503 - PORTLAND CEMENT CONCR ETE PAVEMENT SMOOTHNESS
500-38 Engineer may use a 10-foot straightedge (or other means) to detect irregularitie s outside the required trace paths. The
Engineer may also use the straightedge to de lineate the areas that re quire corrective action. Determine a profile index (in./mi.) for each pavement s ection of finished pavement. A pavement section is a continuous area of pavement surface 0.1 m ile long by 1 lane wide (12 feet nominal). A partial pavement section resulting from an interruption (such as a bridge) of the continuous pavement surf ace is subject to the same testing and evaluation as a whole section. During the initial paving operations (a nd after long shutdown peri ods), profile the pavement as soon as the concrete has cured sufficiently to permit testing. The Engineer and the Contractor will use the results of the initial testing to evaluate the paving met hods and equipment. If the initial pa ving operation produces acceptable results, the Contractor may continue paving. Repair or replace any PCCP curing me dium that is damaged or removed during the testing. On surfaces excluded from profilograph testing, the E ngineer will determine the pavement smoothness using a 10-foot straightedge. The Engineer will select the locations to be tested. Th e variation of the surface from the testing edge of the straightedge shall not exceed ⅛ inch between any 2 contacts, longitudinal or transverse. Correct all irregularities exceeding th e specified tolerance using equipm ent and methods approved by the Engineer. After the irregularities are corrected, the Engineer will retest the area to verify compliance with the specified tolerance.
d.Profilograph Evaluation and Corrective Actions. Evaluate the profilograph results according to KT-
46.Provide the Engineer with the pr ofilograms and their evaluation within 2 working days after placement of the pavement. Determine and evaluate the profile index (in./mi.) fo r each trace and the average profile index (in./mi.) for each section to identify required corrective action. Determine the daily average profile index (in./m i.) for each day’s paving ope ration. A day’s paving operation is the pavement placed in a day (a minimum of 1 pavement section). If less than 1 pavement section is placed in a day, the day’s production is grouped with the next day’s production. If the production of the last day of project paving is less than 1 pavement section, it is grouped with the previous day’s production. The Contractor has the option of profiling the fi nal portion of a day’s production (not to exceed 5 sections) the first working day that paving is conti nued in the same lane. If the Contractor opts to profilograph the final portion of a day’s paving the next working day that paving is continued in the same lane, those results (the final portion of the previous day’s paving) are grouped with the day’s paving as the lane is continued. Make the required corrections for pavement smoothness before making the pavement thickness determinations. Take the require d corrective actions according to TABLE 503-1 . 503 - PORTLAND CEMENT CONCR ETE PAVEMENT SMOOTHNESS
500-39 Table 503-1: Pccp Surface Corrections
Pavement Surface Tolerances (in./mi.) Required Corrective Action Through Lanes Speed Limit Greater than 45 mph Acceleration Lanes1 Deceleration Lanes1 Ramps1 Through Lanes Speed Limit 45 mph or Less Profile Index per Section of 30 or less for an individual trace Profile Index per Section of 40 or less for an individual trace Correct all bumps and dips2 Profile Index per Section of greater than 30for an individual trace Correct the Profile Index of each individual trace to 30 or less per section3 Profile Index per Section of greater than 40 for an individual trace Correct the Profile Index of each individual trace to 40 or less per section Daily Average Profile Index greater than 40 Daily Average Profile Index greater than 65 Suspend the paving operations until corrective actions are taken to improve the paving operations 1Acceleration/deceleration lanes include the taper. Accelera tion lanes that become through lanes are limited to 500 feet from the noes of the ramp. Ramps are from the nos e to the intersection of the adjoining road. 2Correct all areas within each section having high points (bumps) w ith deviations in excess of 0.3 inches in a length of 25 feet or less regardless of the profile index value. 3 Contractor has the option to replace the section when the Profile Index per Section is greater than 65. After the profilograph traces have been ev aluated, make corrections according to TABLE 503-2 . TABLE 503-2: GRINDING REQUIREMENTS Condition Action* Greater than 25% (132 feet) of the 0.1 mi. section requires correction Continuously grind the entire 0.1 mi. section.