all times and, upon consultation with the Engineer, may suspend any item of work that does not meet this specification. Resume work only after the manufacturer’s representative and the Engineer are satisfied that appropriate remedial action has been completed.
a.Quality Assurance .
1.Provide membranes, primers, and under coats from the approved manufacturer supplying the principal materials for the work.
2.Before commencing the installation, with Engineer’s approval, install a mutually agreed upon sample (“mock -up”) to show final color and texture. This mock -up will serve as a work standard for the final installation.
b.Material Delivery and Storage. Store sufficient quantities of materials at the proj ect site to perform the entire application before st arting the deck surface preparation . Deliver materials to the project site in the manufacturer’s original unopened containers bearing manufacturer’s name, product, color, and batch numbers. Include a SDS wit h each product shipment. Store materials in a clean, dry, weather -protected storage facility. Ensure the storage facility has a recording thermometer. Replace the materials at no cost to the Department if the temperature exceeds the range of 50°F to 120°F. Protect from damage, moisture, and direct sunlight. Do not store drums directly on the concrete substrate.
c.Surface Conditions and Preparation. Ensure the environmental and project site conditions are suitable for application and curing of the waterproofing system. Ensure the temperature of the surface meets the temperature required by the manufacturer for all components of the waterproofing system to properly cure. The surface temperature should be 5°F above the dew point temperature of the air and rising. Check dew point in accordance with ASTM E337 or by using an approved digital instrument. Inspect surfaces for contamination and other critical factors at the time of installation. Surfaces to receive the waterproofing system must be structurally sound and thoroughly dry. Do not proceed with installation until unsatisfactory conditions have been corrected. Shot blast surfaces in accordance with ASTM D4259 using self -contained, recirculating blast equipment. Clean surfaces must be free of any visible oil, grease, curing compounds, or other surface contaminants. If required, perform cleaning process in accordance with ASTM D4258. Remove all unsound concrete. Patch holes or spalled areas with Five Star Structural Concrete®, Rapid Set® DOT Mix, or as recommended by the waterproofing manufacturer. Clean and repair the entire concrete deck , approach slabs, and sides of curbs for a height of 2 inches above the finished asphalt grade line. for Highway Construction Page 386 of 71 5 d. Installation. The manufacturer’s representative must be on the project site at all times, and upon consultation with the Engineer, may suspend any item of work that does not meet this specification. Resume work only after the manufacturer’s representative and the Engineer are satisfied that appropriate remedial action has been taken. Concrete surfaces must be dry. Test surfaces to receive coating system using a concrete moisture meter. Moisture content of the concrete surface must be 5.0 percent or less. Spray, squeegee, brush, or roll primer at 130 to 200 square feet per gallon (or at the manufacturer’s written coverage rate) over surfaces to receive coating system. If an adequate chem ical bond between the primer and membrane systems cannot be achieved, small size aggregate may be lightly broadcasted onto the primer to promote interlayer adhesion in accordance with the manufacturer’s written instructions. Allow primer to become tack free before spraying base waterproofing membrane. Reapply primer if allowed to set for more than 24 hours. After becoming tack free, test primed surface using Elcometer adhesion testing in accordance with ASTM D4541. Minimum pull strength is 150 psi or failure in the concrete substrate. Apply the base membrane in accordance with the supplier’s instructions and detail drawings to a total thickness of at least 80 mils (20 square feet per gallon) or the thickness used to pass the ASTM C836 -00. Mechanical application equipment (MAE) that makes automated spray passes and is proven for use with plural c omponent deck membranes may be used. If used, MAE must:
1.Be capable of installing membrane in a monolithic single layer.
2.Be capable of containing overspray when applicable.
3.Be capable of installing at least a 4 foot -wide pass.
4.Install t he lap areas no greater than 75 percent of the diameter of the spray pattern.
5.Be capable of spraying 1,000 square feet an hour. Spray additional base coats to achieve the specified thickness. Retouch as required. Spray a second top coat membrane on top of the base coat at a thickness of 30 to 40 mils and immediately broadcast basalt aggregate at a rate of 0.33 to 0.50 pounds per square foot to achieve at least 95 percent coverage. Apply tack coat as directed by the manufacturer’s representative in accordance with the manufacturer’s written instructions. Place required asphalt overlay surfacing after membrane and tack coat have cured according to manufactur er’s written instructions. Deposit, spread, and roll asphalt material so the membrane is not damaged or compromised. Remove and dispose of waste materials, rubbish, and debris in accordance with local regulations. Clean adjacent surfaces of spillage or overspray, if any. Leave work area in a clean condition.
e.Field Quality Control. The fie ld quality control work will be completed by the waterproofing manufacturer’s onsite representative. The representative must record all readings and test results. for Highway Construction Page 387 of 71 5 Complet e a “quality control daily report” form and submit a copy to the Engineer. Record environmental conditions readings at least once every 4 hours, when ambient conditions significantly change, or immediately before the Contractor performs new tasks (e.g., before installing primer, before installing base membrane), whichever is m ore frequent. Perform dry film thickness tests of base membrane in accordance with SSPC -PA2 or SSPC PA9. Destructive or stroke- per-gallon methods are also suitable methods of thickness assurance on most projects, if approved by the Engineer.
