451 Minimum modulus of r upture...................................... 425 psi at 24 h Minimum modulus of r upture...................................... 550 psi at 3 daysD Relative Yield .............................................................. 1.00 Field Acceptance Properties: Minimum water/cementitious ratio (Type I or Type IL) .... 0.320 C Maximum water/cementitious ratio (Type I or Type IL).... 0.420C Minimum water/cementitious ratio (Type III or Type CSA) ..... 0.340C Maximum water/cementitious ratio (Type III or Type CSA) .... 0.450C Slump .......................................................................... 2 to 6 in. Air Content .................................................................. 5.0% to 8.0% Minimum modulus of r upture...................................... 550 psi at 3 days D Relative Yield .............................................................. 0.98 to 1.02 A The target cement content during production shall not be adjusted from the value stated on the CMDP. 260 B Fly ash or slag cement shall not be used in combination with CSA cement unless approved in writing by the manufacturer of the CSA cement. C The water cementitious ratio during production shall not deviate more than 0.020 from the target stated in the CMDP and shall not fall outside the limits above. D Beams shall be standard cured in a water tank in 270 accordance with AASHTO T 23 and 505.01(a). The water does not need to be saturated with calcium hydroxide.
506.05 Trial Batch A trial batch shall be produced and tested by the Contractor’s certified technician to verify that the CMDS is in accordance with the concrete mix criteria. Concrete
produced at a plant shall be batched within the proportioning tolerances of 502.10. An American Concrete Institute certified concrete field testing technician, grade 1 shall be on site to direct all sampling and testing. The trial batch shall be produced at the plant prior to production. 280 A sufficient number of flexural strength test beams shall be made and will be tested to demonstrate that opening to traffic strength is achieved at an age consistent with the proposed range of usage of the mixture. At a minimum, flexural strength gain will be determined at the target opening to traffic times and at the specified 24 h and 3 day targets as specified by the respective mix criteria. The Engineer will test the concrete’s air content, determine the water/cementitious ratio, and prepare and test flexural beams. The flexural strength will be determined by averaging a minimum of 506.05 452 two beam breaks. The Department will provide the apparatus to test the beams for flexural strength. 290 Personnel shall be provided to assist the Department in casting, curing, and testing the beams. The Engineer will provide the Contractor the results of the tests. The Contractor shall submit, along with the CMDS, all supporting test results for approval to the DTE prior to placing concrete. The supporting test results shall be signed by the technician and include air content, slump, relative yield, water/cementitious ratio, and the flexural strengths at the targets listed in 506.04(a) or 506.04(b). Maturity in accord ance with ITM 402 may be used as an alternate method to determine the flexural strength for opening to traffic. 300 A trial batch will not be required when the total quantity of full depth patching requires less than 10 cu yds of material per contract. The trial batch shall be of sufficient quantity to allow the Engineer to perform all required tests from the same batch. Trial batch concrete shall not be used for more than one test, except concrete used to measure relative yield may also be used to measure air content.
506.06 Job Control 310
Control of PCCP for air content, relative yield, and flexural strength beams will be determined from tests performed by the Engineer in accordance with 505. Concrete and necessary labor for sampling shall be furnished as required by the Engineer. Testing for air content and relative yield will be on the first load of the day and once per every 50 cu yds.
a.Beams for Validation of CMDP At least one set, consisting of three beams per set, will be made once per every 150 cu yds of concrete placed and tested for compliance with either the 3-day or 7-day flexural strength requirements in accordance with 506.04, for the purpose of CMDP 320 validation. Air content and relative yield will be measured on each sample of concrete from which beams are made. Beams for validation shall be placed on the concrete pavement or shoulder adjacent to the patch and cured in a similar manner as the patch in accordance with 505.01(a) until patch area is open to traffic. At which point the beams shall be relocated off-site and standard cured in accordance with AASHTO T 23, Section 10.1.2 with the exception that the water does not need to be saturated with calcium hydroxide until the 3-day or 7-day time period has elapsed. 330 Failure of the validation beams to meet or exceed the 3-day or 7-day flexural strength requirements specified herein will result in the use of the CMDP being suspended until the Department concludes an investigation into why the failure occurred. If the CMDP is subsequently shown to be acceptable, another set of 506.06 453 validation beams will be tested on the next use of the CMDP.
b.Beams for Opening to Traffic Additional beams shall be cast for the purpose of opening to traffic for concrete meeting the requirements of 506.04(a) or 506.04(b). Such beams shall be cast from sampling the last load to finish the patching operations for the day’s production for 340 each of the concrete mixes used. Beams for opening to traffic shall be placed on top of a concrete patch that they represent and cured in a similar manner as the patch. The Engineer will notify the Contractor when test results for air content, relative yield, or flexural strength are outside the requirements of 506.04. Rounding will be in accordance with 109.01(a). CONSTRUCTION REQUIREMENTS
506.07 General 350
Patch areas shown on the plans or marked by the Engineer as greater than 15 ft in length may be subdivided. If a patch is subdivided, concrete mix in accordance with 506.04(b) shall be used in all portions of the patch and the requirements for opening to traffic will be in accordance with 506.12(b).