** Greater than 25% (1320 feet) of 1.0 mi. segment require correction Continuously grind the entire 1.0 mi. segment, when the areas requiring correction are dispersed throughout the 1.0 mi. segment. If the areas re quiring correction are isolated to 1/3 or ½ mi. within the 1.0 mi. segment, then only grind that 1/3 or ½ mi. * Continuously grinding requires a minimu m of 98% of the pavement be ground. **If the skip length between areas to be ground (either within a 0.1 mi. section or between 0.1 mi. sections) is less than eith er grind length, combine the grinds so the area between is also ground. This additional ground area (a rea between) will apply to the computation of the 25% of the 0.1 mi. section. If the Contractor elects or is required by TABLE 503-2 to continuously grind the entire project, the following apply: the areas excluded in subsection 503.3a. are not required to be ground; at intersections constructed with multiple transiti ons for drainage (especially in urban areas), if smoothness meets SECTION 503 , the intersection is not required to be ground; and when transitioning from a ground area to an unground area, feather the grinding a uniform distance throughout the project. Grind and texture the entire surface of the pavement in the longitudinal direction. Provide positive lateral drainage by maintaining a constant cross slope between grinding passes in each lane. Maintain a uniform transverse slope that matches the existing cross slope to the extent possible with no depressions or humps greater than 1/4 inch in 12 feet when tested with a string line or st raightedge. Do not exceed by more than 1/16 inch the vertical ali gnment between adjacent passe s of the cutting head. Begin and end grinding lines 503 - PORTLAND CEMENT CONCR ETE PAVEMENT SMOOTHNESS
500-40 normal to the direction of vehicle trav el. Grind the surface so corrugations ar e parallel to the pavement edge with
ridges 1/16 inch, ±1/32 inch higher than the valleys of the corrugations. Use the following methods for corrections: Diamond grinding or othe r profiling devices appr oved by the Engineer, Remove and replace the entire pavement thickness Apply the corrective measur e to the full lane width of the paveme nt. The corrected areas shall have uniform texture and appearance. The beginning and endi ng of the corrected areas shall be squared normal to centerline of the paved surface.
e.Profilograms. After pavement sections are corrected, re -profile the pavement surface to verify compliance with the specified pavement smoothness. Provide the Engineer with the profilograms and their evaluation within 2 working days af ter correcting the pavement surface. The Engineer may perform profilograph testing on the pavement surface for monitoring and comparison purposes. If the Engineer determines that the Contractor’s certified test results are inaccurate, the Engineer may choose to test the entire project length. The Engineer will charge the Contractor for such testi ng at the rate of $500 per mile per profile track, with a minimum charge of $1000. Providing inaccurate test results may re sult in de-certification of the Contractor’s certified operator. 503.4 MEASUREMENT AND PAYMENT Pay adjustments will be based on the initial average profile index determined for the "sections" prior to performing any corrective work, unless the surface of the entire project is continuously ground. If the Contractor elects or is required by TABLE 503-2 to continuously grind the entire project, pay adjustments will be based on the average profile index determined after all grinding is performed. If the Contractor elects to remove and replace the sections, the Contractor will be paid the price adjustment that corresponds to the initial averag e profile index obtained on the pave ment sections after replacement. The Engineer will apply the contr act price adjustment according to TABLE 503-3. Payments made for "Concrete Pavement Smoothness" will be shown as an added item to the contract. TABLE 503-3: CONCRETE PAVEMENT SMOOTHNESS PAY ADJUSTMENT NEW CONSTRUCTION Average Profile Index (in./mi. per lane per 0.1 mi. section) Contract Price Adjustment (per 0.1 mi. section per lane) 6.0 or less +$1000.00 6.0 to 10.0 +$835.00 10.1 to 15.0 +$625.00 15.1 to 18.0 +$310.00 18.1 to 30.0 0.00 30.1 to 40.0 0.00* 40.1 or more -$615.00* *Correct to 30.0 inch/mile (40.0 in./mi. as noted in TABLE 503-1 ). The pay adjustments in TABLE 503-3 are for 12-inch thick hot mix asphalt and 8-inch thick portland cement concrete pavements. Pay adjustments for pavements of different thicknesses will be reduced or increased proportionally, based on the typical section for the extent. (i.e. pay adjustment for a 12-inch portland cement concrete pavement is equal to the adjustment from the TABLE multiplied by 1.5). 504 – DOWEL BAR RETROFIT-REPAIR NEW PCCP
500-41 Section 504
DOWEL BAR RETROFIT-REPAIR NEW PCCP 504.1 DESCRIPTION Cut slots normal to the transverse cracks and place epoxy-coated st eel dowel bars to repair the newly constructed Portland Cement Concrete Pavement (PCCP) th at is damaged. See Standard Drawing RD723, latest version. 504.2 MATERIALS
a.Epoxy-Coated Dowel Bars. Provide epoxy-coated steel dowel bars that comply with DIVISION 1600 . Provide a tight fitting nonmetallic expansion cap on one end of the dow el bars. The Engineer must approve the expansion cap before it is used. Provide epoxy-coated or nonm etallic chair devices to support and hold the dowel bars. The Engineer must approve the chair devices before they are used.
