1020PORTLAND CEMENT CONCRETE

A rt. 1020.04 Portland Cement Concrete 820 temperature, flow, air content, dynamic cone penetration (DCP), and 28 day compressive strength by the Engineer. The Engineer reserves the right to require a 180 day compressive strength test. Verification of the mix design will include the trial batch test results, field observations (i.e. flowability and solid suspension), and other criteria as determined by the Engineer. The Contractor will be notified in writing of verification. Verification of a mix design by the Engineer shall in no manner be construed as acceptance of any CLSM produced. The Department will maintain a qualified product list.

1019.07Sampling and Testing. The sampling and testing of CLSM shall be

according to ITP 307, "Sampling and Testing of Controlled Low-Strength Material (CLSM)". The dynamic cone penetration test (DCP) shall be according to ITP 501, "Dynamic Cone Penetration (DCP)".

1020.01Description. This item shall consist of the materials, mix design,

production, testing, curing, low air temperature protection, and temperature control of concrete.

1020.02Materials. Materials shall be according to the following

Item Article/Section

102

0.03Equipment. Equipment shall be according to the following.

Item Article/Section

1020.04Concrete Classes and General Mix Design Criteria. The classes of

concrete shown in Table 1 identify the various mixtures by the general uses and mix design criteria. If the class of concrete for a specific item of construction is not specified, Class SI concrete shall be used. P ortland Cement Concrete Art. 1020.04 821 F or the minimum cement factor in Table 1, it shall apply to portland cement, portland-pozzolan cement, and portland blast-furnace slag cement, except when a particular cement is specified in the Table. The Contractor shall not assume that the minimum cement factor indicated in Table 1 will produce a mixture that will meet the specified strength. In addition, the Contractor shall not assume that the maximum finely divided mineral allowed in a mix design according to Article 1020.05(c) will produce a mixture that will meet the specified strength. The Contractor shall select a cement factor within the allowable range that will obtain the specified strength. The Contractor shall take into consideration materials selected, seasonal temperatures, and other factors which may require the Contractor to submit multiple mix designs. For a portland-pozzolan cement, portland blast-furnace slag cement, portland- limestone cement, or when replacing portland cement with finely divided minerals per Articles 1020.05(c) and 1020.05(d), the portland cement content in the mixture shall be a minimum of 400 lbs/cu yd (237 kg/cu m). When calculating the portland cement portion in the portland-pozzolan cement, portland blast-furnace slag cement, or portland-limestone cement the AASHTO M 240 tolerance may be ignored. Special classifications may be made for the purpose of including the concrete for a particular use or location as a separate pay item in the contract. The concrete used in such cases shall conform to this section. TABLE 1. CLASSES OF CONCRETE AND MIX DESIGN CRITERIA Class of Conc. Use Specification Section Reference Cement Factor cwt/cu yd (3) Water / Cement Ratio lb/lb S l u m p in. (4) Mix Design Compressive Strength (Flexural Strength) psi, minimum Air Content % Coarse Aggregate Gradations (14) Days Min. Max. 3 14 28 PV Pavement Base Course Base Course Widening Driveway Pavement Shoulders Shoulder Curb 420 or 421 353 354 423 483 662 5.65 (1) 6.05 (2) 7.05 0.32 - 0.42 2 - 4 (5) Ty III 3500 (650) 3500 (650) 5.0 - 8.0 (5) CA 5 & CA 7, CA 5 & CA 11, CA 7, CA 11, or CA 14 PP Pavement Patching Bridge Deck Patching (10) 442 3200 (600) Article 701.17(e)(3)b. CA 7, CA 11, CA 13, CA 14, or CA 16 PP-1 6.50 6.20 (Ty III) 7.50 7.20 (Ty III) 0.32 - 0.44 2 - 4 at 48 hours 4.0 - 8.0 PP-2 7.35 8.20 0.32 - 0.38 2 - 6 at 24 hours PP-3 7.35 (Ty III) (8) 7.35 (Ty III) (8) 0.32 - 0.35 2 - 4 at 16 hours PP-4 6.00 (9) 6.25 (9) 0.32 - 0.50 2 - 6 at 8 hours PP-5 6.75 (9) 6.75 (9) 0.32 - 0.40 2 - 8 at 4 hours RR Railroad Crossing 422 6.50 6.20 (Ty III) 7.50 7.20 (Ty III) 0.32 - 0.44 2 - 4 3500 (650) at 48 hours 4.0 - 7.0 CA 7, CA 11, or CA 14 BS Bridge Superstructure Bridge Approach Slab 503 6.05 7.05 0.32 - 0.44 2 - 4 (5) 4000 (675) 5.0 - 8.0 (5) CA 7, CA 11, or CA 14 (7) PC Various Precast Concrete Items Wet Cast Dry Cast 1042 5.65 5.65 (TY III) 7.05 7.05 (TY III) 0.32 - 0.44 0.25 - 0.40 1 - 4 0 - 1 See Section 1042 5.0 - 8.0 N/A CA 7, CA 11, CA 13, CA 14, CA 16, or CA 7 & CA 16 PS Precast Prestressed Members 504 5.65 5.65 (TY III) 7.05 7.05 (TY III) 0.32 - 0.44 1 - 4 Plans 5.0 - 8.0 CA 11 (11), CA 13, CA 14 (11), or CA 16 Precast Prestressed Piles and Extensions 512 5000 Precast Prestressed Sight Screen 639 3500 Art. 1020.04 Portland Cement Concrete 822

TABLE 1. CLASSES OF CONCRETE AND MIX DESIGN CRITERIA Class of Conc. Use Specification Section Reference Cement Factor

cwt/cu yd (3) Water / Cement Ratio

lb/lb S l u m p

in. (4) Mix Design Compressive Strength (Flexural Strength)

psi, minimum Air Content

% Coarse Aggregate Gradations

Min. Max. 3 14 28 DS Drilled Shaft Metal Shell Piles (12) Sign Structures Drilled Shaft Light Tower Foundation (12) 516 512 734

837 6.65 7.05 0.32 - 0.44 6 - 8

CA 13, CA 14, CA 16, or a blend of these gradations. SC Seal Coat 503 5.65 (1) 6.05 (2) 7.05 0.32 - 0.44 3 - 5 3500

6.0 max. CA 3 & CA 7, CA 3 & CA 11, CA 5 & CA 7, CA 5 & CA 11, CA 7, or CA 11 SI Structures (except Superstructure) Sidewalk Slope Wall Encasement Retaining Walls Box Culverts End Section and Collar Curb, Gutter, Curb & Gutter, Median, and Paved Ditch Concrete Barrier Sign Structures Spread Footing Concrete Foundation Pole Foundation (12) Traffic Signal Foundation Drilled Shaft (12) Square or Rectangular 503 424 511 512 522 540 542

606 637 734

836 878

5.65 (1) 6.05 (2) 7.05 0.32 - 0.44 2 - 4

(5) CA 3 & CA 7, CA 3 & CA 11, CA 5 & CA 7, CA 5 & CA 11, CA 7, CA 11, CA 13, CA 14, or CA 16 (13) Portland Cement Concrete Art. 1020.04 823

Notes: (1) Central-mixed.

concrete, the cement factor shall be increased by ten percent.

admixture is used. For Class SC, the maximum slump may be increased to 8 in.. For Class PS, the maximum slump may be increased to 8 1/2 in. if the high range water-reducing admixture is the polycarboxylate type.

percent.

point of placement. If a water -reducing admixture is used in lieu of a high range water -reducing admixture according to Article 1020.05(b)(7), the slump shall be 2 - 4 in.

CA 16, except CA 11 may be used for full-depth patching.

of microsilica (silica fume) shall be used. For an air temperature greater than 85 ºF, the Type III portland cement may be replaced with Type I or II portland cement.

aluminate cement for PP-5.

CA 16, except C A 11 may be used for full -depth patching. In addition, the mix design shall have 72 hours to obtain a 4000 psi compressive or 675 psi flexural strength for all PP mix designs used in bridge deck patching.

retains any of the aggregate sample particles.

hour. At the Engineer’s discretion , the Contractor may be requi red to conduct a minimum 2 cu yd trial batch to verify the mix design.

between parallel reinforcement bars, or between the reinforcement bar and the form. Nominal maximum size is defined in Note 11.

Article 1004.02(d) for additional information on combining sizes. Art. 1020.04 Portland Cement Concrete 824

TABLE 1. CLASSES OF CONCRETE AND MIX DESIGN CRITERIA (metric) Class of Conc. Use Specification Section Reference Cement Factor

kg/cu m (3) Water / Cement Ratio

kg/kg S l u m p

mm (4) Mix Design Compressive Strength (Flexural Strength)

kPa, minimum Air Content

% Coarse Aggregate Gradations (14) Days Min. Max. 3 14 28 PV Pavement Base Course Base Course Widening Driveway Pavement Shoulders Shoulder Curb 420 or 421 353 354 423 483 662 335 (1) 360 (2) 418 0.32 - 0.42 50 - 100 (5) Ty III 24,000 (4500) 24,000

(5) CA 5 & CA 7, CA 5 & CA 11, CA 7, CA 11, or CA 14 PP Pavement Patching Bridge Deck Patching (10) 442 22,100 (4150) Article 701.17(e)(3)b.

CA 7, CA 11, CA 13, CA 14, or CA 16 PP-1 385 365 (Ty III) 445 425 (Ty III) 0.32 - 0.44 50 - 100 at 48 hours 4.0 - 8.0 PP-2 435 485 0..32 - 0.38 50 - 150 at 24 hours PP-3 435 (Ty III) (8) 435 (Ty III) (8) 0.32 - 0.35 50 - 100 at 16 hours PP-4 355 (9) 370 (9) 0.32 - 0.50 50 - 150 at 8 hours PP-5 400 (9) 400 (9) 0.32 - 0.40 50 - 200 at 4 hours RR Railroad Crossing 422 385 365 (Ty III) 445 425 (Ty III) 0.32 - 0.44 50 - 100 24,000 (4500) at 48 hours 4.0 - 7.0 CA 7, CA 11, or CA 14 BS Bridge Superstructure Bridge Approach Slab 503 360 418 0.32 - 0.44 50 - 100 (5) 27,500 (4650) 5.0 - 8.0 (5) CA 7, CA 11, or CA 14 (7) PC Various Precast Concrete Items Wet Cast Dry Cast 1042

335 335 (TY III)

418 418 (TY III)

0.32 - 0.44 0.25 - 0.40

25 - 100 0 - 25

See Section 1042

5.0 - 8.0 N/A CA 7, CA 11, CA 13, CA 14, CA 16, or CA 7 & CA 16 PS Precast Prestressed Members 504 335 335 (TY III) 418 418 (TY III) 0.32 - 0.44 25 - 100 Plans 5.0 - 8.0 CA 11 (11), CA 13, CA 14 (11), or CA 16 Precast Prestressed Piles and Extensions 512 34,500 Precast Prestressed Sight Screen 639 24,000 Portland Cement Concrete Art. 1020.04 825

