979 Physical Tests Specifi cations Requirements Setting Time: Normal Weather Hot Weather ASTM C266 Initial at 72°F Final at 72°F Initial at 95°F Final at 95°F 10 – 20 min 12 – 35 min 10 – 20 min 12 – 35 min Compressive Strength, min.* 1 h 2 h 24 h 28 days ASTM C109 72°F, Normal 2,000 psi 3,000 psi 5,000 psi 8,000 psi Compressive Strength, min.* 3 h 24 h 28 days ASTM C109 95°F, Hot 3,000 psi 5,000 psi 8,000 psi Relative Dynamic Modulus Procedure B, 300 cycles ASTM C666 95% min. Slant Shear Bond Strength, min. 28 days ASTM C882 2,500 psi Flexural Strength, 24 h mortar only mortar – aggregate extension ASTM C78 500 psi 600 psi Length Change, maximum 28 days (air storage) ASTM C157 modified C928 -0.075% Scaling Resistance 5 cycles 25 cycles 50+ cycles ASTM C672 0 rating, No scaling 0 rating, No scaling 1.5 rating, Very slight to Slight scaling * Material used shall be neat rapid settin g patch material mixed in accordance with the manufacturer’s installation instructions. All rapid setting patch materials complying with the specified physical requirements will be subjected to a field performance demonstration. The field performance demonstration will take place as directed. Rapid setting patch materials shall be used to patch a designated site, typical of a standard repair. The site will be evaluated after one year’s exposure. Appr oval will be based on visible signs of distress, such as cracking, crazing, scaling, spalling, wearing, edge fraying, corner cracking, or debonding. 540
d.Test Report Testing shall be performed by a recogn ized laboratory in accordance with ITM 806. Test reports shall not be more than five years old on January 1 of the approval year. 901.07
901.08 Packaged Patching Products
Packaged patching products shall be selected from the Department’s QPL of Rapid Setting Patch Materials. A packaged patching product will be considered for inclusion on the QPL by completing the requirements in ITM 806, Procedure F. 550 Packaged patching products shall be in accordance with ASTM C387. All packages shall be identified as conforming to ASTM C387. The markings shall also show the kind and type of material, the net weight in each bag, the yield in cubic feet or yield in square feet per inch of thickness, and the amount of water recommended for mixing to produce a 2 in. to 3 in. slump. The following exceptions to ASTM C387 shall apply for packaged patching products used in accordance with 710. Compressive Strength, min. 24 h 28 days ASTM C109 on 2 in. cubes (neat) 2,000 psi 5,000 psi Length Change, max. 28 days (air storage) 28 days (water storage) ASTM C157, modified C928 -0.09% +0.03% Slant/Shear Bond Strength, min. 28 days ASTM C882 modified* 2,000 psi Modulus of Elasticity Minimum @ 28 days Maximum @ 28 days ASTM C469 3,000,000 psi 5,000,000 psi * Product scrubbed into substrate or as recommended b y the manufacturer.
901.09 Air-Cooled Blast Furnace Slag for Retaining Walls If ACBF or coarse aggregate is used, and soil, B borrow, structural backfill, or coarse aggregate is to be placed above the ACBF or coarse aggregate, a single layer
of geotextile shall be placed on top of the ACBF or coarse aggregate in accordance with 616.11. A Type C certification in accordance with 916 shall be provided for the geotextile materials. 570 ACBF shall be in accordance with the pH , chlorides, sulfates, organic content, resistivity, and permeability requ irements of structure backfill as listed in 211.03.1. It shall also be in accordance with ITM 212. To tal sulfides shall also be determined in accordance with EPA 376.1, using the 100- mL pH water samples obtained during the ITM 212 test, and shall not exceed 400 ppm. 901.08 981 The ACBF shall have a maximum corrosion rate as follows if tested in accordance with ASTM G59.
a.Zinc corrosion rate, first two years ................ 15 μm/yr/side 580
b.Zinc corrosion rate, to depletion .................... 4 μm/yr/side
c.Carbon-steel corrosion rate ............................ 12 μm/yr/side.
901.10 Components of MSE Retaining Walls
a.PCC Components 1. Face Panels Precast concrete face panels shall be produced from a source listed on the QPL of Certified Precast Concrete Producers, in accordance with ITM 813. Concrete shall 590 have a compressive strength equal to or greater than 4,000 psi at 28 days. The target water/cementitious ratio for the concrete mix design shall not exceed 0.435. The cement content and target water/cementitious ratio of the concrete mix design shall be sufficient to obtain the specified minimum 28-day compressive strength. Air-entraining admixture and chemical admixture types A, B, C, D, or E from the QPL of PCC Admixtures and Admixture Systems may be used. Ground-reinforcement connection hardwa re and reinforcing bar lifting devices shall be set in place and secured prior to beginning casting, in accordance with the 600 dimensions and tolerances shown on the working drawings.