506.08 PCCP Removal PCCP removal areas will be marked. The Contractor may saw cut the patch areas
prior to removing the patch. When the lane is subject to intermittent closures, the saw cutting shall occur no more than 24 h prior to removing the patch. Vertical saw cuts around the perimeter of the removal areas shall be made in the PCCP and shall be full depth. Transverse cuts that define the ends of the patch shall be straight and perpendicular to the centerlin e. In no case shall the transverse joint be over-cut into the adjacent pavement. Following the saw cutting, the concrete that remains in the corners of the patch area shall be removed by pneumatic hammers that do not damage the adjacent PCCP or shoulders. Pneumatic hammers shall not exceed 45 lb. PCCP removal areas shall not remain open overnight. Shoulders or adjacent PCCP damaged during the removal shall be repaired as directed. 370
a.Partial Depth Removal The saw cut shall be a minimum of 1 in., to a maximum of 1/3 of the thickness of the existing pavement. Removal of all unsound concrete to a minimum depth of 2 in. shall be by hand chipping tools or handheld mechanically driven equipment. Mechanical hammers shall not be heavier th an a nominal 45 lb class. Mechanically driven tools shall be operated at a maximum angle of 45° from the PCCP surface. If the saw cut face is damaged, a parallel saw cut 1 in. outside the initial saw cut shall be made and the concrete in this area shall be removed by hand chipping. 380 506.08 454 In lieu of using hand chipping tools or handheld mechanically driven equipment, a milling machine may be used. If a milling machine is used it shall be one that does not damage the adjacent pavement. If reinforcing bars are encountered during the removal operation, the patch shall be changed to a full depth patch in ac cordance with 506.08(b). Wire mesh reinforcement exposed during the removal operations shall be removed. If concrete is exposed below 1/3 of the thickness of the existing pavement, the patch shall be changed to a full depth patch in accordance with 506.08(b). 390 Partial depth cavities shall be thoroughly sandblasted and, just prior to placing new concrete, cleaned of all dust, chips, a nd water. The air lines for sandblasting and air cleaning shall be equipped with oil trap s to prevent contamination of the surfaces.
b.Full Depth Removal After the full depth saw cut is completed, vehicle mounted removal equipment may be used to remove the concrete pr ovided this equipment does not damage the adjacent sound concrete. 400 Removal areas in the same lane which are closer than 10 ft shall require the PCCP between these areas to be removed and replaced. If a transverse joint is located within the removal area, the limits of removal shall be as shown on the plans. Full depth saw cutting and removal shall be extended at the direction of the Engineer until sound PCCP is encountered to allow the drilling and installation of dowel bars for load transfer. Removal operations shall not damage the existing PCCP that is sound and is to remain in place. Existing subbase shall be completely removed. Before removing any type of 410 asphalt treated, cement treated, or concrete subbase, the Contractor shall saw cut the outline of the removal area using a power -driven saw with a diamond blade. The Contractor shall cut the asphalt treated s ubbase at least 2 in. deep on a neat line perpendicular to the subbase surface. The Contractor shall cu t the cement treated subbase or concrete subbase full depth. 506.09 Concrete Mixing and Transportation
a.For Patches Less than or Equal to 15 ft in Length Concrete batching tolerances, mixing, and transportation shall be in accordance 420 with 502.10 and the following. Discharge from non-agitating equipment shall be completed within 30 minutes of mixing th e water, cement, aggregates, and calcium chloride solution. Discharge from a truck agitator or a truck mixer shall be completed within 90 minutes of mixing the water, cement, and aggregates or within 30 minutes of the addition of calcium chloride solution. If the location of the plant is such that this time limit cannot be met, the calcium chloride solution shall be added to the concrete 506.09 455 in a transit mixer at the site and the concrete shall then be mixed for an additional 40 revolutions prior to discharge.
1.Central Mixed Concrete 430 Central mixed concrete shall be in accordance with 502.10(a). 2. Shrink Mixed Concrete Shrink mixed concrete shall be in accordance with 502.10(b).
3.Transit Mixed Concrete Transit mixed concrete shall be in accordance with 502.10(c).
b.For Patches Greater than 15 ft in Length For patches containing portland cement, the mixing and transportation shall be in 440 accordance with 502.10. If concrete contai ning CSA cement is used, it may be batched and mixed in a mobile volumetric mixer meeting the requirements of 722.09, regardless of the patch length. Calibration of the mobile mixer shall be in accordance with 722.13. Alternatively, a mixer from a CSA cement supplier may be used, if approved by the Engineer.