TABLE 1. CLASSES OF CONCRETE AND MIX DESIGN CRITERIA (metric) Class of Conc. Use Specification Section Reference Cement Factor

kg/cu m (3) Water / Cement Ratio

kg/kg S l u m p

mm (4) Mix Design Compressive Strength (Flexural Strength)

kPa, minimum Air Content

% Coarse Aggregate Gradations

Min. Max. 3 14 28 DS Drilled Shaft Metal Shell Piles (12) Sign Structures Drilled Shaft Light Tower Foundation (12) 516 512 734

837 395 418 0.32 - 0.44 150 -200

CA 13, CA 14, CA 16, or a blend of these gradations. SC Seal Coat 503 335 (1) 360 (2) 418 0.32 - 0.44 75 - 125 24,000

6.0 max. CA 3 & CA 7, CA 3 & CA 11, CA 5 & CA 7, CA 5 & CA 11, CA 7, or CA 11 SI Structures (except Superstructure) Sidewalk Slope Wall Encasement Retaining Walls Box Culverts End Section and Collar Curb, Gutter, Curb & Gutter, Median, and Paved Ditch Concrete Barrier Sign Structures Spread Footing Concrete Foundation Pole Foundation (12) Traffic Signal Foundation Drilled Shaft (12) Square or Rectangular 503 424 511 512 522 540 542

606 637 734

836 878

335 (1) 360 (2) 418 0.32 - 0.44 50 - 100

(5) CA 3 & CA 7, CA 3 & CA 11, CA 5 & CA 7, CA 5 & CA 11, CA 7, CA 11, CA 13, CA 14, or CA 16 (13)

Art. 1020.04 Portland Cement Concrete 826

Notes: (1) Central-mixed.

concrete, the cement factor shall be increased by ten percent.

admixture is used. For Class SC, the maximum slump may be increased to 200 mm. For Class PS, the m aximum slump may be increased to 215 mm if the high range water-reducing admixture is the polycarboxylate type.

point of placement. If a water-reducing admixture is used in lieu of a high range water-reducing admixture according to Article 1020.05(b)(7), the slump shall be 50 – 100 mm.

CA 16, except CA 11 may be used for full-depth patching.

microsilica (silica fume) shall be used. For an air temperature greater than 30 ºC, the Type III portland cement may be replaced with Type I or II portland cement.

aluminate cement for PP-5.

CA 16, except CA 11 may be used fo r full-depth patching. In addition, the mix design shall have 72 hours to obtain a 27,500 kPa compressive or 4,650 kPa flexural for all PP mix designs used in bridge deck patching.

retains any of the aggregate sample particles.

the Engineer's discretion, the Contractor may be required to conduct a minimum 1.5 cu m trial batch to verify the mix design.

parallel reinforcement bars, or between the reinforcement bar and the form. Nomina l maximum size is defined in Note 11.

Article 1004.02(d) for additional information on combining sizes. Portland Cement Concrete Art. 1020.04 827 A rt. 1020.04 Portland Cement Concrete 828 Self-consolidating concrete is a flowable mixture that does not require mechanical vibration for consolidation. Self-consolidating concrete mix designs may be developed for Class BS, PC, PS, DS, and SI concrete. Self-consolidating concrete mix designs may also be developed for precast concrete products that are not subjected to Class PC concrete requirements according to Section 1042. The mix design criteria for the concrete mixture shall be according to Article 1020.04 with the following exceptions.

“Portland Cement Concrete Level III Technician Course – Manual of Instructions for Design of Concrete Mixtures” may be used to develop the uniformly graded mix design. The coarse aggregate gradations shall be CA 11, CA 13, CA 14, CA 16, or a blend of these gradations. However, the final gradation when using a single coarse aggregate or combination of coarse aggregates shall have 100 percent pass the 1 in. (25 mm) sieve, and minimum 95 percent pass the 3/4 in. (19 mm) sieve. The fine aggregate proportion shall be a maximum 50 percent by weight (mass) of the total aggregate used.

maximum and tested according to ITP SCC-2.

ITP SCC-2.

to ITP SCC-3. The L-Box blocking ratio shall be a minimum of 80 percent and tested according to ITP SCC-4. The Contractor has the option to select either test.

according to ITP SCC-6.

product according to Section 1042, the maximum cement factor shall be 7.05 cwt/cu yd (418 kg/cu m) and the maximum allowable water/cement ratio shall be 0.44.

blocking ratio fall outside the limits specified, a check test will be made. In the event of a second failure, the Engineer may refuse to permit the use of the batch of concrete represented. The Contractor may use water or self-consolidating admixtures at the jobsite to obtain the specified slump flow, visual stability index, J-ring value, or L-box blocking ratio. The maximum design water/cement ratio shall not be exceeded.

Portland Cement Concrete Art. 1020.05 829

1020.05Other Concrete Criteria. The concrete shall be according to the

following.

Contractor’s responsibility to determine mix design material proportions and to proportion each batch of concrete. A Level III PCC Technician shall develop the mix design for all Classes of concrete, except Classes PC and PS. The mix design, submittal information, trial batch, and Engineer verification shall be according to the “Portland Cement Concrete Level III Technician” course material.

For a mix design using a portland-pozzolan cement, portland blast-furnace slag cement, portland-limestone cement, or replacing portland cement with finely divided minerals per Articles 1020.05(c) and 1020.05(d), the Contractor may submit a mix design with a minimum portland cement content less than 400 lbs/cu yd (237 kg/cu m), but not less than 375 lbs/cu yd (222 kg/cu m), if the mix design is shown to have a minimum relative dynamic modulus of elasticity of 80 percent determined according to Illinois Modified AASHTO T 161. Testing shall be performed by an independent laboratory accredited by the AASHTO Materials Reference Laboratory (AMRL) for Portland Cement Concrete.

The Contractor shall provide the mix designs a minimum of 45 calendar days prior to production. More than one mix design may be submitted for each class of concrete.

The Engineer will verify the mix design submitted by the Contractor. Verification of a mix design shall in no manner be construed as acceptance of any mixture produced. Once a mix design has been verified, the Engineer shall be notified of any proposed changes.

Tests performed at the jobsite will determine if a mix design can meet specifications. If the tests indicate it cannot, the Contractor shall make adjustments to a mix design, or submit a new mix design if necessary, to comply with the specifications.

according to the qualified products list. The Contractor shall be responsible for using admixtures and determining dosages for all Classes of concrete, cement aggregate mixture II, and controlled low-strength material that will produce a mixture with suitable workability, consistency, and plasticity. In addition, admixture dosages shall result in the mixture meeting the specified plastic and hardened properties. The Contractor shall obtain approval from the Engineer to use an accelerator when the concrete temperature is greater than 60 °F (16 °C). However, this accelerator approval by the Engineer will not be required for Class PP, RR, PC, and PS concrete. The accelerator shall be the non-chloride type, unless otherwise specified in the contract plans.

Corrosion inhibitor dosage rates shall be according to Article 1020.05(b)(10). For information on approved controlled low-strength material air-entraining admixtures, refer to Article 1019.02. An admixture technical representative

Art. 1020.05 Portland Cement Concrete 830 shall be consulted by the Contractor prior to the pour when determining an admixture dosage or when making minor admixture dosage adjustments at the jobsite. The dosage shall be within the range indicated on the qualified product list, unless the influence by other admixtures, jobsite conditions (such as a very short haul time), or other circumstances warrant a dosage outside the range. The Engineer shall be notified when a dosage is proposed outside the range. To determine an admixture dosage, air temperature, concrete temperature, cement source and quantity, finely divided mineral sources and quantity, influence of other admixtures, haul time, placement conditions, and other factors as appropriate shall be considered. The Engineer may request the Contractor to have a batch of concrete mixed in the lab or field to verify the admixture dosage is correct. An admixture dosage or combination of admixture dosages shall not delay the initial set of concrete by more than one hour. When a retarding admixture is required or appropriate for a bridge deck or bridge deck overlay pour, the initial set time shall be delayed until the deflections due to the concrete dead load are no longer a concern for inducing cracks in the completed work. However, a retarding admixture shall not be used to further extend the pour time and justify the alteration of a bridge deck pour sequence.

When determining water in admixtures for water/cement ratio, the Contractor shall calculate 70 percent of the admixture dosage as water, except a value of 50 percent shall be used for a latex admixture used in bridge deck latex concrete overlays.

The sequence, method, and equipment for adding the admixtures shall be approved by the Engineer. Admixtures shall be added to the concrete separately. An accelerator shall always be added prior to a high range water-reducing admixture, if both are used.

Admixture use shall be according to the following.

higher, a retarding admixture shall be used in the Class BS concrete and concrete bridge deck overlays. The proportions of the ingredients of the concrete shall be the same as without the retarding admixture, except that the amount of mixing water shall be reduced, as may be necessary, in order to maintain the consistency of the concrete as required. In addition, a high range water-reducing admixture shall be used in bridge deck concrete. At the option of the Contractor, a water- reducing admixture may be used with the high range water-reducing admixture in Class BS concrete.

admixture may be used for Class PP-1 or RR concrete. When the air temperature is less than 55 °F (13 °C) and an accelerator is used, the non-chloride accelerator shall be calcium nitrite.

Class PP-1 or RR concrete, a water-reducing or high range water- reducing admixture shall be used.

Portland Cement Concrete Art. 1020.05 831

by a high range water-reducing admixture shall be used, in addition to the air-entraining admixture. The Contractor has the option to use a water-reducing admixture with the high range water-reducing admixture. For Class PP-3 concrete, the non-chloride accelerator shall be calcium nitrite. For Class PP-2 concrete, the non-chloride accelerator shall be calcium nitrite when the air temperature is less than 55 °F (13 °C).

be used in addition to the air-entraining admixture. The Contractor has the option to use a water-reducing admixture with the high range water- reducing admixture. An accelerator shall not be used. A mobile portland cement concrete plant shall be used to produce the patching mixture.

For PP-5 concrete, a non-chloride accelerator, high range water- reducing admixture, and air-entraining admixture shall be used. The accelerator, high range water-reducing admixture, and air-entraining admixture shall be per the Contractor’s recommendation and dosage. The qualified product list of concrete admixtures shall not apply. A mobile portland cement concrete plant shall be used to produce the patching mixture.

maximum chloride dosage shall be 1.0 quart (1.0 L) of solution per 100 lb (45 kg) of cement. The dosage may be increased to a maximum 2.0 quarts (2.0 L) per 100 lb (45 kg) of cement if approved by the Engineer. When a calcium chloride accelerator for Class PP-2 concrete is specified in the contract, the maximum chloride dosage shall be 1.3 quarts (1.3 L) of solution per 100 lb (45 kg) of cement. The dosage may be increased to a maximum 2.6 quarts (2.6 L) per 100 lb (45 kg) of cement if approved by the Engineer.

reducing admixture shall be used. For dry excavations that are 10 ft (3 m) or less, the high range water-reducing admixture may be replaced with a water-reducing admixture if the concrete is vibrated.

range water-reducing admixture is used for Class PV, PP-1, RR, SC, and SI concrete, the cement factor may be reduced a maximum 0.30 hundredweight/cu yd (18 kg/cu m). However, a cement factor reduction will not be allowed for concrete placed underwater.

used, the initial slump shall be a minimum of 1 1/2 in. (38 mm) prior to addition of the Type F or Type G admixture, except as approved by the Engineer.

mixture utilized in the manufacture of precast, prestressed concrete

Art. 1020.05 Portland Cement Concrete 832 members and/or other applications. It shall be added, at the same rate, to all grout around post-tensioning steel when specified.

