SECTION 405 – CONCRETE SURFACE COURSE
405.01 Description
This Section describes the requirements for constructing concrete surface courses.
405.02 Materials
405.02.01 Materials
Provide materials as specified: Sand................................ ................................ ................................ ................................ ......................... 901.06.02 Concrete ................................ ................................ ................................ ................................ ...................... 903.03 Quick-Setting Patch Materials ................................ ................................ ................................ ...................... 903.07 Epoxy Grout ................................ ................................ ................................ ................................ ........ 903.08.02.B Curing Materials ................................ ................................ ................................ ................................ .......... 903.10 Tie Bars (epoxy-coated) ................................ ................................ ................................ ........................... 905.03.01 Joint Ties (epoxy-coated) ................................ ................................ ................................ ......................... 905.03.01 Tie Bolts (epoxy-coated) ................................ ................................ ................................ .......................... 905.03.02 Dowel Bars (epoxy-coated) ................................ ................................ ................................ ...................... 905.03.03 Preformed Joint Filler ................................ ................................ ................................ ................................ ... 914.01 Joint Sealer (hot-poured) ................................ ................................ ................................ ............................... 914.02
405.02.02 Equipment
Provide equipment as specified: Sealer Application System................................ ................................ ................................ ........................... 1003.08 Pavement Forms ................................ ................................ ................................ ................................ ......... 1005.01 Spreading and Finishing Machine ................................ ................................ ................................ ................ 1005.02 Vibrator ................................ ................................ ................................ ................................ ...................... 1005.04 Slip Form Paver ................................ ................................ ................................ ................................ .......... 1005.05 Grinding Machine ................................ ................................ ................................ ................................ ....... 1006.08 Straightedge ................................ ................................ ................................ ................................ ................ 1008.02 Mechanical Sweeper ................................ ................................ ................................ ................................ ... 1008.03 Pavement Saw................................ ................................ ................................ ................................ ............. 1008.04 Hot-Air Lance ................................ ................................ ................................ ................................ ............. 1008.06 Concrete Batching Plant ................................ ................................ ................................ .............................. 1010.01 Concrete Trucks ................................ ................................ ................................ ................................ .......... 1010.02
405.03 Construction
405.03.01 Underlayer Preparation
When placing concrete on an aggregate base or subbase, prepare the underlying surface to 1/2 inch of the required elevation within 3 days of placing concrete. Do not grade and compact the underlying surface when the ambient temperature is below 34 °F, when frozen, or when it is unstable. Compact using the directed method, as specified in
203.03.02 B.3, to produce a firm and even surface. The RE will check the elevations as specified in 202.03.03.D. Correct
damage to the underlying surface and maintain the corrected surface until the concrete is placed. Immediately before placing concrete, spray the underlying surface with water to ensure that the underlying surface is damp to a depth of at least 1/2 inch without forming wet or unstable spots.
405.03.02 Concrete Surface Course
A.Concreting Plan. At least 20 days before placing the concrete surface course, submit to the RE for approval a detailed plan of operation that includes the following:
1.Certified Concrete Construction Technologist as certified by the NJACI.
2.Size and description of crew.
3.Number, type, and model of equipment.
4.Lighting plan for night operations as specified in 108.06.
5.Method of setting forms. When using slipform paving, provide method for locating joints.
6.Plant locations and hauling equipment.
7.Paving procedures for maintaining continuous operation.
8.Paving sequence, production, and schedule for the Project.
9.Method of constructing joints including dowel, joint tie, and tie bar placement.
10.Method of curing the concrete. If using wet burlap, provide the location where burlap will be presoaked.
11.Method of sawcutting and sealing joints.
12.Method for constructing and maintaining concrete washout system. Include placement location. Do not begin paving until the RE approves this plan. Submit an adjusted concreting plan before making adjustments to the paving operation.
B.Weather Limitations. Comply with the limitations of placing as s pecified in 504.03.02.C, except do not place concrete when the ambient temperature is above 85 °F. If within the 12 hours preceding the scheduled concrete placement the National Weather Service (refer to http://www.nws.noaa.gov/) locally forecasts a 40 percent chance or greater of precipitation during the scheduled concrete placement, postpone the placement of bridge decks and pavement.
C.Installing Longitudinal Joint Ties. If paving adjacent to existing concrete pavement, drill 9 inch deep holes into the side of the existing slab. Clean holes with a 150 pounds per square inch water blast to remove remaining debris in the drilled cavity, and then blow out holes with a hot-air lance to provide a dry surface. Immediately after blowing, fill the hole with epoxy grout and insert the joint ties according to the manufacturer’s recommendations. Support the joint ties in position until the grout has set.
