434 SECTION 503 – PCCP JOINTS
503.01 Description
This work shall consist of the construction of joints in PCCP, placing dowel bar assemblies and joint sealing opera tions in accordance with 105.03. MATERIALS
503.02 Materials
Materials shall be in acco rdance with the following: 10 Bridge Expansion Jo int Type PCF .............................. 906.07(c) Chemical Anchor System ............................................ 901.05 Concrete, Class A ........................................................ 702 Dowel Bars .................................................................. 910.01(b)10 Epoxy Coated Reinfo rcing Bars .................................. 910.01(b)9 Hot Poured Joint Sealant ............................................. 906.02(a)2 Joint Filler.................................................................... 906.01 Joint Materials ............................................................. 906 PCC Sealer/Healers ..................................................... 901.06 20 Reinforci ng Bars .......................................................... 910.01 Support Devices .......................................................... 910.01(b)11 Threaded Tie Bar Assembly ........................................ 910.01(b)2 Tie bars shall be epoxy coated reinforcing bars. Bent tie bars shall be deformed billet steel in accordance with 910.01 and ASTM A615, grade 40. The epoxy coating on the bent and straight tie bars shall be protected in 30 accordance with 703.04. CONSTRUCTION REQUIREMENTS
503.03 Joints
Joints shall be constructed in accordance with the type, dimensions, and locations shown on the plans or as directed. All joints shall be perpendicular to the subgrade. Longitudinal joints shall be parallel to the centerline. The longitudinal joint shall not deviate from the true line shown on the plans by more than 1/4 in. Transverse joints 40 shall be at right angles to the centerline and be continuous for the full width of the pavement. All joints shall be cut to the required dimensions and sealed. All sawed joints shall be made by sawing equipment in accordance with 508.07 and shall be in accordance with the following. 503.01 435 (a) Type D-1 Contraction Joint Type D-1 contraction joints shall be created by sawing slots in the pavement unless alternative methods are approved. The sawed contraction joint spacing shall be 50 as shown on the plans or as directed, but shall not exceed 18 ft. The saw cut shall commence as soon as th e concrete has hardened sufficiently to enable sawing without raveling, usually 2 to 12 h after placement. All joints shall be saw cut through the edges of the pavement to the required depth before uncontrolled shrinkage cracking takes place. The sawing operations shall be carried on during day and night, regardless of weather conditions. The sawing of a joint shall be omitted if a crack occurs at or near the joint location prior to the time of sawing. Sawing shall be discontinued if a crack develops ahead of the saw. Formed contraction joints may be used where conditions make sawing impractical. 60 The width of the saw cut will be measured for specification compliance at the time of the sawing operations. Slurry or saw residue remaining in the slot shall be immediately flushed with water. Construction traffic shall not be allowed on the PCCP after the saw cut until the joint is sealed. The sawed slot shall be cleaned to remove all foreign matter from the entire depth of cut. Joint sealing shall be in accordance with 503.05.
b.Longitudinal Joint 70 Longitudinal joints shall be created by sawing slots in the pavement unless alternative methods are approved. The longitudinal joint spacing shall be as shown on the plans or as directed, but shall not ex ceed 14 ft. Tie bars shall be placed by mechanical equipment in acc ordance with 508.04(a), or rigidly secured in place. Longitudinal joints shall be cut to the depth, width, and line shown on the plans. The longitudinal joint slots shall be sawed concurrently with the D-1 contraction joint slots. If random cracking occurs ahead of sawing, the sawing operations shall be discontinued in that area. The sawed joint shall be cleaned as specified in 503.03(a). Joint sealing shall be in accordance with 503.05. 80 Longitudinal joints may be replaced with longitudinal construction joints when approved by the Engineer.