506.10 Weather Limitations
PCCP patches shall not be placed on frozen subgrade, subbase, or PCCP. 506.11 Placing Concrete 450 The concrete shall be placed level to the adjacent PCCP and consolidated by internal vibration. The concrete shall be hand finished in accordance with 504. Texturing and tining are not required if the PCCP is to be resurfaced with HMA or diamond ground in accordance with 507.06. The PCCP patch shall be cured with liquid membrane forming curing compound in accordance with 504.04(a). In addition to applying liquid memb rane forming curing compound, if the ambient temperature is below 55°F at the time of placement, polyethylene film shall be placed over the pa tch and covered with a 4 in. layer of rigid or flexible insulation and firmly anchored. Otherwise, polyethylene film, insulation, 460 or any other covering shall not be used. Small dimension lumber weighted with sandbags may be used, but large objects such as rocks or concrete blocks shall not be used. Covering with polyethylene film or any other covering does not replace the requirement to use liquid membrane forming curing compound. The PCCP patch shall be inspected in accordance with 502.17. For patches which are not to be overlaid and have a length greater than 20 ft, 470 pavement smoothness will be in accordance with 501.25 except inertial profiler requirements will not apply. 506.11
a.Partial Depth A non-vapor barrier type bonding agent shall be applied to the vertical and horizontal surfaces prior to placing concrete. Coated surfaces shall be protected from contaminants such as dust and dirt. Cont aminated surfaces shall be recleaned and recoated. The bonding agent and concrete shall be placed in accordance with the bonding agent manufacturer’s recommendations. The recommended time limits will be strictly enforced. 480 Existing joint openings within the patch shall be maintained for the full depth of the patch by preformed joint fillers or forms. After the patch has cured, these joints shall be sawed and sealed in accordance with 503.
b.Full Depth Subgrade treatment and subbase shall be constructed as shown on the plans. Dowel bars shall be installed to provide load transfer from the adjoining PCCP to the patch. The diameter of the drilled holes shall be no more than 1/8 in. greater than 490 the diameter of the dowel bar. Dowel bars shall be placed parallel to the pavement surface and to the longitudinal joint. Dowel alignment tolerances shall be as shown on the plans. Dowel holes shall be drilled using hydraulic, electric, or pneumatic percussion drills without spalling or damaging the exis ting concrete. Drills shall be capable of independent adjustment of each drill shaft in the horizontal and vertical direction. The device used to drill dowel holes shall be slab-riding and be capable of drilling a minimum of three holes at a time. The drilled holes shall be free of dust, moisture, and grease prior to installation of the dowel bars. The chemical anchor system shall be 500 injected to the back of the hole to elimin ate air pockets prior to inserting the dowel bar. The quantity of material injected shall be sufficient to disperse the chemical anchor material along the entire length of the dowel bar and completely fill all voids around the bar. Application of the chemical anchor system by buttering it onto the dowel bar will not be allowed. After the anchor system has been injected, the dowel bar shall be fully inserted in the hole using a back-and-forth twisting motion, leaving the proper length exposed. If 510 it is necessary to use a hammer to seat the dowel bar, the exposed end shall be protected with a wood block. A lightweight plastic, clear or semi-transparent grout retention ring shall be installed after each dowel bar is inserted in to the hole. The grout retention ring shall be pushed flush to the vertical ly sawn concrete surface and shall be used to help retain the chemical anchor syst em in the dowel hole. 506.11 457 Retrofit tie bars shall be installed in accordance with 503 and as shown on the plans. The tolerance for horizontal and vertical translation shall be the same as for 520 dowel bars. Joint filler and grout retention rings shall be placed and installed at the pressure relief joint as shown on the plans. Oversized holes shall be drilled in the joint filler no more than 1/2 in. over the dowel bar diameter and at a spacing to match the installed dowel bars. The oversized holes are to allow a tolerance for ease of installation of the joint filler up against the sawed face without interference with the dowel bars. The joint filler shall be attach ed to the sawed face wit hout wrinkles or buckling. Joint filler material with vertical slits or cuts will be rejected. Grout retention discs 530 shall be installed to make the annular sp ace between the dowel and the oversized hole mortar-tight. The joint material may be spliced along vertical joints that are joined and sealed with tape. The joint material shall not be spliced in the horizontal direction. An alternate method of installing a joint filler that has a mortar tight seal around the dowel bar may be used if approved by the Engineer. All patches longer than 15 ft shall be placed in accordance with 502.12 and shall have joints in accordance with 503. Dowel bars shall be installed within the boundaries of the patch at a spacing as shown on the plans or as approved by the Engineer. Patches longer than 15 ft shall be finished in accordance with 504. Patches longer than 15 ft, constructed with concrete containing portland cement, shall be cured in accordance with 504.04(a) unless ambient air and concrete temperatures warrant following the requirements in 506.11. Patches constructed in accordance w ith 506.04(b) and containing CSA cement shall be water cured in accordance with 702. 