When calcium nitrite is used, it shall be added at the rate of 4 gal/cu yd (20 L/cu m), and shall be added to the mix immediately after all compatible admixtures have been introduced to the batch.

When MASTERLIFE CI 222 is used, it shall be added at the rate of 1.0 gal/cu yd (5.0 L/cu m), and the batching sequence shall be according to the manufacturer's specifications.

the following.

partially replace portland cement in cement aggregate mixture II, Class PV, PP-1, PP-2, RR, BS, PC, PS, DS, SC, and SI concrete.

The use of fly ash shall be according to the following.

to the nearest 5 lb (2.5 kg).

Class PV, BS, PC, PS, DS, SC, and SI concrete, the amount of portland cement replaced shall not exceed 25 percent by weight (mass).

Class PV, PP-1, PP-2, RR, BS, PC, PS, DS, SC, and SI concrete, the amount of portland cement replaced shall not exceed 30 percent by weight (mass).

is below 40 °F (4 °C), but the Engineer may request a trial batch of the concrete mixture to show the mix design strength requirement will be met.

option, GGBF slag may partially replace portland cement in Class PV, PP-1, PP-2, RR, BS, PC, PS, DS, SC, and SI concrete. For Class PP-3 concrete, GGBF slag shall be used according to Article 1020.04.

The use of GGBF slag shall be according to the following.

rounded up to the nearest 5 lb (2.5 kg).

PS, DS, SC and SI concrete, the amount of portland cement replaced shall not exceed 35 percent by weight (mass).

Portland Cement Concrete Art. 1020.05 833

temperature is below 40 °F (4 °C), but the Engineer may request a trial batch of the concrete mixture to show the mix design strength requirement will be met.

maximum of 5.0 percent by weight (mass) of the cement and finely divided minerals summed together.

Microsilica shall be used in Class PP-3 concrete according to Article 1020.04.

may be added at a maximum of 5.0 percent by weight (mass) of the cement and finely divided minerals summed together.

Class PP-3 concrete, the Contractor has the option to use more than one finely divided mineral in Class PV, PP-1, PP-2, RR, BS, PC, PS, DS, SC, and SI concrete as follows.

The finely divided mineral in portland-pozzolan cement or portland blast-furnace slag cement shall count toward the total number of finely divided minerals allowed. The finely divided minerals shall constitute a maximum of 35.0 percent of the total cement plus finely divided minerals. The fly ash portion shall not exceed 30.0 percent for Class C fly ash or 25.0 percent for Class F fly ash. The Class C and F fly ash combination shall not exceed 30.0 percent. The ground granulated blast-furnace slag portion shall not exceed 35.0 percent. The microsilica or high reactivity metakaolin portion used together or separately shall not exceed ten percent. The finely divided mineral in the portland-pozzolan cement or portland blast-furnace slag cement shall apply to the maximum 35.0 percent.

shall contain a minimum of 565 lbs/cu yd (335 kg/cu m) of cement and finely divided minerals summed together. If a water-reducing or high range water-reducing admixture is used, the Contractor has the option to use a minimum of 535 lbs/cu yd (320 kg/cu m).

the mixture shall contain a minimum of 605 lbs/cu yd (360 kg/cu m) of cement and finely divided minerals summed together. If a water- reducing or high range water-reducing admixture is used, the Contractor has the option to use a minimum of 575 lbs/cu yd (345 kg/cu m).

RR concrete, the mixture shall contain a minimum of 650 lbs/cu yd (385 kg/cu m) of cement and finely divided minerals summed

Art. 1020.05 Portland Cement Concrete 834 together. For Class PP-1 and RR concrete using Type III portland cement, the mixture shall contain a minimum of 620 lbs/cu yd (365 kg/cu m).

For Class PP-2 concrete, the mixture shall contain a minimum of 735 lbs/cu yd (435 kg/cu m) of cement and finely divided minerals summed together. For Class BS concrete, the mixture shall contain a minimum of 605 lbs/cu yd (360 kg/cu m). For Class DS concrete, the mixture shall contain a minimum of 665 lbs/cu yd (395 kg/cu m).

If a water-reducing or high range water-reducing admixture is used in Class PP-1 and RR concrete, the Contractor has the option to use a minimum of 620 lbs/cu yd (365 kg/cu m) of cement and finely divided minerals summed together. If a water-reducing or high range water-reducing admixture is used with Type III portland cement in Class PP-1 and RR concrete, the Contractor has the option to use a minimum of 590 lbs/cu yd (350 kg/cu m).

mixture shall contain a minimum of 565 lbs/cu yd (335 kg/cu m) of cement and finely divided minerals summed together.

(418 kg/cu m) of cement and finely divided mineral(s) summed together for Class PV, BS, PC, PS, DS, SC, and SI concrete. For Class PP-1 and RR concrete, the mixture shall contain a maximum of 750 lbs/cu yd (445 kg/cu m). For Class PP-1 and RR concrete using Type III portland cement, the mixture shall contain a maximum of 720 lbs/cu yd (425 kg/cu m). For Class PP-2 concrete, the mixture shall contain a maximum of 820 lbs/cu yd (485 kg/cu m).

be placed underwater, except Class DS concrete, the allowable cement and finely divided minerals summed together shall be increased by ten percent.

with Article 1020.05(d).

mixture II with portland cement content greater than 300 lbs/cu yd (178 kg/cu m) and latex mixtures), precast, and precast prestressed concrete, one of the mixture options provided in Article 1020.05(d)(2) shall be used to reduce the risk of a deleterious alkali-silica reaction in concrete exposed to humid or wet conditions. The mixture options are not intended or adequate for concrete exposed to potassium acetate, potassium formate, sodium acetate, or sodium formate. The mixture options will not be required for the dry environment (humidity less than 60 percent) found inside buildings for residential or commercial occupancy.

Portland Cement Concrete Art. 1020.05 835 The mixture options shall not apply to concrete revetment mats, insertion lining of pipe culverts, portland cement mortar fairing course, controlled low- strength material, miscellaneous grouts that are not prepackaged, Class PP-3 concrete, Class PP-4 concrete, and Class PP-5 concrete.

will be assigned to an aggregate group. The point at which the coarse aggregate and fine aggregate expansion values intersect in the following table will determine the group.

Aggregate Groups Coarse Aggregate or Coarse Aggregate Blend

ASTM C 1260 Expansion Fine Aggregate Or Fine Aggregate Blend

ASTM C 1260 Expansion

≤0.16%

>0.16% - 0.27%

>0.27% ≤0.16% Group I Group II Group III >0.16% - 0.27% Group II Group II Group III >0.27% Group III Group III Group IV

mixture options shall be used. However, the Department may prohibit a mixture option if field performance shows a deleterious alkali-silica reaction or Department testing indicates the mixture may experience a deleterious alkali-silica reaction.

Reduction of Risk for Deleterious Alkali-Silica Reaction Aggregate Groups Mixture Options Option 1 Option 2 Option 3 Option 4 Option 5

Group I

Mixture options are not applicable. Use any cement or finely divided mineral.

Group II

X

X

X

X

X

Group III

X Combine Option 2 with Option 3 Combine Option 2 with Option 3

X

X

Group IV

X Combine Option 2 with Option 4

Invalid Option Combine Option 2 with Option 4

X “X” denotes valid mixture option for aggregate group.

to place the material in a group that will allow the selected cement

Art. 1020.05 Portland Cement Concrete 836 or finely divided mineral to be used. Coarse aggregate may only be blended with another coarse aggregate. Fine aggregate may only be blended with another fine aggregate. Blending of coarse with fine aggregate to place the material in another group will not be permitted.

When a coarse or fine aggregate is blended, the weighted expansion value shall be calculated separately for the coarse and fine aggregate as follows:

Weighted Expansion Value = (a/100 x A) + (b/100 x B) + (c/100 x C) + …

Where: a, b, c… = percentage of aggregate in the blend; A, B, C… = expansion value for that aggregate.

described in 1., 2., 3., or 4. that follow. In addition, for 1., 2., or 3., a combination of fly ashes or fly ash and ground granulated blast- furnace slab according to Article 1020.05(c)(5) may be used, except the minimum combined percentage shall be 25 percent by weight (mass) of the cement and finely divided minerals summed together. Article 1020.05(c)(5) also applies to 4., except the percentage of microsilica solids or high reactivity metakaolin shall not be reduced below the minimum specified in 4..

BS, PC, PS, DS, SC, and SI concrete, the Class F fly ash shall be a minimum of 25.0 percent by weight (mass) of the cement and finely divided minerals summed together.

If the maximum total equivalent available alkali content (Na 2O + 0.658K 2O) exceeds 4.50 percent for the Class F fly ash, it may be used only if it complies with Mixture Option 5.

PP-1, PP-2, RR, BS, PC, PS, DS, SC, and SI concrete, Class C fly ash shall be a minimum of 25.0 percent by weight

together.

If the maximum total equivalent available alkali content (Na 2O + 0.658K 2O) exceeds 4.50 percent or the calcium oxide exceeds 26.50 percent for the Class C fly ash, it may be used only per Mixture Option 5.

PP-2, RR, BS, PC, PS, DS, SC, and SI concrete, ground granulated blast-furnace slag shall be a minimum of 25.0 percent by weight (mass) of the cement and finely divided minerals summed together.

Portland Cement Concrete Art. 1020.05 837 If the maximum total equivalent available alkali content (Na 2O + 0.658K 2O) exceeds 1.00 percent for the ground granulated blast-furnace slag, it may be used only per Mixture Option 5.

high reactivity metakaolin shall be a minimum 5.0 percent by weight (mass) of the cement and finely divided minerals summed together.