D.Concrete Placing Methods. Appoint sufficient number of personnel, who are certified by the NJACI as Concrete Construction Technologist or by ACI as Concrete Transportation Construction Inspectors, to monitor daily operations for concrete placement. The certified personnel are responsible for ensuring proper dimensions of forms; position of reinforcement steel; proper handling, placement, consolidation, and finishing of concrete; and proper curing of the concrete. When placing concrete on asphalt-stabilized drainage course, spread sand over the surface to ensure that the surface voids are filled.
1.Fixed-Form Method.
a.Setting Forms, Ties Bars, and Joint Assemblies. Set forms, tie bars, and joint assemblies for the entire area to be paved at least 1 day before placing concrete. Set forms at grade in full contact with the underlying surface. Ensure that concrete does not seep beneath the form. Stake forms into place with at least 3 pins for each 10 foot section. Lock form sections together to prevent movement in any direction. Install longitudinal tie bars through the forms and secure in place. Ensure that concrete does not seep around the bar. If longi tudinal joint ties cannot be installed before placing concrete, install joint ties as specified in 405.03.02.C or use tie bolts as an alternate. Install joint assemblies and secure in place wit h anchor stakes. Ensure that devices for contraction joint assemblies are capable of holding dowels firmly in place during the entire construction operation. Place dowels across joint assemblies, parallel to and level with the surface course. Place 1/2 inch preformed joint filler along curb and around structures and other objects protruding into the slab. Check the alignment and grade elevations of the forms and joint assemblies and make corrections before placing the concrete. Ensure that the forms do n ot deviate from the requ ired alignment by more than 1/4 inch. Reset, or remove and replace, forms that settle or deflect under the spreading and finishing equipment. Clean the top and face of forms, and oil the face before placing concrete.
b.Placing Concrete. Obtain RE approval of forms and joint placement before placing concrete. Place concrete across the formed area to minimize rehandling. Ensure that concrete is not discharged into windrows or piles. Continuously place concrete between transverse joints without the use of intermediate bulkheads. If a slab is not completed from transverse joint to transverse joint, remove the incomplete slab and replace. Terminate each day’s pavin g at a transverse joint. If concrete becomes segregated during placement, suspend operations and correct handling operations. To prevent bowing or misalignment of the transverse joints, place concrete simultaneously on both sides of transverse joints without disturbing the joints.
c.Consolidation, Strike Off, and Finishing. Consolidate concrete using vibrators. Ensure that consolidating operations do not segregate the concrete or disturb the transverse joint assemblies, joint ties, the underlying surface, or side forms. Immediately after consolidating the concrete, strike off the surface to ensure that a uniform ridge of concrete, of between 2 and 6 inches, is maintained in front of the screed along the entire width of the pavement. Immediately after strike off, begin finishing operations to achieve the specified line and grade of the surface. Ensure that the finishing equipment is maintained true without lift, wobble, or other disturbances that could affect the specified line and grade. Use hand methods to finish variable -width areas or areas that would make the use of finishing equipment impractical. If the finishing equipment breaks down, the Contractor may use hand methods to screed and finish the concrete to the next joint assembly. At expansion joint assemblies, advance the finishing equipment, avoiding damage to or misalignment of joint assemblies. If advancing the finishing equipment over expansion joints causes concrete segregation or damage to, or misalignment of, the joint assemblies, stop the finishing equipment when the screed is approximately 8 inches from the joint assembly. Remove segregated concrete from the joint, lift the screed and set directly on top of the joint, and resume advancement of the finishing equipment. If screeding operations produce a surface containing voids, bubbles, or other imperfections, then hand finish the surface with a metal float. Do not add water to the surface of the concrete to assist in finishing operations. Texture the surface of shoulders with a broom after finishing the concrete.
d.Control Testing and Surface Correction. After advancing finishing equipment, check the concrete surface with a straightedge parallel to the centerline of the traveled way. Correct surface deviations determined by control testing before the concrete sets. Correct major deviations using the finishing equipment. Correct minor deviations and any defects caused by the control testing using a metal float. Do not add water to the concrete surface to assist in surface correction.
e.Removing Forms. Remove forms no sooner than 12 hours after completing concrete placement. If using mineral admixtures in the concrete, remove forms no sooner than 24 hou rs after completing concrete pavement. Repair voids and honeycombed areas.