22(a)1 except that soaker hoses will not be required. Water curing shall be initiated after finishing and as soon as the concrete patch can support the wet covering. Water curing shall be maintained for a minimum 550 of 1 1/2 h and shall be removed no sooner than 1 h before the patch is opened to traffic. Concrete shall be placed around manholes or similar structures in accordance with 720. Sawing and sealing of transverse joints may be omitted when the existing PCCP is to be overlaid as part of the contract. 506.12 Opening to Traffic For purposes of this section, traffic shall include construction vehicles, 560 construction equipment, and all non-construction vehicles. Any construction vehicle or equipment that may damage the PCCP shall not be used on the PCCP unless adequate protection is provided. Joint cutting saws may be operated on the PCCP as determined by the Contractor. 506.12
a.For Patches Less than or Equal to 15 ft in Length A patch may be opened to traffic in acco rdance with the following when calcium chloride is used in accordance with 506.04(a). T H HT T H HT 40 - 42°F 30 26 61 - 63°F 14 9 43 - 45°F 27 23 64 - 66°F 14 9 46 - 48°F 24 21 67 - 69°F 14 8 49 - 51°F 21 19 70 - 72°F 14 7 52 - 54°F 19 16 73 - 75°F 14 6 55 - 57°F 16 14 above 75°F 14 5 58 - 60°F 16 11 T = Lowest ambient temperature during placement, or the temperature of concrete at time of delivery, whichever is lower. H = Time in hours to open to traffic. HT = Time in hours to open to traffic when the average daily traffic is less than 10,000. PCCP patches with calcium chloride ma y be opened to traffic sooner than specified in the above table if test beams indicate a modulus of rupture of 300 psi or greater. ITM 402 may be used as an altern ative method to determine the flexural strength. When other admixtures or admixture systems are used, the PCCP patches may be opened to traffic when flexural strength tests indicate a modulus of rupture of 300 psi or greater. ITM 402 may be used as an alternate method to determine the flexural strength. 580
b.For Patches Greater than 15 ft in Length Traffic shall not be allowed on the PCCP until a modulus of rupture of 425 psi from flexural strength testi ng is achieved. The modulus of rupture will be determined by averaging two beams.
506.13 Method of Measurement
Partial depth patching and full depth patching will be measured by the square yard. D-1 contraction joints and retrofitted tie bars used in PCCP patching will be 590 measured in accordance with 503.07. When subgrade treatment is specified, it will be measured in accordance with
207.05 New subbase will be measured in accordance with 302.08. PCCP removal, subbase removal, conc rete, finishing, curing, and sawing and
sealing of joints will not be measured for payment. 506.13 Retrofit pressure relief joints, retrofit contraction joints, non-vapor barrier bonding agent, anchored dowel bars installed at the beginning and end of the patch, 600 individual dowel bars, joint fillers, joint materials, drilling holes for dowel bars, grout retention rings, and chemical anchor systems will not be measured for payment. 506.14 Basis of Payment PCCP patching will be paid for at the contract unit price per square yard for the type of patching required. D-1 contraction joints and retrofitted tie bars used in PCCP patching will be paid for in accordance with 503.08. 610 Subgrade treatment will be paid for in accordance with 207.06. New subbase will be paid for in accordance with 302.09. Partial depth patches which have been directed to be full depth will be paid for at the contract unit price per square yard for PCCP patching, partial depth, plus 80% of the contract unit price per square yard for PCCP patching, full depth. Payment will be made under: Pay Item Pay Unit Symbol 620 PCCP Patching, Full Depth ....................................................... SYS PCCP Patching, Partial Depth ................................................... SYS The cost of PCCP removal, subbase removal, concrete, finishing, curing, and sawing and sealing of joints shall be included in the cost of PCCP patching. The cost of retrofit pressure relief joints, retrofit contraction joints, non-vapor barrier bonding agent, anchored dowel bars installed at the beginning and end of the patch, individual dowel bars, joint fillers, joint materials, drilling holes for dowel bars, 630 grout retention rings, and chemical anchoring system shall be included in the cost of PCCP patching. The cost of corrections for pavement sm oothness and retexturing shall be included in the cost of PCCP patching. Repair or replacement of adjacent PC CP or shoulder damaged by the Contractor shall be made at no addition al cost to the Department. 640 506.14
Source: Indiana Standard Specifications, 2024 Edition. Pages 449–458 of 1,248.