If the maximum total equivalent available alkali content (Na 2O + 0.658K 2O) exceeds 1.00 percent for the microsilica or high reactivity metakaolin, it may be used only if it complies with Mixture Option 5.

equivalent alkali content (Na2O + 0.658K2O) of 0.60 percent. When aggregate in Group II is involved and the Contractor desires to use a finely divided mineral, any finely divided mineral may be used with the cement unless the maximum total equivalent available alkali content (Na 2O + 0.658K 2O) exceeds 4.50 percent for the fly ash; or 1.00 percent for the ground granulated blast-furnace slag, microsilica, or high reactivity metakaolin. If the alkali content is exceeded, the finely divided mineral may be used only per Mixture Option 5.

equivalent alkali content (Na2O + 0.658K2O) of 0.45 percent. When aggregate in Group II or III is involved and the Contractor desires to use a finely divided mineral, any finely divided mineral may be used with the cement unless the maximum total equivalent available alkali content (Na 2O + 0.658K 2O) exceeds 4.50 percent for the fly ash; or 1.00 percent for the ground granulated blast-furnace slag, microsilica, or high reactivity metakaolin. If the alkali content is exceeded, the finely divided mineral may be used only per Mixture Option 5.

may be used if the ASTM C 1567 expansion value is ≤ 0.16 percent when performed on the aggregate in the concrete mixture with the highest ASTM C 1260 test result. The laboratory performing the ASTM C 1567 test shall be approved by the Department according to the Bureau of Materials Policy Memorandum “Minimum Laboratory Requirements for Alkali-Silica Reactivity (ASR) Testing”. The ASTM C 1567 test will be valid for two years, unless the Engineer determines the materials have changed significantly.

For latex concrete, the ASTM C 1567 test shall be performed without the latex.

The 0.20 percent autoclave expansion limit in ASTM C 1567 shall not apply.

Art. 1020.05 Portland Cement Concrete 838 If during the two year time period the Contractor needs to replace the cement, and the replacement cement has an equal or lower total equivalent alkali content (Na 2O + 0.658K 2O), a new ASTM C 1567 test will not be required.

The Engineer reserves the right to verify a Contractor’s ASTM C 1567 test result. When the Contractor performs the test, a split sample may be requested by the Engineer. The Engineer may also independently obtain a sample at any time. The proposed cement or finely divided mineral will not be allowed for use if the Contractor or Engineer obtains an expansion value greater than 0.16 percent.

1020.06Water/Cement Ratio. The water/cement ratio shall be determined on

a weight (mass) basis. When a maximum water/cement ratio is specified, the water shall include mixing water, water in admixtures, free moisture on the aggregates, and water added at the jobsite. The quantity of water may be adjusted within the limit specified to meet slump requirements.

When fly ash, ground granulated blast-furnace slag, high reactivity metakaolin, or microsilica (silica fume) are used in a concrete mix, the water/cement ratio will be based on the total cement and finely divided minerals contained in the mixture.

1020.07Slump. The slump shall be determined according to Illinois Modified

AASHTO T 119.

If the measured slump falls outside the limits specified, a check test will be made. In the event of a second failure, the Engineer may refuse to permit the use of the batch of concrete represented.

If the Contractor is unable to add water to prepare concrete of the specified slump without exceeding the maximum design water/cement ratio, a water-reducing admixture shall be added.

1020.08Air Content. The air content shall be determined according to Illinois

Modified AASHTO T 152 or Illinois Modified AASHTO T 196. The air-entrainment shall be obtained by the use of cement with an approved air entraining admixture added during the mixing of the concrete or the use of air-entraining cement.

If the air-entraining cement furnished is found to produce concrete having air content outside the limits specified, its use shall be discontinued immediately and the Contractor shall provide other air-entraining cement which will produce air contents within the specified limits.

If the air content obtained is above the specified maximum limit at the jobsite, the Contractor may have the concrete further mixed, within the limits of time and revolutions specified, to reduce the air content. If the air content obtained is below the specified minimum limit, the Contractor may add to the concrete a sufficient quantity of an approved air-entraining admixture at the jobsite to bring the air content within the specified limits.

Portland Cement Concrete Art. 1020.11 839

1020.09Strength Tests. The specimens shall be molded and cured according

to Illinois Modified AASHTO T 23. Specimens shall be field cured with the construction item as specified in Illinois Modified AASHTO T 23. The compressive strength shall be determined according to Illinois Modified AASHTO T 22. The flexural strength shall be determined according to Illinois Modified AASHTO T 177.

Except for Class PC and PS concrete, the Contractor shall transport the strength specimens from the site of the work to the field laboratory or other location as instructed by the Engineer. During transportation in a suitable light truck, the specimens shall be embedded in straw, burlap, or other acceptable material in a manner meeting with the approval of the Engineer to protect them from damage; care shall be taken to avoid impacts during hauling and handling. For strength specimens, the Contractor shall provide a field curing box for initial curing and a water storage tank for final curing. The field curing box will be required when an air temperature below 60 °F (16 °C) is expected during the initial curing period. The device shall maintain the initial curing temperature range specified in Illinois Modified AASHTO T 23, and may be insulated or power operated as appropriate.

1020.10Handling, Measuring, and Batching Materials. Aggregates shall be

handled in a manner to prevent mixing with soil and other foreign material.

Aggregates shall be handled in a manner which produces a uniform gradation before placement in the plant bins. Aggregates delivered to the plant in a nonuniform gradation condition shall be stockpiled. The stockpiled aggregate shall be mixed uniformly before placement in the plant bins.

Aggregates shall have a uniform moisture content before placement in the plant bins. This may require aggregates to be stockpiled for 12 hours or more to allow drainage, or water added to the stockpile, or other methods approved by the Engineer. Moisture content requirements for crushed concrete, crushed slag, or lightweight aggregate shall be according to Article 1004.01(e)(5).

Aggregates, cement, and finely divided minerals shall be measured by weight (mass). Water and admixtures shall be measured by volume or weight (mass).

The Engineer may permit aggregates, cement, and finely divided minerals to be measured by volume for small isolated structures and for miscellaneous items. Aggregates, cement, and finely divided minerals shall be measured individually. The volume shall be based upon dry, loose materials.

1020.11Mixing Portland Cement Concrete. The mixing of concrete shall be

according to the following.

mixed, or shrink-mixed concrete transported and delivered in a plastic state ready for placement in the work and shall be according to the following.

been completely mixed in a stationary mixer and delivered in a truck agitator, a truck mixer operating at agitating speed, or a nonagitator truck.

Art. 1020.11 Portland Cement Concrete 840 The stationary mixer shall operate at the drum speed for which it was designed. The batch shall be charged into the drum so that some of the water shall enter in advance of the cement, finely divided minerals, and aggregates. The flow of the water shall be uniform and all water shall be in the drum by the end of the first 15 seconds of the mixing period. Water shall begin to enter the drum from zero to two seconds in advance of solid material and shall stop flowing within two seconds of the beginning of mixing time.

Some coarse aggregate shall enter in advance of other solid materials. For the balance of the charging time for solid materials, the aggregates, finely divided minerals, and cement (to ensure thorough blending) shall each flow at acceptably uniform rates, as determined by visual observation. Coarse aggregate shall enter two seconds in advance of other solid materials and a uniform rate of flow shall continue to within two seconds of the completion of charging time.

The entire contents of the drum, or of each single compartment of a multiple-drum mixer, shall be discharged before the succeeding batch is introduced.

The volume of concrete mixed per batch shall not exceed the mixer's rated capacity, as shown on the standard rating plate on the mixer, by more than ten percent.

The minimum mixing time shall be 75 seconds for a stationary mixer having a capacity greater than 2 cu yd (1.5 cu m). For a mixer with a capacity equal to or less than 2 cu yd (1.5 cu m) the mixing time shall be 60 seconds. Transfer time in multiple drum mixers is included in the mixing time. Mixing time shall begin when all materials are in the mixing compartment and shall end when the discharge of any part of the batch is started. The required mixing times will be established by the Engineer for all types of stationary mixers.

When central-mixed concrete is to be transported in a truck agitator or a truck mixer, the stationary-mixed batch shall be transferred to the agitating unit without delay and without loss of any portion of the batch. Agitating shall start immediately thereafter and shall continue without interruption until the batch is discharged from the agitator. The ingredients of the batch shall be completely discharged from the agitator before the succeeding batch is introduced. Drums and auxiliary parts of the equipment shall be kept free from accumulations of materials.

The vehicles used for transporting the mixed concrete shall be of such capacity, or the batches shall be so proportioned, that the entire contents of the mixer drum can be discharged into each vehicle load.

delivered in a truck mixer. When the mixer is charged with fine and coarse aggregates simultaneously, not less than 60 nor more than 100 revolutions of the drum or blades at mixing speed shall be required, after all of the ingredients including water are in the drum. When fine

Portland Cement Concrete Art. 1020.11 841 and coarse aggregates are charged separately, not less than 70 revolutions will be required. For self-consolidating concrete, a minimum of 100 revolutions is required in all cases. Additional mixing beyond 100 revolutions shall be at agitating speed unless additions of water, admixtures, or other materials are made at the jobsite. The mixing operation shall begin immediately after the cement and water, or the cement and wet aggregates, come in contact. The ingredients of the batch shall be completely discharged from the drum before the succeeding batch is introduced. The drum and auxiliary parts of the equipment shall be kept free from accumulations of materials. If additional water or an admixture is added at the jobsite, the concrete batch shall be mixed a minimum of 40 additional revolutions after each addition.

stationary mixer and completed in a truck mixer for delivery. The mixing time of the stationary mixer may be reduced to a minimum of 30 seconds to intermingle the ingredients, before transferring to the truck mixer. All ingredients for the batch shall be in the stationary mixer and partially mixed before any of the mixture is discharged into the truck mixer. The partially mixed batch shall be transferred to the truck mixer without delay and without loss of any portion of the batch, and mixing in the truck mixer shall start immediately. The mixing time in the truck mixer shall be not less than 50 nor more than 100 revolutions of the drum or blades at mixing speed. For self-consolidating concrete, a minimum of 100 revolutions is required in the truck mixer. Additional mixing beyond 100 revolutions shall be at agitating speed, unless additions of water, admixtures, or other materials are made at the jobsite. Units designed as agitators shall not be used for shrink mixing. The ingredients of the batch shall be completely discharged from the drum before the succeeding batch is introduced. The drum and auxiliary parts of the equipment shall be kept free from accumulations of materials. If additional water or an admixture is added at the jobsite, the concrete batch shall be mixed a minimum of 40 additional revolutions after each addition.

drum or container before a batch is introduced. All mixing water shall be added at the plant and any adjustment of water at the jobsite by the Contractor shall not exceed the specified maximum water/cement ratio or slump. If strength specimens have been made for a batch of concrete, and subsequently during discharge there is more water added, additional strength specimens shall be made for the batch of concrete. No additional water may be added at the jobsite to central- mixed concrete if the mix design has less than 565 lbs/cu yd (335 kg/cu m) of cement and finely divided minerals summed together.

truck mixers or truck agitators shall be per the manufacturer’s rating plate.

Art. 1020.11 Portland Cement Concrete 842

determined according to AASHTO T 121, based on the total weight

materials, including water, entering the batch or directly from the net weight (mass) of the concrete in the batch as delivered.

The volume of mixed concrete in truck mixers or truck agitators shall in no case be greater than the rated capacity determined according to the Truck Mixer, Agitator, and Front Discharge Concrete Carrier Standards of the Truck Mixer Manufacturer's Bureau, as shown by the rating plate attached to the truck. If the truck mixer does not have a rating plate, the volume of mixed concrete shall not exceed 63 percent of the gross volume of the drum or container, disregarding the blades. For truck agitators, the value is 80 percent.

