834 - UNDERSEALING
800-91 Produce grout slurry to a 12 second flow cone time. Pump the grout into the holes using an injection pump
with a pressure capability of 250 to 300 psi when pumping grout slurry mixed to a 12 second flow cone time. Cease injection of grout when grou t appears at any joint, crack or ad jacent hole, or when monitoring devices indicate slab movement. Cease injection at a hole when gr out flow does not occur after 7 seconds of sustained 150 psi gauge pressure, and there is no indication of slab movement. Prevent grout from being injected into any drainage facility or other open structure. Prevent excessive loss of grout through cracks, joints, other drilled holes or back pressure. KDOT will not pay for wasted material. Prior to grout drying on the drilled holes, fill the holes with a fast setting sand/cement mixture or other patching material approved by the Engineer Replace slabs in which cracks emanate radially from the grout injection holes and in slabs where cracks develop between adjacent grout injection holes at no additional cost to KDOT. The Engineer may approve cross- stitching of the cracks if the cracking is minor.
d.Deflection Testing. KDOT may use the Falling Weight Deflectom eter (FWD) at sample locations to determine the effectiveness of the undersealing operation. Voids detected under the slabs using this procedure will be filled a second time by the Contractor at no additional cost to KDOT. 834.4 MEASUREMENT AND PAYMENT The Engineer will measure fly ash by the ton. The Engineer will measure each injection holes. Monito ring for pavement lift is subsidiary to the injection holes. "Fly Ash (Undersealing)" and "Injection Holes" will be paid for at the contract unit prices which is full compensation for the specified work. No adjustment in contra ct unit prices will be made regardless of the amount of underruns or overruns. 835 - RESEALING JOINTS AND SEALING CRACKS IN EXISTING PCCP AND HMA PAVEMENTS
800-92 Section 835
RESEALING JOINTS AND SEALING CRACKS IN EXISTING PCCP AND HMA PAVEMENTS 835.1 DESCRIPTION Concrete Pavement. Re-saw the longitudinal and transverse joints, and saw or rout the random cracks in the PCCP at the locations designated in the Contract Docu ments or as required by the Engineer. Clean and fill the sawed or routed joints and cracks w ith hot type joint sealing compound. Asphalt Pavement and Concrete Pavement with Spalled Joints and Cracks. Prepare the existing cracks and joints at the locations designated in the Contract Docume nts or as required by the Engineer. Fill the cracks and joints with the specified materials. Asphalt Shoulder Adjacent to Concrete Pavement. Clean the existing longitudinal joint between PCCP and asphalt shoulder at the locations designated in the Cont ract Documents or as required by the Engineer. Fill the joint with hot fiber-reinforced asphalt. The bid items in this section are exempt from SECTION 104 . There will be no price adjustments due to quantity changes for these items. B I D I T E M S U N I T S Sealing PCCP Joints (Longitudinal) Linear Foot Sealing PCCP Joints (Transverse) Linear Foot Sealing PCCP Cracks (> ⅛" <2") Linear Foot Sealing Spalled PCCP Joints & Cracks (>2" ≤3") Linear Foot Sealing Spalled PCCP Joints & Cracks, Type A or B (>2" ≤3") Linear Foot Sealing Asphalt Cracks (> ⅛" ≤ ½ " ) L i n e a r F o o t Sealing Asphalt Cracks (> ½" <2") Linear Foot Sealing Longitudinal Asphalt Shoulder Joint Linear Foot 835.2 MATERIALS
a.Hot Type Joint Sealing Compound. When required, provide hot type joint sealing compound that complies with DIVISION 1500 . When required, provide backer rod intended for use with the hot type joint sealing compound.
b.Fiber-Reinforced Asphalt. When required, provide a mixture of performance graded asphalt binder and polypropylene fibers. Provide a mixture that has not less than 8% fiber content by weight. Provide PG 64-22 asphalt binder that complies with DIVISION 1200 . Provide polypropylene fibers suitable for the intended use that have a denier of 15 ± 3. The Engineer will accept the polypropylene fibers based on a Type D Certification according to DIVISION 2600 , and visual inspection of the mixture.
c.Rapid-Set Concrete Patching Material. When required, provide rapid-set concrete patching material that complies with DIVISION 1700 . Provide foam core backer board intended for use with the rapid-set concrete patching material. 835.3 CONSTRUCTION REQUIREMENTS.
a.Concrete Pavement, Joints and Cracks.