1.If the onsite representative uses magnetic test equipment, testing must be performed in accordance with SSPC -PA2.
2.If onsite representative uses ultrasonic t est equipment, testing must be performed in accordance with SSPC -PA9.
3.Spray equipment is calibrated and tested to a stroke count per gallon of product sprayed. This is suitable for thickness assurance on most projects, if approved by the En gineer.
4.Ultrasonic testing is usually accurate to within 5 percent.
5.Repair destructive areas by respraying or filling with special 2- component gun grade material provided by manufacturer. Other system components may be tested for thickness using wet film or stroke per gallon methods. Perform tensile adhesion bond testing of the primer and base membrane in accordance with ASTM D4541. On concrete surfaces, the minimum adhesion value is 150 psi. For the concrete on metal surfaces, the minimum adhesion value is 300 psi. The manufacturer’s onsite representative will perform visual inspections throughout the installation process. Holidays or other defects in the waterproofing membrane must be marked and repaired. Maintain spray and other installation equipment in proper operating condition throughout the installation. Provide reserve equipment as required.
f.Manufacturer Quality Control. Spray two 12 inch by 12 inch samples of base membrane and top coat membranes, once at the beginning of the day and once at the e nd of the day. Record the time and date, product batch numbers, and equipment processing settings. Samples must be sent to the manufacturer’s laboratory or a third party laboratory for physical property testing . The physical properties of field samples must be in accordance with the material properties listed in Table 511.02- 2 and Table 511.0 2-3. The manufacturer must submit a physical properties report to the Engineer upon completion. The manufacturer must provide certificates of analysis (COA) and infrared spectroscopy scans of all materials used. The COAs must illustrate accordanc e of each batch of liquid material to known manufacturing standards.
g.Limitation of Operations . Obtain the Engineer’s approval before performing work. Unless otherwise approved, the following conditions govern work on each portion of a structure:
1.Ensure the environmental and project site conditions are suitable for application and curing of the waterproofing system. for Highway Construction Page 388 of 715 (2) Temperature of the surface should be at least 5°F above the dew point temperature of the air and rising. Check dew point in accordance with ASTM E337 or by using an approved digital instrument.
3.Inspect surfaces for contamination a nd other critical factors at time of installation. Surfaces to receive waterproofing system must be structurally sound and thoroughly dry. Do not proceed with application until unsatisfactory conditions have been corrected.
h.Repair Procedure. If cores are t aken to test the asphalt overlay and the membrane is damaged, the following repair procedure must be fol lowed:
1.Expose additional sound and well -bonded membrane up to a perimeter width of at least 3 inches beyond the periphery of the damaged area, removing contaminates.
a.If using a 4- inch hole saw to take the asphalt core, use at least a 10- inch hole saw to expand the area of exposed membrane.
b.If using a 6- inch hole saw to take the asphalt core, use a 12- inch hole saw to expand the area of exposed membrane.
c.When drilling a secondary core:
i.Measure the depth of the asphalt in at least 4 areas around the initial core. ii. Drill the secondary core ¼ inch less than the lowest reading.
d.Remove the asphalt between the primary and secondary core using hand tools, taking care not to damage the waterproofing membr ane. If using a chipping hammer, exercise extreme caution.
2.In the event the membrane becomes delaminated, the area must be cut back to s ound, well - bonded materials.
3.The surface of the exposed membrane must be cleaned of all loose dirt, dust, debris, contam inates, and/or other deleterious material that could interfere with the adhesion of the repair membrane.
4.Existing asphalt , tack coat , and other difficult to remove contaminates must be completely removed using dry abrasive blast equipment, hand tools, or power tools.
5.Any exposed substrate must be prepared in accordance with SSPC -SP13/NACE No. 6 for cementi tious substrates or SSPC -SP10 for steel substrates.
6.Wipe the exposed membrane with acetone using clean, lint -free rags. Allow acetone to flash off.