c.Transverse Construction Joints Transverse construction joints shall be constructed when there is an interruption of more than 30 minutes in the PCCP pl acement operations. A transverse construction joint located at a D-1 contraction joint shall be in accordance with 503.03(a), except the initial saw cut shall be omitted. All other transverse construction joints shall be located at least 6 ft from an adjacent D-1 contraction joint. 90 Tie bars for transverse construction joints may be placed in the plastic or hardened concrete. A header board with openings for tie bars shall be used when placing tie bars 503.03 436 in plastic concrete. The header board shall be rigid and accurately set to grade. Tie bars placed in hardened concrete shall be retrofitted in accordance with 503.03(g).
d.Longitudinal Construction Joint The longitudinal construction joint spacing shall be as shown on the plans or as approved. Tie bars shall be placed by me chanical equipment in accordance with 508.04(a) or other approved methods. Longitudinal construction joint saw cuts may 100 be made as soon as the PCCP has sufficiently hardened. Longitudinal construction joints shall be cut to the depth, width, and line shown on the plans. Construction traffic shall not be allowed on the PCCP after the saw cuts are made until the joints are sealed. Joint sealing shall be in accordance with 503.05. Bent tie bar spacing shall be adjusted to prevent interference with the D-1 contraction joints. Bent tie bars shall not be omitted. Bent tie bars shall be replaced with retrofitted tie bars when more than one tie bar breaks within 30 ft during straightening. 110 The longitudinal construction joint for shoulder widths 4 ft or less may be replaced by a longitudinal joint with tie bars. If the construction joint is eliminated, the mainline and shoulder shall be constructed at the same time.
e.Terminal Joints A terminal joint of the type specified shall be constructed at the locations as shown on the plans. The embankment shall be shaped to the required grade and section, free from all ruts, corrugations, or other irregularities, and uniformly compacted in accordance with 203. The embankment shall be finished within a tolerance of 1/2 in. 120 from the grade as shown on the plans. The subgrade shall be prepared as shown on the plans and in accordance with 207. The sleeper slab shall be placed on top of the prepared subgrade.
1.Terminal Joint, Type PCCP Terminal joint, Type PCCP, shall consist of a sleeper slab, polyethylene bond breaker, Type PCF bridge expansion joint, and JRCP transition slabs. The polyethylene bond breaker shall be an approved polyethylene sheeting having a thickness of 6 mils or greater. The portion of the sleeper slab on which the polyethylene bond breaker is to be placed shall be finished to a smooth trowel finish. 130 The Type PCF bridge expansion joint shall be in accordance with 724 and as shown on the plans. The concrete and placement for JRCP transition slabs shall be in accordance with 502 and as shown on the plan s. Steel reinforcem ent shall be epoxy coated and placed in accordance with 703. Th e metal chairs, spacers, clips, wire, or other mechanical means used for fastening or holding reinforcement in place shall be epoxy coated.
2.Terminal Joint, Type HMA Terminal joint, Type HMA, shall cons ist of a sleeper slab, concrete lug, 503.03 437 polyethylene bond breaker, and Type PCF bridge expansion joint. The polyethylene 140 bond breaker shall be an approved polyethylene sheeting having a thickness of 6 mils or greater. The portion of the sleeper slab on which the polyethylene bond breaker is to be placed shall be finished to a smooth trowel finish. A Type A construction joint shall be constructed as shown on the plans. The Type PCF bridge expansion joint shall be in accordance with 724 and as shown on the plans. The saw cut shall be sealed with hot poured joint sealant in accordance with 906.02(a)2.