1.Transverse Joints. Saw the existing transverse joints with a saw blade wi de enough to clean both surfaces of the cut removing the existing sealant. Configure the transverse joints according to FIGURE 835-1 . 835 - RESEALING JOINTS AND SEALING CRACKS IN EXISTING PCCP AND HMA PAVEMENTS 800-93 FIGURE 835-1: PCCP SAWE D TRANSVERSE JOINT DETAIL 4 3 TABLE 835-1: PCCP SAWED JOINT DIMENSIONS* Joint Width 2 Recess Below Surface 3 Sealant Thickness Backer Rod Diameter 4 Total Joint Depth ¼" ⅛" to ¼" ⅜" ⅜" 1" ⅜" ⅛" to ¼" ⅜" ½" 1⅛" ½" ⅛" to ¼" ⅜" ⅝" 1¼" ⅝" ⅛" to ¼" ½" ¾" 1½" ¾" ⅛" to ¼" ½" ⅞" 1 ⅝" ⅞" ⅛" to ¼" ½" 1" 1¾" 1" ⅛" to ¼" ½" 1⅛" 1⅞" 1½ " ⅛" to ¼" ¾" 1¾" 2 ⅜" 2" ⅛" to ¼" 1" 2½" 3⅝" *All dimensions are nominal. Clean, and fill the transverse joints according to subsections 502.3g.(8) and (9).
2.Longitudinal Joints. Saw the existing longitudinal joints with a saw blade ⅛" to ¼" wider than the joint, cleaning both surfaces of the cut, and, rem oving all existing sealant Configure the longitudinal joints to the width in column 1 in TABLE 835-1 , with the depth equal to the original depth of the longitudinal joint. Clean and fill the longitudinal joints according to subsections 502.3g.(8) and (9). Fill the longitudinal joint with hot type joint sealant compound to within ⅛ to ¼ inch of the surface. Do not use backer rods in the longitudinal joints.
3.Random Cracks. Rout or saw random cracks greater than ⅛ inch wide with a blade ⅛ to ¼ inch wider than the crack and to a depth equal to the full width of th e blade to produce a cut on eac h side of the crack for the full length of the crack. Clean, a nd fill the random cracks according to subsections 502.3g.(8) and (9). Fill the random cracks (routed or sawed reservoir) with a hot type joint sealing compound to within ⅛ to ¼ inch of the surface. Do not use backer rods in the random cracks.
b.Concrete Pavement, Spalled Joints and Cracks. Clean the full depth of the spalled joints and cracks. Remove all foreign material that will prevent bonding of the sealant. Clean the joints and cracks by sandblasting. Remove loose material on the surface immedi ately adjacent to the joints and cracks. Do not seal PCCP spalled joints or cracks greater than 3 inches wide. If the PCCP joints and cracks are 3 inches or less wide and 1 ⅝ inches or less deep, fill the joints and cracks with hot fiber-reinforced asphalt. See FIGURE 835-2 . Fill the joints and cracks to a level slightly recessed from the pavement surface. 835 - RESEALING JOINTS AND SEALING CRACKS IN EXISTING PCCP AND HMA PAVEMENTS 800-94 FIGURE 835-2: SEALING PCCP , SPALLED JOIN TS AND CRACKS (>2" ≤ 3" wide, ≤1⅝" deep) >2" ≤ 3" ≤1⅝” Clean and fill with hot fiber- reinforced asphalt. If the PCCP joints and cracks are 3 inch es, or less, wide and greater than 1 ⅝ inches deep, use either the Type A option ( FIGURE 835-3 ) or the Type B option ( FIGURE 835-4 ) to fill the joints and cracks: FIGURE 835-3: TYPE A, SEALIN G PCCP, SPALLED JO INTS AND CRACKS (>2" ≤ 3" wide, >1 ⅝" deep) >2" ≤ 3" > 1 ⅝" Clean, place the foam core backer board, and fill with rapid-set concrete patching material on both sides of the backer board. After the patching material is set, remove the backer board and fill the reservoir with hot type joint sealing compound. FIGURE 835-4: TYPE B, SEALIN G PCCP, SPALLED JO INTS AND CRACKS (>2" ≤ 3" wide, >1 ⅝" deep) >2" ≤ 3" 1⅝" >1⅝" Clean, place the backer board to within 1⅝" of the surface, fill the lower cavity with rapid-set concrete patching material on both sides of the backer board, to the top of the backer board. After the patching material is set, fill the upper cavity with hot fiber-reinforced asphalt (do not remove the backer board). Fill the joints and cracks to a level slightly r ecessed from the pavement surface.