The delivery ticket shall be stamped no later than five minutes after the addition of the mixing water to the cement, or after the addition of the cement to the aggregate when the combined aggregates contain free moisture in excess of two percent by weight (mass). If more than one batch is required for charging a truck using a stationary mixer, the time of haul shall start with mixing of the first batch. Haul time shall end when the truck is emptied for incorporation of the concrete into the work.

The time elapsing from when water is added to the mix until it is deposited in place at the site of the work shall not exceed 30 minutes when the concrete is transported in nonagitating trucks.

The maximum haul time for concrete transported in truck mixers or truck agitators shall be according to the following.

Concrete Temperature at Point of Discharge °F (°C) Haul Time Hours Minutes 50-64 (10-17.5) 1 30 >64 (>17.5) - without retarder 1 0 >64 (>17.5) - with retarder 1 30

To encourage start-up testing for mix adjustments at the plant, the first two trucks will be allowed an additional 15 minutes haul time whenever such testing is performed.

For a mixture which is not mixed on the jobsite, a delivery ticket shall be required for each load. The following information shall be recorded on each delivery ticket: (1) ticket number; (2) name of producer and plant location; (3) contract number; (4) name of Contractor; (5) stamped date and time batched; (6) truck number; (7) quantity batched; (8) amount of admixture(s) in the batch; (9) amount of water in the batch; and

Portland Cement Concrete Art. 1020.11 843 For concrete mixed in jobsite stationary mixers, the above delivery ticket may be waived, but a method of verifying the haul time shall be established to the satisfaction of the Engineer.

be such that the operations of placing and finishing will be continuous insofar as the job operations require. The Contractor shall be responsible for producing concrete that will have the required workability, consistency, and plasticity when delivered to the work. Concrete which is unsuitable for placement as delivered will be rejected. The Contractor shall minimize the need to adjust the mixture at the jobsite, such as adding water and admixtures prior to discharging.

may simultaneously use central-mixed, truck-mixed, and shrink-mixed concrete from more than one plant, for the same construction item, on the same day, and in the same pour. However, the following criteria shall be met.

aggregates, admixtures, and fibers.

proportions may be altered slightly in the field to meet slump and air content criteria. Field water adjustments shall not result in a difference that exceeds 0.02 between plants for water/cement ratio. The required cement factor for central-mixed concrete shall be increased to match truck-mixed or shrink-mixed concrete, if the latter two types of mixed concrete are used in the same pour.

shall be 3/4 in. (19 mm) when tested at the jobsite. If the difference is exceeded, but test results are within specification limits, the concrete may be used. The Contractor shall take immediate corrective action and shall test subsequent deliveries of concrete until the slump difference is corrected. For each day, the first three truckloads of delivered concrete from each plant shall be tested for slump by the Contractor. Thereafter, when a specified test frequency for slump is to be performed, it shall be conducted for each plant at the same time.

shall be 1.5 percent when tested at the jobsite. If the difference is exceeded, but test results are within specification limits, the concrete may be used. The Contractor shall take immediate corrective action and shall test subsequent deliveries of concrete until the air content difference is corrected. For each day, the first three truckloads of delivered concrete from each plant shall be tested for air content by the Contractor. Thereafter, when a specified test frequency for air content is to be performed, it shall be conducted for each plant at the same time.

Art. 1020.11 Portland Cement Concrete 844

plant. When a specified strength test is to be performed, it shall be conducted for each plant at the same time. The difference between plants for strength shall not exceed 900 psi (6200 kPa) compressive and 90 psi (620 kPa) flexural. If the strength difference requirements are exceeded, the Contractor shall take corrective action.

shall be 15 minutes. If the difference is exceeded, but haul time is within specification limits, the concrete may be used. The Contractor shall take immediate corrective action and check subsequent deliveries of concrete.

Variations in plastic concrete properties shall be minimized between batches.

shrink-mixed.

The required mixing time for stationary mixers with a capacity greater than 2 cu yd (1.5 cu m) may be less than 75 seconds upon satisfactory completion of a mixer performance test. Mixer performance tests may be requested by the Contractor when the quantity of concrete to be placed exceeds 50,000 sq yd (42,000 sq m). The testing shall be conducted according to the Bureau of Materials Policy Memorandum, ”Field Test Procedures for Mixer Performance and Concrete Uniformity Tests”.

The Contractor will be allowed to test two mixing times within a range of 50 to 75 seconds. If satisfactory results are not obtained from the required tests, the mixing time shall continue to be 75 seconds for the remainder of the contract. If satisfactory results are obtained, the mixing time may be reduced. In no event will mixing time be less than 50 seconds.

The Contractor shall furnish the labor, equipment, and material required to perform the testing according to the Bureau of Materials Policy Memorandum, “Field Test Procedures for Mixer Performance and Concrete Uniformity Tests”.

A contract which has 12 ft (3.6 m) wide pavement or base course, and a continuous length of 1/2 mile (0.8 km) or more, shall have the following additional requirements.

minimum of 50 cu yd (38 cu m) of concrete per hour.

mixed, or shrink-mixed concrete.

Portland Cement Concrete Art. 1020.13 845

1020.12Mobile Portland Cement Concrete Plants. The use of a mobile

portland cement concrete plant may be approved under the provisions of Article 1020.10 for volumetric proportioning in small isolated structures, thin overlays, and for miscellaneous and incidental concrete items.

The first 1 cu ft (0.03 cu m) of concrete produced may not contain sufficient mortar and shall not be incorporated in the work. The side plate on the cement feeder shall be removed periodically (normally the first time the mixer is used each day) to see if cement is building up on the feed drum.

Sufficient mixing capacity of mixers shall be provided to enable continuous placing and finishing insofar as the job operations and the specifications require.

Slump and air tests made immediately after discharge of the mix may be misleading, since the aggregates may absorb a significant amount of water for four or five minutes after mixing.

1020.13Curing and Protection. The method of curing, curing period, and

method of protection for each type of concrete construction is included in the following Index Table.

Art. 1020.13 Portland Cement Concrete 846

INDEX TABLE OF CURING AND PROTECTION OF CONCRETE CONSTRUCTION CURING CURING LOW AIR TYPE OF CONSTRUCTION METHODS PERIOD TEMPERATURE DAYS PROTECTION METHODS Cast-in-Place Concrete 11/ Pavement Shoulder 1020.13(a)(1)(2)(3)(4)(5) 3/ 5/ 3 1020.13(c) Base Course Base Course Widening 1020.13(a)(1)(2)(3)(4)(5) 2/ 3 1020.13(c) Driveway Median Barrier Curb Gutter 1020.13(a)(1)(2)(3)(4)(5) 4/ 5/ 3 1020.13(c) 16/ Curb & Gutter Sidewalk Slope Wall Paved Ditch Catch Basin Manhole 1020.13(a)(1)(2)(3)(4)(5) 4/ 3 1020.13(c) Inlet Valve Vault Pavement Patching Bridge Deck Patching

(a)(1)(2)(3)(4)(5) 2/

(a)(3)(5)

3 12/ 3 or 7 12/

Railroad Crossing 1020.13(a)(3)(5) 1 1020.13(c) Piles and Drilled Shafts 1020.13(a)(3)(5) 7 1020.13(d)(1)(2) Foundations & Footings Seal Coat

(a)(1)(2)(3)(4)(5) 4/ 6/

(d)(1)(2)

Substructure 1020.13(a)(1)(2)(3)(4)(5) 1/ 7/ 7 1020.13(d)(1)(2) Superstructure (except deck) 1020.13(a)(1)(2)(3)(5)(6) 8/ 19/ 7 1020.13(d)(1)(2) Superstructure (Approach Slab) 1020.13(a)(5)(6) 19/ 3 1020.13(d)(1)(2) 17/ Deck 1020.13(a)(5)(6) 19/ 7 1020.13(d)(1)(2) 17/ Retaining Walls 1020.13(a)(1)(2)(3)(4)(5) 1/ 7/ 7 1020.13(d)(1)(2) Pump Houses 1020.13(a)(1)(2)(3)(4)(5) 1/ 7 1020.13(d)(1)(2) Culverts 1020.13(a)(1)(2)(3)(4)(5) 4/ 6/ 7 1020.13(d)(1)(2) 18/ Other Incidental Concrete 1020.13(a)(1)(2)(3)(5) 3 1020.13(c) Precast Concrete 11/ Bridge Slabs Piles and Pile Caps 1020.13(a)(3)(5) 9/ 10/ As 13/ 9/ Other Structural Members Required All Other Precast Items 1020.13(a)(3)(4)(5) 2/ 9/ 10/ As 14/ Required 9/ Precast, Prestressed Concrete 11/ Until Strand All Items 1020.13(a)(3)(5) 9/ 10/ Tensioning is 9/ Released 15/

Notes-General:

1/ Type I, membrane curing only

2/ Type II, membrane curing only

3/ Type III, membrane curing only

4/ Type I, II, and III membrane curing

Portland Cement Concrete Art. 1020.13 847

5/ Membrane Curing will not be permitted between November 1 and April 15.

6/ The use of water to inundate foundations and footings, seal coats, or the bottom slab of culverts is permissible when approved by the Engineer, provided the water temperature can be maintained at 45 °F (7 °C) or higher.

7/ Asphalt emulsion for waterproofing may be used in lieu of other curing methods when specified and permitted according to Article 503.18. The top surfaces of abutments and piers shall be cured according to Article 1020.13(a)(3) or (5).

8/ On non-traffic surfaces which receive protective coat according to Article

503.19, a linseed oil emulsion curing compound may be used as a substitute

for protective coat and other curing methods. The linseed oil emulsion curing compound will be permitted between April 16 and October 31 of the same year, provided it is applied with a mechanical sprayer according to Article 1101.09(b).

9/ Steam, supplemental heat, or insulated blankets (with or without steam/supplemental heat) are acceptable and shall be according to the Bureau of Materials Policy Memorandum “Quality Control/Quality Assurance Program for Precast Concrete Products” and the “Manual for Fabrication of Precast Prestressed Concrete Products”.

10/ A moist room according to AASHTO M 201 is acceptable for curing.

11/ If curing is required and interrupted because of form removal for cast-in- place concrete items, precast concrete products, or precast prestressed concrete products, the curing shall be resumed within two hours from the start of the form removal.

12/ Curing maintained only until opening strength is attained for pavement patching, with a maximum curing period of three days. For bridge deck patching the curing period shall be three days if Class PP concrete is used and seven days if Class BS concrete is used.

13/ The curing period shall end when the concrete has attained the mix design strength. The producer has the option to discontinue curing when the concrete has attained 80 percent of the mix design strength or after seven days. All strength test specimens shall remain with the units and shall be subjected to the same curing method and environmental condition as the units, until the time of testing.

14/ The producer shall determine the curing period or may elect to not cure the product. All strength test specimens shall remain with the units and shall be subjected to the same curing method and environmental condition as the units, until the time of testing.

15/ The producer has the option to continue curing after strand release.