a.Production Control Testing and Inspection The manufacturer shall provide for all testing and inspection services during each day’s production of the panels. The frequenc y of production control testing shall be based on a lot of 50 panels, or fraction thereof, for each day’s production. Sampling and testing of the plastic concrete shall be in accordance with 505.01, or the ASTM equivalent. A minimum of one water/cementitious ratio, slump, air content, and relative yield tests shall be run per production lot, per day. A minimum of two 6 in. by 12 in. cylinders shall be cast per day’s production lot for compressive strength 610 determination. Cylinders shall be cured in the same manner as the panels they represent. Relative yield, air content, and sl ump of the concrete shall be in accordance with 702.05. Compressive strength shall be determined in accordance with AASHTO T 22 or ASTM C39, with lot acceptance based on the average of 2 cylinders tested at an age no greater than 28 days. Panels shall not be shipped until the compressive strength meets or exceeds the 28-day requirement. If the cylinder-test results do not satisfy the requirements described herein, and additional cylinders for testing are not availa ble, the manufacturer may core the panels. The wall manufacturer shall randomly select two panels from the lot for coring in 620 accordance with AASHTO T 24 or ASTM C42. The wall manufacturer shall obtain one core on the backside of each panel w ith a device that produces uniform test 901.10 982 samples without coring completely through the panel. Coring shall not be located within 6 in. of the panel fasteners or the e dges of the panels and shall avoid the panel's reinforcing steel. The wall manufacturer shall fill the core holes with equivalent concrete materials or rapid setting patch materials, and trowel to produce a smooth finish. Excess material removed during troweling shall not be reused. If rapid setting patch material is used, mixing and curing shall be in accordance with the manufacturer's recommendations. Compressive strength testing shall be performed on the cores. If the average st rength-test results from the cores satisfy or exceed the 630 requirements described herein, the pr oduction lot panels may be shipped. b . C a s t i n g The panels shall be cast on a flat area, wi th the front face of the form at the bottom, and the back face at the upper part. Tie strip guides shall be set on the rear face. The concrete in each unit shall be placed without interruption and shall be consolidated as necessary to prevent the formation of segreg ation or cleavage planes. Clear form oil from one manufacturer shall be used throughout the casting operation. c. Curing 640 The panels shall be cured for a sufficient length of time such that the concrete develops the specified compressive strength.
d.Removal of Forms The forms shall remain in place until they can be removed without damage to the unit.
e.Concrete Finish The concrete surface for the front panel face shall have a surface finish produced from contact with the form. The rear face of the panel shall be sc reeded to eliminate 650 open pockets of aggregate and surface distortions in excess of 1/4 in. f. Tolerances All panels shall be manufactured within the tolerances as follows:
1.Panel Dimensions Lateral position of tie strips shall be within 1 in. All other dimensions shall be within 3/16 in.
2.Panel Squareness 660 Squareness, as determined by the differ ence between the two diagonals, shall not exceed 1/2 in. (3) Panel-Surface Finish Surface defects on smooth formed surfaces measured on a length of 5 ft shall not exceed 1/8 in. Surface defects on textured fi nished surfaces measured on a length of 5 ft shall not exceed 5/16 in. 901.10 983 g. Compressive Strength Verification Verification of panel compressive strength will be conducted by the Engineer. 670 The frequency of verification testing will be one test for every 750 panels per manufacturer with a minimum of one test per contract. One panel will be randomly selected and two locations will be selected for coring. In the presence of the Engineer, the Contractor shall obtain two 4 in. cores on the backside of the panel without coring completely through the panel. The Contract or shall refill the core holes with rapid setting patch materials and trowel to produce a smooth finish. Excess material removed during troweling shall not be reused. Mixing and curing of the patching materials shall be in accordance with the manufacturer’s recommendations. The Engineer will test the cores in accordance with AASHTO T 24. The 680 verification test results will be averaged a nd shall be in accordance with 901.10(a)1a. If the initial verification test results do not satisfy the requirements described herein, the Engineer will randomly select two different panels for additional verification testing. If the additional verification tests satisfy the requirements described herein, no further action is required. If the test results still do not satisfy the requirements described herein, installation of panels sh all cease and the Engineer will conduct an investigation. Panels manufactured on th e same dates as the panels cored for verification tests that have already been in stalled will be considered and adjudicated as failed material in accordance with 105.03. The Engineer will conduct verification testing until three consecutive dates of production satisfy the strength requirements 690 described herein. The Contractor or wall manufacturer shall make arrangements so panels from three consecutive dates of production are accessible for coring. Installation of panels may resume once acceptable verification testing results are achieved.
h.Rejection Units will be subject to rejection due to their failure to be in accordance with the requirements as specified herein. The following defects may result in rejection:
1.Defects which indicate imperfect molding. 700
2.Defects which indicate honeycombed or open texture concrete.
3.Defects in the physical characteristics of the concrete, such as broken or chipped concrete, or color variations or dunnage marks on the front face due to excessive form oil or other reasons. The Engineer will determine whether spalled, honeycombed, chipped, or 710 otherwise defective concrete shall be repaired or be cause for rejection. Repair of concrete, if allowed, shall be completed in a manner which is acceptable to the Engineer. Repair to concrete surfaces that are to be exposed to view after completion of construction shall be subject to approval. 901.10
i.Marking The place and date of manufacture, and production lot number shall be shown on the rear face of each panel. 720
j.Handling, Storage, and Shipping All panels shall be handled, stored, and shipped to eliminate the danger of chipping, cracks, fractures, or excessive bend ing stresses. Panels in storage shall be supported on blocking located immediately adjacent to tie strips to avoid bending the tie strips. 2. Coping The coping may be precast or cast-in-place.
b.Joint Spacers and Joint Covering 730 The horizontal and vertical joint spacer s shall include compression blocks, pins, or other manufacturer’s recommended materials to provide a uniform joint. The joint cover shall be either a non-woven needle-punch polyester geotextile or a woven monofilament polypropylene. The joint cover shall be attached to the rear face of the panels with a manufacturer’s recommended adhesive. A letter certifying that th e joint spacers and joint cover adhesive material supplied is in accordance with the manufacturer’s r ecommendations shall be provided prior to use of the materials. 740
Source: Indiana Standard Specifications, 2024 Edition. Pages 1000–1005 of 1,248.