2.Slip-Form Method. The Contractor may construct concrete pavement using the slip-form paving method. To control the operation of the slip -form paver, 1 day before placing concrete, set string lines at least 25 feet beyond the length to be paved. Mark joint locations of the entire area to be paved 1 day before placing concrete. Install and anchor each joint assembly before placing concrete, and ensure that each joint assembly is sufficiently secured to the underlying surface to prevent mov ement during paving. Place 1/2 inch preformed joint filler along the curb and around structures and other objects protruding into the slab. Place the concrete for the full depth of the slab with a slip -form paver in 1 pass of the machine. Consolidate the concrete for the full width and depth o f the concrete pavement. Before finishing the concrete, install longitudinal tie bars and joint ties. Ensure that surface deformations caused by the installation of longitudinal tie bars and joint ties is corrected by the finishing operation. Finish the concrete in such a manner that a minimum of hand finishing is necessary to provide a dense and homogeneous concrete pavement. Operate the slip -form paver with a continuous forward movement, and coordinate all operations of mixing, delivering, and spreading concrete to provide uniform progress and to minimize stopping and starting of the paver. Texture the surface of shoulders with a broom after finishing the concrete. Continuously place concrete between transverse joints without the use of intermediate bu lkheads. If a slab is not completed from transverse joint to transverse joint, remove the incomplete slab and replace. Terminate each day’s paving at a transverse joint. Correct concrete ed ge deformities greater than 1/4 inch before the concrete has take n initial set. Modify operations to prevent recurrence.
E.Curing. Ensure that the concrete is not exposed for more than 30 minutes after finishing. The RE will direct a suspension, as specified in 108.13, of concrete operations if the curing procedure is delayed or is not followed. Apply curing compound as specified in 504.03.02.F.1, or wet bu rlap and white polyethylene sheeting as specified in
504.03.02 F.2. Maintain the curing material for 7 days.
F.Protecting Concrete Surface Course. Protect concrete, as specified in 504.03.02.I, for the duration of the curing period. Construct wood bridging for pedestrian crossovers at street intersections and at other established pedestrian crosswalks. G Sawcutting Relief Joints. Relief joints are a preliminary step in the construction of transverse and longitudinal joints. The Contractor may begin sawcutting relief joints as soon as hardened concrete can support operations without spalling and must finish within 18 hours of placing concrete. Sawcut transverse relief joints above the joint assembly and sawcut longitudinal relief joints if more than 1 lane was paved in 1 paving operation. Sawcut 1/8 inch wide relief joints to a depth of 1/3 of the thickness of the concrete pavement. Do not sawcut expansion joints or butt joints created by 2 separate paving operations.
H.Sawcutting and Sealing Joints. After completion of diamond grinding operations as specified in 405.03.04 and before opening to traffic as specified in 405.03.02.K, sawcut 3/8 inch wide transverse and longitudinal joints to a depth of 1/2 inch at relief joints and butt joints. After sawcutting, immediately remove sawing slurry from the sawcut cavity and surrounding pavement surface. Clean sawcuts with a 150 pounds per square inch water blast to remove remaining debris in the sawcut cavity, and then blow sawcuts w ith a hot -air lance to provide a dry surface. Seal sawcuts immediately after blowing. Seal joints with joint sealer before opening to traffic. Seal joints when the ambient t emperature is between 50 and 80 °F. Pour joint sealer in the sawcuts, ensuring that joint sealer is not spilled on the surface of the concrete. If spillage occurs, immediately remove spilled joint sealer from the surface of the concrete. Fill joints to ensure that the joint sealer is 1/8 to 1/4 inch below the adjacent surface. Do not allow traffic over the poured joints until the joint sealer has hardened to resist pickup.
I.Thickness Requirements. The ME will divide the concrete pavement into lots of approximately 5,000 square yards. The ME will divide each lot into 5 equal sections. The RE will direct the Contractor to drill 1 core, as specified in
405.03 03, from a randomly selected location within each section . The ME will test these cores for thickness as
specified in ASTM C 174. The Department will determine conformance with thickness requirements as follows and will either assess the greater of the pay reduction for average core thickness or individual core thickness, or the Department will direct the Contractor to remove and replace the lot:
1.Average Core Thickness. If the average core thickness is greater than or equal to the specified core thickness, the Department will not apply a payment reduction. If the average thickness is less than the specified thickness, but is greater than or equal to the specified thickness minus 1/2 inch, the Department will determine payment reduction by the following formula: Payment Reduction = Q x BP x PPR Where: Q = Thickness Lot Quantity BP = Bid Price TS = Specified Thickness. TA = Average Thickness PPR = Percent Payment Reduction = TS − TA TS
2.Individual Core Thickness. When more than 2 individual cores in the lot are less than the specified thickness minus 1/4 inch, the Department will determine the payment reduction using for the above noted formula and using a PPR equal to 2 percent.
3.Remove and Replace. If the average thickness is less than the specified thickness minus 1/2 inch, the RE will require that the lot be removed and replaced.