Art. 1020.13 Portland Cement Concrete 848 16/ When structural steel or structural concrete is in place above slope wall, Article 1020.13(c) shall not apply. The protection method shall be according to Article 1020.13(d)(1).

17/ When Article 1020.13(d)(2) is used to protect the deck, the housing may enclose only the bottom and sides. The top surface shall be protected according to Article 1020.13(d)(1).

18/ For culverts having a waterway opening of 10 sq ft (1 sq m) or less, the culverts may be protected according to Article 1020.13(d)(3).

19/ The cellulose polyethylene or synthetic fiber with polymer polyethylene blanket method shall not be used on latex modified concrete, or vertical concrete surfaces greater than 1 ft (300 mm), e.g. parapets.

Protection of Concrete Construction, curing shall be accomplished by one of the following described methods. When water is required to wet the surface, it shall be applied as a fine spray so that it will not mar or pond on the surface. Except where otherwise specified, the curing period shall be at least 72 hours.

covered with waterproof paper as soon as the concrete has hardened sufficiently to prevent marring the surface. The surface of the concrete shall be wetted immediately before the paper is placed. The blankets shall be lapped at least 12 in. (300 mm) end to end, and these laps shall be securely weighted with a windrow of earth, or other approved method, to form a closed joint. The same requirements shall apply to the longitudinal laps where separate strips are used for curing edges, except the lap shall be at least 9 in. (225 mm). The edges of the blanket shall be weighted securely with a continuous windrow of earth or any other means satisfactory to the Engineer to provide an air-tight cover. Any torn places or holes in the paper shall be repaired immediately by patches cemented over the openings, using a bituminous cement having a melting point of not less than 180 °F (82 °C). The blankets may be reused, provided they are air-tight and kept serviceable by proper repairs.

A longitudinal pleat shall be provided in the blanket to permit shrinkage where the width of the blanket is sufficient to cover the entire surface. The pleat will not be required where separate strips are used for the edges. Joints in the blanket shall be sewn or cemented together in such a manner that they will not separate during use.

covered with white polyethylene sheeting as soon as the concrete has hardened sufficiently to prevent marring the surface. The surface of the concrete shall be wetted immediately before the sheeting is placed. The edges of the sheeting shall be weighted securely with a continuous windrow of earth or any other means satisfactory to the Engineer to provide an air-tight cover. Adjoining sheets shall overlap not less than

Portland Cement Concrete Art. 1020.13 849 12 in. (300 mm) and the laps shall be securely weighted with earth, or any other means satisfactory to the Engineer, to provide an air tight cover. For surface and base course concrete, the polyethylene sheets shall be not less than 100 ft (30 m) in length nor longer than can be conveniently handled, and shall be of such width that, when in place, they will cover the full width of the surface, including the edges, except that separate strips may be used to cover the edges. Any tears or holes in the sheeting shall be repaired. When sheets are no longer serviceable as a single unit, the Contractor may select from such sheets and reuse those which will serve for further applications, provided two sheets are used as a single unit; however, the double sheet units will be rejected when the Engineer deems that they no longer provide an air tight cover.

with wetted burlap blankets as soon as the concrete has hardened sufficiently to prevent marring the surface. The blankets shall overlap 6 in. (150 mm). At least two layers of wetted burlap shall be placed on the finished surface. The burlap shall be kept saturated by means of a mechanically operated sprinkling system. In place of the sprinkling system, at the Contractor's option, two layers of burlap covered with impermeable covering shall be used. The burlap shall be kept saturated with water. Plastic coated burlap may be substituted for one layer of burlap and impermeable covering.

The blankets shall be placed so that they are in contact with the edges of the concrete, and that portion of the material in contact with the edges shall be kept saturated with water.

where a protective coat, concrete sealer, or waterproofing is to be applied, or at areas where rubbing or a normal finish is required, or at construction joints other than those necessary in pavement or base course. Concrete at these locations shall be cured by another method specified in Article 1020.13(a). However, application of membrane curing will be allowed in areas with a rubbed or normal finish if the finish work is started immediately after form removal and the curing resumed within two hours after interruption.

After all finishing work to the concrete surface has been completed, it shall be sealed with membrane curing compound of the type specified within ten minutes. The seal shall be maintained for the specified curing period. The edges of the concrete shall, likewise, be sealed within ten minutes after the forms are removed. Two separate applications, applied at least one minute apart, each at the rate of not less than 1 gal/250 sq ft (0.16 L/sq m) will be required upon the surfaces and edges of the concrete. These applications shall be made with the mechanical equipment specified. Type III compound shall be agitated immediately before and during the application.

At locations where the coating is discontinuous or where pin holes show or where the coating is damaged due to any cause and on areas

Art. 1020.13 Portland Cement Concrete 850 adjacent to sawed joints, immediately after sawing is completed, an additional coating of membrane curing compound shall be applied at the above specified rate. The equipment used may be of the same type as that used for coating variable widths of pavement. Before the additional coating is applied adjacent to sawed joints, the cut faces of the joint shall be protected by inserting a suitable flexible material in the joint, or placing an adhesive width of impermeable material over the joint, or by placing the permanent sealing compound in the joint. Material, other than the permanent sealing compound, used to protect cut faces of the joint, shall remain in place for the duration of the curing period. In lieu of applying the additional coating, the area of the sawed joint may be cured according to any other method permitted.

When rain occurs before an application of membrane curing compound has dried, and the coating is damaged, the Engineer may require another application be made in the same manner and at the same rate as the original coat. The Engineer may order curing by another method specified, if unsatisfactory results are obtained with membrane curing compound.

textured or finished, it shall be covered immediately with dry or damp cotton mats. The cotton mats shall be placed in a manner which will not mar the concrete surface. A texture resulting from the cotton mat material is acceptable. The cotton mats shall then be wetted immediately and thoroughly soaked with a gentle spray of water. For bridge decks, a foot bridge shall be used to place and wet the cotton mats.

The cotton mats shall be maintained in a wetted condition until the concrete has hardened sufficiently to place soaker hoses without marring the concrete surface. The soaker hoses shall be placed on top of the cotton mats at a maximum 4 ft (1.2 m) spacing. The cotton mats shall be kept wet with a continuous supply of water for the remainder of the curing period. Other continuous wetting systems may be used if approved by the Engineer.

After placement of the soaker hoses, the cotton mats shall be covered with white polyethylene sheeting or burlap-polyethylene blankets.

For construction items other than bridge decks, soaker hoses or a continuous wetting system shall not be required if the alternative method keeps the cotton mats wet. Periodic wetting of the cotton mats is acceptable.

For areas inaccessible to the cotton mats on bridge decks, curing shall be according to Article 1020.13(a)(3).

Polymer Polyethylene Blanket Method. After the surface of concrete has been textured or finished, it shall be covered immediately with a wetted cellulose polyethylene blanket or wetted synthetic fiber with

Portland Cement Concrete Art. 1020.13 851 polymer polyethylene blanket. The blankets shall be installed with the white perforated polyethylene side facing up. The blanket’s fiber side shall be wetted immediately prior to placement or as the blanket is being placed, and the polyethylene side shall be thoroughly soaked with a gentle spray of water immediately after placement. For bridge decks, a foot bridge shall be used to place and wet the blankets.

Adjoining blankets shall overlap a minimum of 8 in. (200 mm). Bubbles and wrinkles shall be removed with a broom, squeegee, or as recommended by the manufacturer.

The blankets shall be maintained in a wetted condition until the concrete has hardened sufficiently to place soaker hoses without indentations to the concrete surface. The soaker hoses shall be placed on top of the blankets at a maximum 4 ft (1.2 m) spacing. The blankets shall be kept wet with a continuous supply of water for the remainder of the curing period. Other continuous wetting systems may be used if approved by the Engineer.

For areas inaccessible to the blankets, curing shall be according to Article 1020.13(a)(3).

in Article 1020.13(a)(1), (2), (3), or (5) are used for concrete pavement, the curing covering for each day's paving may be removed to permit surface testing for smoothness using a straightedge. Immediately after testing, the surface of the pavement shall be wetted thoroughly and the curing coverings replaced. The top surface and the edges of the concrete shall not be left unprotected for a period of more than 1/2 hour. When surface testing for smoothness using the inertial profiling system, testing shall be performed after the specified cure time.

When the official National Weather Service forecast for the construction area predicts a low temperature of 32 °F (0 °C) or below, or if the actual temperature drops to 32 °F (0 °C) or below, concrete less than 72 hours old shall be provided the following minimum protection.

Art. 1020.13 Portland Cement Concrete 852

Low Air Temperature Forecast, °F (°C) Minimum Protection 32 to 25 (0 to -4) Two layers of polyethylene sheeting, one layer of polyethylene and one layer of burlap, or two layers of waterproof paper. 24 to 17 (-4 to -8) Insulating material covered with one layer of polyethylene sheeting. The insulating material shall be according to Article 1020.13(d)(1) and have a minimum R value of 6. < 17 (-8) A cold weather protection plan shall be submitted, which may include cold weather adjustments to the concrete mix design, such as the heating of concrete materials.

The protective cover shall be placed as soon as possible without marring the concrete surface. The protective cover shall be secured to prevent infiltration of wind or water beneath it and shall extend over any exposed vertical edge. The protective cover shall also extend a minimum of 1 ft. (300 mm) beyond the placed concrete and shall remain in place until the concrete is at least 96 hours old. Polyethylene sheeting used for cold weather protection shall be according to Article 1022.03, except any color is acceptable.

The Contractor shall provide means for checking the temperature near the surface of the concrete during the protection period according to Article 1020.13(d)(1).

During the first 48 hours after placement of the concrete, the concrete temperature should be a minimum of 40 °F (4 °C), but shall not be less than 35 °F (2 °C). The Contractor is advised the protection specified, including the insulation R value, is an approximation for meeting the 40 °F (4 °C) minimum. The concrete temperature during the first 48 hours of placement is influenced by several factors. This includes the amount of cement and finely divided minerals in the concrete mix design, the initial concrete temperature, and how soon after concrete placement the protection is installed. Therefore, additional insulation during the protection period may be required.

Upon completion of the protection period, if the temperature differential between the concrete and the ambient air temperature exceeds 35 °F (19 °C), the concrete shall be gradually cooled to prevent thermal shock which may cause cracking of the concrete. This may consist of various methods such as removal of the polyethylene sheeting followed by a cool down period before removal of the next layer of sheeting or insulating material. Care shall also be taken to prevent thermal shock when temporary removal of protection materials is required prior to the completion of the protection period.

Portland Cement Concrete Art. 1020.13 853 After September 15, there shall be available to the work within four hours, sufficient materials to cover at least two days’ production. Regardless of the precautions taken, the Contractor shall be responsible for protection of the concrete placed and any concrete damaged by cold temperatures shall be removed and replaced.

official National Weather Service forecast for the construction area predicts a low temperature below 45 °F (7 °C), or if the actual temperature drops below 45 °F (7 °C), concrete less than 72 hours old shall be provided protection. This protection shall remain in place until the concrete is at least seven days old, except approach slabs which shall remain in place for 96 hours. Concrete shall also be provided protection when placed during the winter period of December 1 through March 15. Concrete shall not be placed until the materials, facilities, and equipment for protection are approved by the Engineer.