f.Expansion Joints 150 Expansion joints shall be constructed at the locations shown on the plans and shall consist of joint filler. The joint filler shall be shaped to the subgrade, parallel to the surface, and be full width of the pavement. Damaged or repaired joint filler shall not be used. The joint filler shall be held in a position which is normal to the surface. Finished joints shall deviate no more than 1/4 in. in the horizontal alignment from a straight line. There shall be no offsets between adjacent sections when the joint filler consists of more than one section. No plugs of concrete shall be within the expansion joint. 160
g.Retrofitted Tie Bars Retrofitted tie bars shall be secured at right angles to the pavement with a chemical anchor system in accordance with the manu facturer’s recommendation. The chemical anchor system shall be injected to the back of the hole to eliminate air pockets prior to inserting the bar. The quantity of material in jected shall be sufficient to disperse the material along the entire length of the bar an d completely fill the annular space. After the anchor system has been in jected, the bar shall be fully inserted using a back-and- forth twisting motion, leaving the proper length exposed. If it is necessary to use a hammer to seat the bar, the exposed end shall be protected with a wood block. 170 When a capsule type chemical anchor system is used, the capsules shall be conditioned as per the manufacturer’s installation instructions, if required, and placed at the back of the hole. The number of capsu les shall be sufficient to disperse the material along the entire length of the bar an d completely fill the annular space. After the capsules have been placed the bar shall be fully inserted in accordance with the manufacturer’s installation instructions.
h.Expansion Joint with Load Transfer Expansion joints with load transfer shall be constructed at the locations shown on 180 the plans. The joint shall be an assembly of dowel bars, expansion caps, and joint filler components as shown on the plans. The co mponents shall be supported in accordance with 503.04(a). Damaged or repaired joint filler shall not be used. The joint filler shall be held in 503.03 438 a position which is normal to the surface and secured in place. The bottom of the joint filler shall be set firmly in place. The top of the joint filler shall be parallel to the pavement surface and be the full width of th e pavement. The expansion joint assembly shall be held in place in acco rdance with 503.04(g). Finished joints shall deviate no more than 1/4 in. in the horizontal alignment from a straight line. There shall be no 190 offsets between adjacent sections when th e joint filler consists of more than one section. No plugs or leakage of concrete shall be allowed to occur through the joint filler or into the air gap of expansion caps. The expansion joint opening shall be sealed with hot poured joint sealant in accordance with 906.02(a)2. 503.04 Dowel Bar Assemblies The dowel bar assemblies shall be in accordance with the following:
a.The dowel bars shall be supported by an approved welded wire assembly which shall hold the bars rigid during placement of the PCCP. The wire for the welded asse mbly shall be in accordance with ASTM A1064. The maximum angle of deviation shall not exceed 1 in 48 units during placement.
b.The assembly shall have two continuous parallel spacer bars and two continuous parallel bearing members of size W 7.5 or greater. One spacer bar shall be located at or n ear each end of the dowel. Alternate ends of dowels shall be welded to a spacer bar so that the dowels 210 remain parallel to each other and enable sliding movement in the joint. The free ends of each dowel shall be retained securely in place by means of wire loops.
c.Suitable struts or tie wires shall be provided to hold the assembly in correct position during installation. The tie wires shall be size W 7.5 or smaller and there shall be a maximum of five tie wires for each dowel bar assembly.
d.The assembly shall have an upright support welded to the spacer bar 220 and a continuous bearing member at the end of each dowel.
e.If the upright support consists of a single vertical wire, the support shall be size W 7.5 or greater wire. Otherwise, the support shall be 1/4 in. or greater in diameter.
f.At the time of placement, dowel bars shall be free of dirt, loose rust, or scale. If the Engineer susp ects the epoxy coating has been damaged by exposure to ultraviolet light, a sample will be obtained and will be tested in accordance with 910.01(b)9. 230 503.04 439 (g) The dowel bar assembly shall be held securely in place during placing, consolidating, and finishing the PCCP by means of metal pins. Pins used on granular subbase shall penetrate a minimum of 12 in. below the dowel bar assembly. Pins shall be size W 7.5 or greater wire and shall be provided with a hook or arm welded to the pin so that it shall secure the assembly in place. A minimum of eight pins shall be used for each 10, 11, or 12 ft section of assembly. A minimum of 10 pins shall be used for assembly sections greater than 12 ft and less than or equal to 16 ft. 240
h.Dowel bars shall be coated with a bond breaking material and the coating shall be evident at th e time of placement of the PCCP.
i.Dowel bars shall be placed 6 in. from the edges of the pavement and spaced at 1 ft on cen ter across the joint.