J.Ride Quality Requirements. Ensure that diamond grinding is completed before testing ride quality. The Department will evaluate the ride quality of the concrete surface course on the project using the International Roughness Index (IRI) according to ASTM E 1926. The concrete surface course will be evaluated using the target IRI (T) determined from Table 405.03.02-2. The Department will evaluate the ride quality of the final riding surface of the mainline travel lanes. The Department will use the measured IRI to calculate the pay adjustment ( PA) using pay adjustment equation (PAE) type PA1 as specified in Table 405.03.02-1. PA will be based on lots of 0.01 mile length. The PA will be positive for superior quality work or negative for inferior quality work. For paving on ramps and shoulders, the RE will visually inspect the final riding surface. Based on visual inspection, if the RE determines that the work may not conform to the ride quality requirements, then the Department will evaluate the ride quality of the final riding surface using IRI. Visual inspection by the RE is considered sufficient grounds for such evaluation. The Department will use the measured IRI to calculate the PA using pay equation type PA2 as specified in Table 405.03.02-1.
1.Smoothness Measurement. The Department will test the longitudinal profile of the final riding surface for ride quality with a Class 1 Inertial Prof iling System according to NJDOT R-1. If project conditions preclude the use of the Class 1 Inertial Profiling System, the Department will use a Class 1 Walking Pr ofiler or Lightweight Profiler.
2.Quality Control Testing. Perform quality control testing during lift placement to ensure compliance with the ride quality requirements specified in Table 405.03.02-2.
3.Preparation for IRI Testing. Notify the RE when all paving is complete and the RE will request IRI testing by Pavement & Drainage Management & Technology (PDMT) unit . Provide traffic control when the Department performs IRI testing. Perform mechanical sweeping of the surface before IRI testing. To facilitate auto triggering on laser profilers, place a single line of temporary pavement marking tape perpendicular to the roadway baseline at the beginning and end of each lane, shoulder, and ramp to be tested or at the directio n of the Department. Submit the actual stationing for each temporary pavement marking tape location to the RE.
4.Quality Acceptance. The Department will determine acceptance and provide PA based on the following:
a.Pay Adjustment . The acceptable IRI f or the roadway pavement will be the target IRI (T) from Table 405.03.02-2 for which full payment will be made. The number of lots for final pay adjustment will be reduced by the number of lots excluded for each segment shown in Table 405.03.02-1. Lots excluded from final PA will be those with the highest recorded IRI numbers for respective roadway and bridge deck segments. A single average IRI value and the corresponding PA for each 0.01 mile lot will be reported. IRI units are in inches per mile. Table 405.03.02-1 Pay Equations for Ride Quality Pay Equation Type Excluded Lots Pay Equation(s) PA1 As shown in the Special Provisions Table 405.03.02-1A IRI < (T – 25) PA1 = $50 (T – 25) ≤ IRI < (T – 5) PA1 = (T – IRI – 5) x 2.5 (T – 5) ≤ IRI ≤ (T + 5) PA1 = 0 (T + 5) < IRI ≤ (T + 75) PA1 = – (IRI – T – 5) x 7.1429 IRI > (T + 75) PA = – $500 PA2 Will include, if tested IRI ≤ 120 PA2 = $0 120 < IRI ≤ 170 PA2 = (IRI − 120) x (−$10.00) IRI > 170 Maximum Negative Pay or Corrective Action Table 405.03.02-2 Target IRI for Concrete Surface Course (T) Roadway Type Target IRI (T) Freeways or Limited Access Highways 50 Other than Freeways or Limited Access Highways with speed limit > 35 MPH 60 Other than Freeways or Limited Access Highways with speed limit ≤ 35 MPH 70
b.Corrective Action. If the average IRI is greater than T+75 inches per mile after testing is performed, the Department may require corrective action or assess the maximum negat ive pay adjustment as computed in Table 405.03.02-1. If the Department requires corrective action, submit a plan for corrective action. If the plan for corrective action is approved and the lot is corrected, the Department will retest and evaluate the corrected area as a new lot that must meet the same requirements as the initial work. If the plan for corrective action is not approved, the Department may require removal and replacement. The replacement work is subject to the same requirements as the initial work.
K.Opening to Traffic. Ensure that diamond grinding is completed before opening to traffic. The RE will determine when the concrete surface is to be opened to traffic or construction equipment. Do not allow construction vehicles or equipment on the concrete pavement within 10 days of placing, or until the concrete has achieved a compressive strength of 3 ,000 pounds per square inch as determined by 2 test cylinders that are field cured according to AASHTO T 23. For concrete containing fly ash, opening to traffic is governed solely by the 3,000 pounds per square inch compressive strength requirement and not by time elapsed.
Referenced in this section
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Source: Standard Specifications for Road and Bridge Construction, 2019 (rev. 2022-12-21) Edition. Pages 209–214 of 651. View official source ↗