When directed by the Engineer, the Contractor may be required to place concrete during the winter period. When winter construction is specified, the Contractor shall proceed with the construction, including excavation, pile driving, concrete, steel erection, and all appurtenant work required for the complete construction of the item, except at times when weather conditions make such operations impracticable.

Regardless of the precautions taken, the Contractor shall be responsible for protection of the concrete placed and any concrete damaged by cold temperatures shall be removed and replaced.

commercial insulating material such as insulated blankets or insulated tarps having the minimum thermal resistance R, as defined in ASTM C 168, for the corresponding least dimension of pour shown in the following table.

MINIMUM THERMAL RESISTANCE, R Least Dimension of Pour Low Air Temperature Forecast, °F (°C) in. (mm) 44 to 35 (7 to 2) 34 to 25 (-2 to -4) 24 to 17 (-4 to -8) < 17 (< -8) ≤ 6 (150) R=4 R=6 R=8 Protection Method II according to Article 1020.13(d)(2) shall be used. > 6 (150) to 12 (300) R=3 R=4 R=6 > 12 (300) to 18 (450) R=2 R=3 R=4 > 18(450) R=1 R=2 R=3

Multiple layers of insulation may be used to meet the minimum R value. The insulation shall be covered with a layer of polyethylene sheeting and the sheeting properly secured. Polyethylene sheeting used for cold weather protection shall be according to Article 1022.03, except any color is acceptable. When nominal 0.75 in. (19 mm) thick wood forms are used, an R value of 1 may be assumed. Power operated heating blankets are acceptable for use and will not require an R value.

Art. 1020.13 Portland Cement Concrete 854

The insulating material manufacturer shall provide documentation or clearly mark the insulating material with the thermal resistance R value. The insulating material shall be a closed-cell foam, air-filled bubble, or other material which continues to perform well when wet. The insulating material shall be completely enclosed on sides and edges with a waterproof liner and shall be maintained in a serviceable condition. Tears in the liner shall be repaired, and the overall acceptable condition of the insulating material for use shall be determined by the Engineer.

On formed surfaces, the insulation shall be securely attached to the outside of the forms prior to concrete placement. The insulation shall be applied tightly against the forms to prevent infiltration of wind or water. Where tie rods or reinforcement bars protrude, these areas shall be wrapped in a manner that will prevent heat loss. Where practicable, the insulation shall overlap previously placed concrete by at least 1 ft (300 mm). Insulation on the underside of floors on steel members shall cover the top flanges of supporting members. On horizontal surfaces, the insulation shall be placed as soon as possible without marring the concrete surface.

The Contractor shall provide means for checking the temperature near the surface of the concrete during the protection period. Special attention shall be given to checking the temperature of corners and edges. The means for checking the concrete temperature shall consist of a monitoring system and three sensors. One sensor shall be used for the ambient air temperature and two sensors shall be used for the concrete. The Engineer will select the sensor locations. The temperature monitoring system shall have a minimum temperature range of 0 °F (-18 °C) to 212 °F (100 °C), an accuracy of ± 2 °F (± 1 °C), and be able to automatically record temperatures without external power. Temperature monitoring shall begin once the sensor is encased in concrete, and at a maximum interval of 1 hour. Temperature monitoring results shall be provided to the Engineer at a minimum of once each day. The report shall indicate the location of each sensor, the temperature recorded, and the time recorded.

During the first 72 hours after placement of the concrete, the concrete temperature should be a minimum of 45 °F (7 °C), but shall not be less than 40 °F (4 °C). The Contractor is advised the protection specified, including the insulation R value, is an approximation for meeting the 45 °F (7 °C) minimum. The concrete temperature during the first 72 hours of placement is influenced by several factors. This includes the amount of cement and finely divided minerals in the concrete mix design, the initial concrete temperature, and how soon after concrete placement the protection is installed. Therefore, additional insulation during the protection period may be required.

The Contractor may remove the forms, providing the temperature is a minimum of 35 °F (2 °C) and rising, and the Contractor is able to wrap the particular section within two hours from the time of the start of the

Portland Cement Concrete Art. 1020.14 855 form removal. Care shall be taken to prevent thermal shock which may cause cracking of the concrete.

Upon completion of the protection period, if the temperature differential between the concrete and the ambient air temperature exceeds 35 °F (19 °C), the concrete shall be gradually cooled to prevent thermal shock. This may consist of various methods such as removal of the polyethylene sheeting followed by loosening of forms to allow a cool down period before removal of the insulating material.

housing and the air surrounding the concrete kept at a temperature of not less than 50 °F (10 °C) nor more than 80 °F (27 °C). The enclosure shall be properly vented to prevent surface damage to the concrete from excessive carbon dioxide gas.

The Contractor shall provide means for checking the temperature near the surface of the concrete during the protection period and cooling period according to Article 1020.13(d)(1), except the ambient air temperature shall be monitored within the housing. Exposed surfaces within the housing shall be cured according to the Index Table.

The Contractor shall provide adequate fire protection where heating is in progress and such protection shall be accessible at all times. The Contractor shall maintain labor to keep the heating equipment in continuous operation.

At the close of the heating period, the temperature shall be decreased to the approximate temperature of the outside air at a rate not to exceed 15 °F (8 °C) per 12 hour period, after which the housing may be removed. The surface of the concrete shall be permitted to dry during the cooling period.

1020.14Temperature Control for Placement. Temperature control for

concrete placement shall be according to the following.

temperature is above 35 °F (2 °C) and rising, and concrete placement shall stop when the falling temperature reaches 40 °F (4 °C) or below, unless otherwise approved by the Engineer.

The temperature of concrete immediately before placement shall be a minimum of 50 °F (10 °C) and a maximum of 90 °F (32 °C). If concrete is pumped, the temperature of the concrete at point of placement shall be a minimum of 50 °F (10 °C) and a maximum of 90 °F (32 °C). A maximum concrete temperature shall not apply to Class PP concrete.

is above 40 °F (4 °C) and rising, and concrete placement shall stop when the falling temperature reaches 45 °F (7 °C) or below, unless otherwise approved by the Engineer.

Art. 1020.15 Portland Cement Concrete 856

approach slabs the Contractor shall schedule placing and finishing of the concrete during hours in which the ambient air temperature is forecast to be lower than 85 °F (30 °C). It shall be understood this may require scheduling the deck pour at night in order to utilize the temperature window available. The temperature of the concrete immediately before placement shall be a minimum of 50 °F (10 °C) and a maximum of 85 °F (30 °C).

the concrete immediately before placement shall be a minimum of 50 °F (10 °C) and a maximum of 90 °F (32 °C).

If concrete is pumped, the temperature restrictions above shall be considered at point of placement. When insulated forms are used according to Article 1020.13(d)(1), the maximum temperature of the concrete mixture immediately before placement shall be 80 °F (27 °C). When concrete is placed in contact with previously placed concrete, the temperature of the freshly mixed concrete may be increased by the Contractor to offset anticipated heat loss, but in no case shall the maximum concrete temperature be permitted to exceed the limits stated in this Article.

uniformly and as necessary to produce concrete within the specified temperature limits. No frozen aggregates shall be used in the concrete.

ASTM C 1064 (C 1064M).

1020.15Heat of Hydration Control for Concrete Structures. The Contractor

shall evaluate the heat of hydration and submit a thermal control plan for concrete structures when the least dimension for a foundation, footing, substructure, or superstructure concrete pour exceeds 5.0 ft (1.5 m).

For a drilled shaft, the Contractor shall evaluate the heat of hydration and submit a thermal control plan when the least dimension exceeds 8.0 ft (2.4 m). However, for any drilled shaft with a least dimension exceeding 5.0 ft (1.5 m), the portland cement content in the mix design shall be a maximum of 500 lbs/cu yd (295 kg/cu m). The portland cement content maximum shall also apply to the portland cement in a portland-pozzolan cement or portland blast-furnace slag cement, if used. When a thermal control plan is required to be submitted for a drilled shaft, the use of cooling tubes for thermal control shall be avoided unless alternative methods to control heat of hydration become uneconomical or are limited by specification requirements.

The heat of hydration evaluation and any necessary thermal controls shall be according to the following.

placement shall not exceed 150 °F (66 °C). However, this may be increased to 177 °F (81 °C) when the minimum cement replacement is 25 percent with Class F fly ash, 35 percent with Class C fly ash, or 35 percent with ground granulated blast-furnace slag. Additional finely divided mineral cement

Portland Cement Concrete Art. 1020.15 857 replacement options shall include 5 percent microsilica and minimum 25 percent ground granulated blast-furnace slag, or 5 percent microsilica and minimum 20 percent Class F fly ash. A portland-pozzolan cement or portland blast-furnace slag cement which complies with the previously listed cement replacements is also acceptable.

The maximum temperature differential between the internal concrete core and concrete 2 to 3 in. (50 to 75 mm) from the exposed surface shall not exceed 35 °F (19 °C). However, this may be increased according to Article 1020.15(b)(2). For drilled shafts, a maximum temperature differential shall not apply.

The Contractor shall perform temperature monitoring to ensure compliance with the temperature restrictions.

minimum of 30 calendar days prior to concrete placement for review by the Engineer. Acceptance of the thermal control plan by the Engineer shall not preclude the Contractor from specification compliance, and from preventing cracks in the concrete. At a minimum, the thermal control plan shall provide detailed information on the following requested items and shall comply with the specific specifications indicated for each item.

with embedded pipe.

In addition to the second paragraph of Article 1020.15, the mix design requirements in Articles 1020.04 and 1020.05 shall be revised to include the following additional requirements to control the heat of hydration.

for larger size aggregate should be used in the mix design. Article 1004.02(d)(2) shall apply and information in the “Portland Cement Concrete Level III Technician Course – Manual of Instructions for Design of Concrete Mixtures” may be used to develop the uniformly graded mixture.

or when self-consolidating concrete is desired. For central-mixed concrete, the Contractor shall have the option to develop a mixture with a minimum of 520 lbs/cu yd (309 kg/cu m) of cement and finely divided minerals. For truck-mixed or shrink-mixed concrete, the Contractor shall have the option to develop a mixture with a minimum of 550 lbs/cu yd (326 kg/cu m) of cement and finely divided minerals. A water-reducing or high range water-reducing admixture shall be used in the central mixed, truck-mixed or shrink- mixed concrete mixture. For any mixture to be placed underwater, the minimum cement and finely divided minerals shall be 550 lbs/cu yd (326 kg/cu m) for central-mixed concrete, and 580 lbs/cu yd (344 kg/cu m) for truck-mixed or shrink-mixed concrete.

