808Joint Repair

808.01 Description. All joints requiring repair sha ll be reconstructed with specified

materials according to details shown on the pl ans and instructions contained herein. All other requirements shall be in accordance with the applicable provisions of Sections 501 and 804 of the Standard Specifications.

808.02 Materials.

808.02.1 General. When materials from the Depart ment's current list of approved

materials are to be used, the Contractor sha ll submit documentation to the Engineer that the epoxy and all components meet the requirements of the contract. If the materials proposed for use are not from the Department's current list of approved materials, a sample of the epoxy and all components required for the epoxy mortar mix shall be submitted to the Engineer for evaluation and approval at least 30 calendar days prior to placement. Subsequent approval of each new lot may be by certification. The manufacturer must certify that the new lot of material is the same composition as that originally approved by the Department and that the material has not been changed or altered in any way. A representative of the epoxy manufacturer must be present for sufficient time to assure that the Contractor is properly schooled in the use of the epoxy materials.

808.02.2 Epoxy Resin. The material shall meet the requirements of ASTM C 881, Type

I, Grade 2, Class C.

808.02.3 Silica Sand. The material shall be bagged general purpose blast cleaning sand.

808.02.4 Epoxy Mortar Mix. The mortar mix shall consist of one part liquid epoxy to

3.5 parts clean dry sand by volume.

808.02.5 Mixing and Curing. Mixing of all epoxy materials shall be accomplished with

a mechanical mixer. A trial batch of mortar, approximately one c ubic foot, will be mixed and used for joint repair. From this batch, the pot life and subsequent amount of material to be mixed will be determined. Workers should wear rubber gloves and any other protective measures necessary to minimize contact with skin, eyes, etc. The curing time shall be regulated so the repaired area may be open to traffic in four hours from time of placement. To meet the above requirement, it may be necessary to store materials in heated enclosures and provide temporary cover and heat to the repaired area.

808.03 Construction Details. All repair areas are to be thoroughly cleaned by chipping

and sandblasting to sound concrete. To form joints, insert styrofoam or other ap proved forming materials to desired grade. Forms are to be greased lightly to assist in removal. The mortar mix shall be prepared and placed during periods of warm weather if at all possible. The prepared surface shall be lightly primed with neat epoxy prior to placement of the mortar mix. Placement of the mortar mix shall start at the earliest practical time and may continue until approximately four and one-half hours prior to opening the section of roadway or bridge to traffic. The mortar mix shall be finished to the line of the existing joint an d to the grade of the adjacent pavement or bridge deck.