7.Wipe the exposed membrane with a single component cleaner and surface activator specifically designed to rea ctivate the surface of bridge deck membranes using clean, lint - free rags.
8.Apply a w aterproofing membrane patch coat or waterproofing membrane material in a continuous layer over the prepared substrate with at least a 2- inch overlap ont o the existing sound membrane. The final thickness of the repair material must be at least 80 mils. Allow to dry to the touch. for Highway Construction Page 389 of 71 5 (9) Apply an additional waterproofing membrane patch coat or waterproofing membrane top coat in a continuous layer over the newly installed membrane at a minimum thickness of 40 mils.
10.Immediately broadcast aggregate into the wet material to a final coverage rate of 85- 95 percent.
11.Ensure the repair material is only applied to the prepared substrate and existing prepared membrane. Do not apply any repair material to the inside face of the asphalt .
12.Clean out any excess aggregate, loosely adhered asphalt, dirt, dust, debris, or other deleterious material.
13.The asphalt may be repaired using asphalt or other Department -approved materials 1 hour after installation of the final coat.
14.Submit a repair procedure and proposed materials for approval before performing the work. All required repairs must b e performed by the waterproofing membrane installers.
C.Protection and Overlaying. Only use rubber -tired vehicles necessary for construction of overlays on the completed membrane system. Do not allow public traffic. The Contractor may place a thin dusting coat of portland cement by hand to prevent paver or truck tires from sticking to the membrane during overlay work. Uniformly place 1 to 2 inches of sand (See 703.02.B) over the membrane surface if a base aggregate or borrow course is to be placed on the waterproof membrane. Construct plant mix overlays as soon as practical after completing the membrane and as specified in 405, except the minimum plant mix temperature when compaction begins is 234°F. Roll using st eel-wheel rollers with no vibration. Use special compactors or rollers to achieve adequate compaction adjacent to curbs or deck drains.
511.04 Meth od of Measurement.
The Engineer will measure acceptabl y completed work by the square yard in place as determined from the plans and include horizontal and vertical surfaces. The Engineer will measure the placement of pavement overlay s under their respective contract pay items .
511.05 Basis of Payment .
The Department will pay for accepted quantities as follows: Pay Item Pay Unit Concrete Waterproof System ................................................................. SY The Department will pay for the placement of pavement overlay s under their respective contract pay items . for Highway Construction Page 390 of 71 5 SECTION 512 – GABION STRUCTURE
512.01 Description.
Construct gabion structure consisting of rock -filled wire gabion baskets. Gabion structure can be a concept design or a plan detailed design.
A.Concept Design. Submit a detailed design of the gabion structure based on the information provided in the concept design. Submit a design in accordance with the latest version, at the time of design, of the AASHTO LRFD Bridge Design Specifications that is signed and s ealed by an Idaho licensed professional engineer. Construct as specified in the design.
512.02 Materials.
Provide gabion materials as specified in 715. Provide riprap/erosion control geotextile as specified in 718.06. Provide granular borrow as specified in 205.02.B.
512.03 Construction Requirements.
A.Preparation of Foundation. Excavate the foundation materials for gabion structure to the lines and grades as specified. Where soft, yielding material is encountered, remove the material below the structure fo undation to a depth of at least 2 feet or as directed. Ensure the width of the excavation is at least 1 foot greater than the bottom width of the gabion structure. Backfill the excavated area below the structure bottom with granular borrow and compact in layers not to exceed 6 inches in uncompacted depth to form a uniform and stable foundation. Repair slipouts caused by the Contractor’s operations to the Engineer’s satisfaction and at no additional cost to the Department.
B.Assembly, Erection, and Filling Gabion Baskets . Submit a detailed, step- by-step construction procedure prepared by the gabion structure manufacturer for approval 15 calendar days before the construction begins. Do not start the gabion structure construction until the submitted procedure is approved in writing.
C.Backfilling the Gabion Structure . Backfill the area behind the gabion structure with granular borrow . Spread riprap/erosion control geotextile uniformly at the bottom and over the back of the gabion structure, if required. Overlap joining edges of the geotextile at least 1 foot and anchor in position with approved anchoring devices. Place the backfill material so the geotex tile does not tear, puncture, or shift. Place the granular borrow backfill material in layers and compact until a uniform density of at least 95 percent of the maximum density is attained as determined by AASHTO T 99 Method C. Do not exceed 1 foot thickness before compaction. Decrease this lift thickness, if necessary, to obtain the specified density.
Source: Idaho Standard Specifications for Highway Construction, 2023 Edition. Pages 416–425 of 768.