Art. 1020.15 Portland Cement Concrete 858

For Class DS concrete, CA 11 may be used. If CA 11 is used, the Contractor shall have the option to develop a mixture with a minimum cement and finely divided minerals of 605 lbs/cu yd (360 kg/cu m). If CA 11 is used and either Class DS concrete is placed underwater or a self-consolidating concrete mixture is desired, the Contractor shall have the option to develop a mixture with a minimum cement and finely divided minerals of 635 lbs/cu yd (378 kg/cu m).

375 lbs/cu yd (222 kg/cu m). When the total of organic processing additions, inorganic processing additions, and limestone addition exceed 5.0 percent in the cement, the minimum portland cement content in the mixture shall be 400 lbs/cu yd (237 kg/cu m). For a drilled shaft, foundation, footing, or substructure, the minimum portland cement may be reduced to as low as 330 lbs/cu yd (196 kg/cu m) if the concrete has adequate freeze/thaw durability. The Contractor shall provide freeze/thaw test results according to Illinois Modified AASHTO T 161, and the relative dynamic modulus of elasticity of the mix design shall be a minimum of 80 percent. Testing shall be performed by an independent laboratory accredited by the AASHTO Materials Reference Laboratory

be required for concrete that will not be exposed to freezing and thawing conditions as determined by the Engineer.

40.0 percent. The maximum cement replacement with ground granulated blast-furnace slag shall be 65.0 percent. When cement replacement with ground granulated blast-furnace slag exceeds 35.0 percent, only Grade 100 shall be used.

The finely divided mineral in portland-pozzolan cement or portland blast-furnace slag cement shall count toward the total number of finely divided minerals allowed. The finely divided minerals shall constitute a maximum of 65.0 percent of the total cement plus finely divided minerals. The fly ash portion shall not exceed 40.0 percent. The ground granulated blast-furnace slag portion shall not exceed 65.0 percent. The microsilica or high reactivity metakaolin portion used together or separately shall not exceed 5.0 percent.

maximum 56 days, provided the curing period specified in Article 1020.13 is increased to a minimum of 14 days.

The minimum grout strength for filling embedded pipe shall be as specified for the concrete, and strength testing shall be according to AASHTO T 106.

Portland Cement Concrete Art. 1020.15 859

thermal effects, which shall include the calculated adiabatic temperature rise, calculated maximum concrete temperature, and calculated maximum temperature differential between the internal concrete core and concrete 2 to 3 in. (50 to 75 mm) from the exposed surface. The time when the maximum concrete temperature and maximum temperature differential will occur is required.

Acceptable mathematical methods include ACI 207.2R “Report on Thermal and Volume Change Effects on Cracking of Mass Concrete” as well as other proprietary methods. The Contractor shall perform heat of hydration testing on the cement and finely divided minerals to be used in the concrete mixture. Testing will be required for each material source, and for each cement replacement percentage with a finely divided mineral. The test shall be according to ASTM C 1702 or other applicable test methods, and the result for heat shall be used in the equation to calculate adiabatic temperature rise. Other required test parameters for the mathematical model may be assumed if appropriate.

The Contractor has the option to propose a higher maximum temperature differential between the internal concrete core and concrete 2 to 3 in. (50 to 75 mm) from the exposed surface. This may be accomplished by determining the concrete mixture coefficient of thermal expansion according to AASHTO T 336. In addition, based on strength gain of the concrete, multiple maximum temperature differentials at different times may be proposed. The proposed value shall be justified through a mathematical method.

that will be used during construction of the project when placing concrete. Article 1020.14 shall apply, except a minimum 40 °F (4 °C) concrete temperature will be permitted.

used to ensure the concrete will comply with the specified maximum temperature and specified or proposed temperature differential. For reinforcement that extends beyond the limits of the pour, the Contractor shall indicate if the reinforcement is required to be covered with insulation.

Refer to ACI 207.4R “Cooling and Insulating Systems for Mass Concrete” for acceptable methods that will be permitted. If embedded pipe is used for post-cooling, the material shall be polyvinyl chloride or polyethylene. The embedded pipe system shall be properly supported, and the Contractor shall subsequently inspect glued joints to ensure they are able to withstand free falling concrete. The embedded pipe system shall be leak tested after inspection of the glued joints, and prior to the concrete placement. The leak test shall be performed at maximum service pressure or higher for a minimum of 15 minutes. All leaks shall be repaired. The embedded pipe cooling water may be from natural sources such as streams and rivers, but shall be filtered to prevent system stoppages. When the embedded pipe is no longer

Art. 1020.15 Portland Cement Concrete 860 needed, the surface connections to the pipe shall be removed to a depth of 4 in. (100 mm) below the surface of the concrete. The remaining pipe shall be completely filled with grout. The 4 in. (100 mm) deep concrete hole shall be filled with nonshrink grout. Form and insulation removal shall be done in a manner to prevent cracking and ensure the maximum temperature differential is maintained. Insulation shall be in good condition as determined by the Engineer and properly attached.

placement operations, pour pattern, lift heights, and time delays between lifts.

Refer to ACI 207.1R “Guide to Mass Concrete” for acceptable placement operations that will be permitted.

temperature monitoring systems and corresponding sensors shall be used. One sensor shall be used for the ambient air temperature and two sensors shall be used for the concrete. The sensor for ambient air temperature shall be placed in a shaded location near the concrete structure and away from artificial heat sources.

A temperature sensor shall be located at the theoretical hottest portion of the concrete, normally the geometric center, and near the exterior face that will provide the maximum temperature differential. At the exterior face, the sensor shall be located 2 to 3 in. (50 to 75 mm) from the surface of the concrete. Sensors shall also be located a minimum of 1 in. (25 mm) away from reinforcement, and equidistant between cooling pipes, if either applies. The entrant/exit cooling water temperature for embedded pipe shall also be monitored.

The temperature monitoring system shall have a minimum temperature range of 0 °F (-18 °C) to 212 °F (100 °C), an accuracy of ± 2 °F (± 1 °C), and be able to automatically record temperatures without external power. Temperature monitoring shall begin once the sensor is encased in concrete, and at a maximum interval of one hour. Temperature monitoring may be discontinued after the maximum concrete temperature has been reached, post-cooling is no longer required, and the maximum temperature differential between the internal concrete core and the ambient air temperature does not exceed 35 °F (19 °C). The Contractor has the option to select a higher maximum temperature differential according to Article 1020.15(b)(2).

Temperature monitoring results shall be provided to the Engineer a minimum of once each day. The report shall indicate the location of each sensor, the temperature recorded, and the time recorded. The report shall be for all sensors and shall include ambient air temperature and entrant/exit cooling water temperatures. The temperature data in the report may be provided in tabular or graphical format, and the report shall indicate any corrective actions during the monitoring period. At the completion of the monitoring period, the Contractor shall provide the

Portland Cement Concrete Art. 1020.15 861 Engineer a final report that includes all temperature data and corrective actions.

or temperature differential of the concrete is reached after placement.

maximum temperature of the concrete after placement exceeds 150 °F (66 °C), but is equal to or less than 158 °F (70 °C), the concrete will be accepted unless defects are identified. If the concrete temperature exceeds 158 °F (70 °C), the concrete will not be accepted even if no defects are identified.

maximum temperature of the concrete after placement exceeds 177 °F (81 °C), but is equal to or less than 185 °F (85 °C), the concrete will be accepted unless defects are identified. If the concrete temperature exceeds 185 °F (85 °C), the concrete will not be accepted even if no defects are identified.

between the internal concrete core and concrete 2 to 3 in. (50 to 75 mm) from the exposed surface exceeds the specified or proposed maximum value allowed, the concrete will be accepted unless defects are identified.

or the maximum allowable temperature differential is violated, the Contractor shall implement corrective action prior to the next pour. In addition, the Engineer reserves the right to request a new thermal control plan for acceptance before the Contractor is allowed to pour again.

cracks after the temperature monitoring is discontinued, and the Contractor shall provide access for the Engineer to do the inspection. A crack may require repair by the Contractor as determined by the Engineer.

The Contractor shall be responsible for the repair of all cracks. Protective coat or a concrete sealer shall be applied to a crack less than 0.007 in. (0.18 mm) in width. A crack that is 0.007 in. (0.18 mm) or greater shall have the surface sealed with an epoxy according to ASTM C 881 or the crack shall be pressure injected with epoxy according to Section 590. The Engineer will determine the repair method to be used for cracks 0.007 in. (0.18 mm) or greater based on the location and severity of the crack.

Art. 1021.01 Concrete Admixtures 862

SECTION 1021. CONCRETE ADMIXTURES

1021.01General. Admixtures shall be furnished in liquid form ready for use

The admixtures shall be delivered in the manufacturer's original containers, bulk tank trucks or such containers or tanks as are acceptable to the Engineer. Delivery shall be accompanied by a ticket which clearly identifies the manufacturer and trade name of the material. Containers shall be readily identifiable as to manufacturer and trade name of the material they contain.

Corrosion inhibitors and all other concrete admixtures shall be on the Department’s qualified product list. For the admixture submittal, a report prepared by an independent laboratory accredited by the AASHTO Materials Reference Laboratory (AMRL) for Portland Cement Concrete shall be provided. The report shall show the results of physical tests conducted no more than five years prior to the time of submittal, according to applicable specifications. However, for corrosion inhibitors the ASTM G 109 test information specified in ASTM C 1582 is not required to be from an independent lab. All other information in ASTM C 1582 shall be from an independent lab.

Tests shall be conducted using materials and methods specified on a "test" concrete and a "reference" concrete, together with a certification that no changes have been made in the formulation of the material since the performance of the tests. Per the manufacturer’s option, the cement content for all required tests shall either be according to applicable specifications or 5.65 cwt/cu yd (335 kg/cu m). Compressive strength test results for six months and one year will not be required.

Prior to the approval of an admixture, the Engineer reserves the right to request a sample for testing. The test and reference concrete mixtures tested by the Engineer will contain a cement content of 5.65 cwt/cu yd (335 kg/cu m). For freeze- thaw testing, the Department will perform the test according to Illinois Modified AASHTO T 161. The flexural strength test will be performed according to AASHTO T 177. If the Engineer decides to test the admixture, the manufacturer shall submit AASHTO T 197 water content and set time test results on the standard cement used by the Department. The test and reference concrete mixture shall contain a cement content of 5.65 cwt/cu yd (335 kg/cu m). The manufacturer may select their lab or an independent lab to perform this testing. The laboratory is not required to be accredited by AASHTO.

The manufacturer shall include in the submittal the following information: the manufacturing range for specific gravity, the midpoint and manufacturing range for residue by oven drying, and manufacturing range of pH. The submittal shall also include an infrared spectrophotometer trace no more than five years old. If an accelerating admixture according to Article 1020.04 contains calcium salts, the midpoint and manufacturing range for residue by oven drying will not be required.

For air-entraining admixtures according to Article 1021.02, the specific gravity allowable manufacturing range shall be established by the manufacturer and the test method shall be according to ASTM C 494. For residue by oven drying and pH, the allowable manufacturing range and test methods shall be according to ASTM C 260.