b.Bondbreaker for Dowel Bars. Provide a bondbreaker that complies with DIVISION 1700 .
c.Caulking Filler. Provide a silicone sealant caulking filler intended for filling cracks in PCCP. The Engineer must approve the caulking filler before it is used.
d.Board Filler. Provide a closed-cell foam core board fille r (the width of the joint thick) faced with poster board material on each side. The Engineer must approve the board filler before it is used.
e.Grout. Provide a product that complies with DIVISION 1700 and is prequalified as “very rapid hardening” when extended. The grout may be extended as the manufacturer recommends. The extender aggregate must be of size to allow complete distribution and consolidation around the bar. For practical purposes the maximum aggregate size should be no more than 1/2 the size of the distance be tween the dowel bar and the adjacent concrete pavement. All extender aggregate used on contr acts must be from a source th at has a current Official Quality approval status for Mixed Aggregate per
Division 1100
f.Liquid Membrane-Forming Compound. Provide a liquid membrane-forming compound that complies with DIVISION 1400 . 504.3 CONSTRUCTION REQUIREMENTS Cut slots for the dowel bars into the PCCP as needed to repair the damaged PCCP. Use a gang saw capable of simultaneously cutting all the slots at one location (one wheel path). A single or dual blade saw may be used provided the production rate for sa wing equals or exceeds 15 slots per hour . Hand saws are prohibited. Make the slots large enough to provide the minimum clearances s hown in the Contract Docume nts. If necessary, make multiple parallel saw cuts to remove the existing concrete from the slot. If jackhammers are used to break the concrete loos e, do not use jackhammers larger than the nominal 15 pound class. Sandblast and clean all surfaces of the slot. Sandblast and clean all cracks in the slot. Remove all broken concrete and debris from the project. Fill the transverse crack in the bottom and sides of th e slot with caulking filler. Prevent the caulking filler from contacting the surfaces outside the crack. Before the dowel bar is placed in the slot, cut a pi ece of the board filler materi al to fit tightly around the dowel bar and against the bottom and sides of the slot. Place the board filler mate rial vertically above the transverse crack in the bottom of the slot and prev ent it from being displaced in the slot. Keep the board filler material in this position during placement of the grout. Use chair devices to position and hold the dowel bars parallel (± 1/8 inch) to the pavement centerline and the pavement surface, and at the depth shown in the Contract Documents. Co at the dowel bars with an approved bondbreaker before the grout is placed. 504 – DOWEL BAR RETROFIT-REPAIR NEW PCCP
500-42 Place and consolidate the grout as recommended by the manufacturer. Cure the surface of the grouted slots
with a liquid membrane-forming compound. The extended grout must obtain a minimum of 2000 psi compressive strength before the roadway can be opened to traffic, but no sooner than 2 hours. Provide data that accounts fo r actual temperatures work is being performed. Saw the transverse joint through th e patched areas within 24 hours of the placement of the grout. Saw and seal the joint as shown in the Contract Documents. 504.4 MEASUREMENT AND PAYMENT This work is subsidiary to bid items in DIVISIONS 501 and 502.
Source: Kansas Standard Specifications for State Road and Bridge Construction, 2015 Edition. Pages 232–236 of 978.