503.05 Sealing Cracks and Joints All joints and cracks in the PCCP shall be cleaned and sealed with hot poured
joint sealant in acco rdance with the sealant manufact urer’s recommendations. Water 250 blasting shall not be applied under pressu re which may damage the concrete. All cracks and joints shall be sealed prior to discontinuing work for the winter.
503.06 Random Crack Remediation
Random cracks shall be corrected.
a.Transverse Random transverse cracks shall be corrected by PCCP replacement. The replacement shall be full lane width and a minimum of 6 ft in length. Transverse PCCP removal limits shall be perpendicular to the centerline and shall include the entire 260 random crack. Load transfer for the repl acement PCCP shall be obtained by using dowel bars and retrofit epoxy coated tie bars. PCCP replacement areas shall have dowel bars which match contraction joints in any adjacent panels. All remaining panels shall be a minimum of 6 ft in length. (b) Longitudinal Random longitudinal and skewed cracks within 18 in. of a longitudinal joint shall be routed and sealed. All longitudinal saw cuts in areas of random cracks shall be sealed with a sealer/healer or a bonding agent in accordance with ASTM C881, grade 1. 270 Random longitudinal and skewed cracks outside 18 in. of a longitudinal joint shall be corrected by PCCP replacement in accordance with 503.06(a).
503.07 Method of Measurement
D-1 contraction joints, expansion joint with load transfer, and terminal joints will be measured by the linear foot as measured along the centerline of the joint. The 503.07 440 sleeper slab, reinforcing bars, bond breaker, s ealants for the termin al joint will not be measured. When required, removal of an existing terminal joint or sleeper slab will not be measured. 280 JRCP will be measured by the square yard of the thickness specified. Reinforcing bars, the metal chairs, spacers, clips, wi re, or other mechanical means used for fastening or holding reinforcement in place in the JRCP will not be measured. Retrofitted tie bars will be measured by the number of units installed. Type PCF bridge expansion joints, join t fillers, and joint sealants will not be measured. 290
503.08 Basis of Payment
D-1 contraction joints, expansion joint with load transfer, and terminal joints will be paid for at the contract unit pri ce per linear foot, complete in place. JRCP will be paid for at the contract unit price per square yard of the thickness specified, complete in place. Retrofitted tie bars will be paid for at the contract unit price per each, complete in place. 300 Payment will be made under: Pay Item Pay Unit Symbol D-1 Contraction Joint ................................................................ LFT Expansion Joint with Load Transfer .......................................... LFT Jointed Reinforced Concrete Pavement, ____ in. ..................... SYS thickness Retrofitted Tie Bars ................................................................... EACH Terminal Joint, Type _______................................................... LFT 310 The cost of furnishing and placing all ma terials, not specified as a pay item, shall be included in the cost of PCCP. The cost of reinforcing bars, metal chairs , spacers, clips, wire, or other mechanical means used for fastening or holding reinforcement in place shall be included in the cost of the JRCP. For D-1 contraction joints, the cost of dowels, dowel bar assemblies, backer rod, joint sealants, and a ll necessary incidentals shall be included in the cost of D-1 320 contraction joints. For the construction of expansion joints, the cost of dowels, dowel bar assemblies, 503.08 441 expansion caps, joint filler, joint sealants, and all necessary incidentals shall be included in the cost of the expansion joint with load transfer. The cost of the sleeper slab, reinforcing bars, bond breaker, Type PCF bridge expansion joint, joint sealant, and all necessary incidentals shall be included in the cost of the terminal joint. When required, removal of an existing terminal joint and sleeper slab shall be included in the cost of the terminal joint. 330 The cost of retrofitted tie bars or PCCP replacement used to repair damaged PCCP due to fault or negligence, remediation of random cracking, or the replacement of broken deformed bars shall be included in the cost of the PCCP.
Source: Indiana Standard Specifications, 2024 Edition. Pages 6–14 of 1,248.