c.Asphalt Pavement Cracks. Seal cracks in asphalt pavement th at are equal to or greater than ⅛ inch wide. Do not seal cracks less than ⅛ inch wide. Do not seal cracks wider than 2 inches. See FIGURE 835-5 . 835 - RESEALING JOINTS AND SEALING CRACKS IN EXISTING PCCP AND HMA PAVEMENTS
800-95 Rout all the cracks that are ⅛ to ½ inch wide following the existing crack. Route cracks ⅛ to ⅜ inch with a ⅝
inch router head, ⅜ to ½ inch with a ¾ inch router h ead and to a depth equal to or great er than the router head width. Cracks wider than ½ inch do not require routing. Clean the full depth of the cracks. Remove all foreign material that will prevent bonding of the sealant. Remove loose material on the surface imme diately adjacent to the joints and cr acks. Clean and dry the cracks with a heat lance. Do not burn the pavement (indicated by smoke) with the heat lance. Fill the routed cracks ( ⅛ to ½ inch) with hot type joint sealing compound. Fill un-routed cracks wider than ½ inch with hot fiber-reinforced asphalt. Fill all cracks to a level slightly recessed from the pavement surface. FIGURE 835-5: SEALING ASPHALT PAVEMENT CRACKS) (> ⅛"<2") Note: Cracks > ⅛", but <⅜" and >⅜" but </= ½" wide shall be routed to a depth and width of ⅝" and ¾" respectively, then cleaned and filled with hot type joint sealing compound asphalt. Do not rout cracks >1/2" wide. Clean and fill cracks >1/2" wide with hot fiber-reinforced asphalt.
d.Asphalt Shoulder Adjacent to Concrete Pavement. Saw the concrete pavement to asphalt shoulder joint a minimum of ½ inch by 1inch or ⅛ inch greater than the width of the existing crack 1 inch deep Clean the joints as required in subsection 502.3g.(8) . Fill the joint with hot fiber-reinforced asphalt. Fill the joint with sealant to within ⅛ to ¼ inch of the surface. Do not use backer rods in the joints.
e.Manufacturer’s Representative. Notify the sealant manufacturer’s t echnical representative of the starting date of the initial installation. Demonstrate competence in applying sealant to the Engineer and the manufacturer’s representative. Do not perform operations or procedures that would be detrimental to the sealing of joints and cracks. This requirement will be waived for experienced Contr actor’s crews. Submit waiv er request, along with a list of joint sealant crews successfully completed joint and crack sealing projects, to the Engineer for consideration.
f.Preparation of Asphalt for Crack Sealing. Heat the material to the temperature recommended by the manufacturer.
g.Weather Limitations. Do not place sealant when: the ambient air temperature is below 40 F, or the pavement temperature is above 105 F. 835.4 MEASUREMENT AND PAYMENT The Engineer will measure sealing of joints and random cracks by the linear foot along the center of the joint or crack. The bid items in this section are exempt from SECTION 104 . There will be no price adjustments due to quantity changes for these items. Payment for "Sealing PCCP Joints (Longitudinal)", "Sealing PCCP Joints (Transverse)", "Sealing PCCP Cracks (> ⅛" <2")", "Sealing Spalled PCCP Joints & Cracks (>2" ≤3")", "Sealing Spalled PCCP Joints & Cracks, Type A or B (>2" ≤3")", "Sealing Asphalt Cracks (> ⅛" ≤ ½")", "Sealing Asphalt Cracks (> ½" <2")" and "Sealing Longitudinal Asphalt Shoulder Joint" at the contract unit prices is full compensation for the specified work.
Source: Kansas Standard Specifications for State Road and Bridge Construction, 2015 Edition. Pages 582–586 of 978.