SECTION 453 – FULL DEPTH CONCRETE PAVEMENT REPAIR
453.01 Description
This Section describes the requirements for constructing full depth concrete pavement repairs with concrete or HMA.
453.02 Materials
453.02.01 Materials
Provide materials as specified: Coarse Aggregate (No. 8) ................................ ................................ ................................ ............................. 901.03 Hot Mix Asphalt ................................ ................................ ................................ ................................ .......... 902.02 Concrete, Class A ................................ ................................ ................................ ................................ ......... 903.03 Concrete, Class V or E ................................ ................................ ................................ ................................ . 903.04 Epoxy Grout ................................ ................................ ................................ ................................ ........ 903.08.02.B Curing Materials ................................ ................................ ................................ ................................ .......... 903.10 Reinforcement Steel ................................ ................................ ................................ ................................ ...... 905.01 Joint Ties (epoxy-coated) ................................ ................................ ................................ ......................... 905.03.01 Dowel Bars ................................ ................................ ................................ ................................ .............. 905.03.03 Preformed Joint Filler ................................ ................................ ................................ ................................ ... 914.01 Use an approved 9.5 or 12.5 nominal maximum size HMA surface course mix for patching areas after form removal. Use an approved HMA 25M64 base course for full depth HMA pavement repairs. If Class V concre te is used and the item FLEXURAL BEAM TESTING EQUIPMENT is not provided in the Contract, deliver the flexural beam test specimens for testing 1/2 hour before the scheduled testing time to the location provided in the Special Provision or to where directed by the RE.
453.02.02 Equipment
Provide equipment as specified: HMA Paver................................ ................................ ................................ ................................ ................. 1003.03 HMA Compactor ................................ ................................ ................................ ................................ ........ 1003.05 Vibratory Drum Compactor ................................ ................................ ................................ ......................... 1003.06 Sealer Application System................................ ................................ ................................ ........................... 1003.08 Forms ................................ ................................ ................................ ................................ ......................... 1005.01 Spreading and Finishing Machine ................................ ................................ ................................ ................ 1005.02 Vibrator ................................ ................................ ................................ ................................ ...................... 1005.04 Grinding Machine ................................ ................................ ................................ ................................ ....... 1006.08 Straightedge ................................ ................................ ................................ ................................ ................ 1008.02 Pavement Saw................................ ................................ ................................ ................................ ............. 1008.04 Hot-Air Lance ................................ ................................ ................................ ................................ ............. 1008.06 HMA Plant ................................ ................................ ................................ ................................ ................. 1009.01 HMA Trucks ................................ ................................ ................................ ................................ ............... 1009.02 Concrete Batching Plant ................................ ................................ ................................ .............................. 1010.01 Concrete Trucks ................................ ................................ ................................ ................................ .......... 1010.02 For Class V, mix concrete in a concrete mobile mixer or transit mix truck. Use a gang drill capable of maintaining vertical and horizontal alignment and drilling the group of holes in 30 seconds or less.
453.03 Construction
453.03.01 Full Depth Concrete Pavement Repair, Concrete
A.Preparation. Arrange a project site meeting with the RE to establish the limits of repair. Additional repairs, not delineated by the RE during the project site meeting with the Contractor, may be required if the need for them is established by the RE. Sawcut full depth at the limits of the repair. Remove existing concrete or composite pavement using the lift out method. Do not use in-place breaking to remove concrete. Ensure that spalling of the remaining concrete does not occur during the lifting. Reuse removed pavement as specified in 202.03.03.C.1. The Contractor may sawcut the slab and drill the lift out holes up to 5 days before the concrete removal. Only remove concrete that can be replaced during the workday. Repair any damage to remaining pavements. After the existing concrete has been removed, the RE will examine underlying material to determine its condition. If water or excess moisture exists in the area, remove the underlying material to the depth specified by the RE. Place and compact coarse aggregate using the directed method as specified in 203.03.02.B.3. Grade the underlying surface so that the thickness of the repair matches the existing slab thickness.
B.Placing Limitations. Comply with the concrete placing limitations specified in 504.03.02.C. For Class V concrete, do not place concrete if the ambient temperature or the surface temperature of the underlying layer falls below 50 °F. Ensure that the temperature of the Class V concrete is at least 80 °F at the time of placement.
C.Setting Forms, Joint Ties, and Dowels. For the sides of repair areas that are not in contact with sound concrete, set forms for the entire area of the repair before placing concrete. Set forms at grade in full contact with the underlying surface. Ensure that concrete does not seep beneath the fo rm. Stake forms into place with at least 3 pins for each 10 foot section. Lock form sections together to prevent movement in any direction. Place 1/2 inch preformed joint filler along curb and around structures and other objects protruding into the slab. For repairs that are longer than 15 feet, install longitudinal joint ties in the abutting concrete face. Drill holes into the face of the existing concrete pavement not more than 1/4 inch in diameter greater than the maximum measured dimension of the joint tie. For transverse joints abutting concrete pavement to remain, drill holes into the face of the existing concrete pavement not more than 1/4 inch in diameter greater than the dowels. Use a gang drill to install the dowels in the face of the slab. Maintain vertical and horizontal alignment during drilling and do not damage existing concrete surrounding the hole. Before installing dowels and joint ties, clean the holes of cement dust, standing water, and materials that interfere with proper bonding of the epoxy grout. Mix the epoxy grout according to the manufacturer’s recommendations. Introduce the epoxy grout by low-pressure injection through a polyethylene tube, reaching to the end of the hole. Slowly withdraw the tube as the hole is filled. Fill the holes to approximately 70 percent of their depth. Install plastic grout-retention disks to prevent the escape of grout. Insert the dowel or joint tie into the hole slowly and twist 1 full revolution to evenly distribute the grout, ensuring that no bubbles are introduced within the grout. Ensure that there is sufficient epoxy grout so that it rises to the surface and overflows from the sides of the disk upon introduction of the dowel or joint tie. Spread overflow epoxy grout on the concrete face. Pr ovide temporary support for dowels and joint ties after insertion to prevent movement and damage to the bond. Ensure that the dowels and joint ties are not disturbed before the final cure of the grout is achieved. Lightly coat the exposed end of the dowel bars with form oil or light grease. Do not coat joint ties. When replacing portions of slabs greater than 20 feet in length, install joint assemblies and secure in place with anchor stakes. Ensure that devices for contraction joint assemblies are capab le of holding dowels firmly in place during the entire construction operation. Place dowels across joint assemblies, parallel to and level with the surface course. Set joint assemblies in line with existing, adjacent joints and perpendicular to the existing longitudinal joint. Space additional joint assemblies equidistantly between transverse joints between 13 and 20 feet apart and perpendicular to the existing longitudinal joint. Check the alignment and grade elevations of the forms and joint assemblies and make corrections before placing the concrete. Ensure that the forms do not deviate from the required 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.
D.Placing, Consolidating, and Finishing Concrete. Place concrete as specified in 405.03.02.D.1.b. Consolidate, strike-off, and finish concrete as specified in 405.03.02.D.1.c, except for the following:
1.The Department will only require mechanical finishing equipment for repairs longer than 50 feet.
2.Place concrete in 2 layers with the first layer placed to such a depth that the surface of the layer is at the proper elevation to receive the reinforcement steel. Place the reinforcement steel followed by the next layer of concrete. Remove and replace the lower layer concrete if it has developed initial set or has been in place more than 30 minutes before being covered with the next layer.
3.Texture the surface using a stiff broom.
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. Except for Class V, apply curing compound as specified in 504.03.02.F.1, or wet burlap and white polyethylene sheeting as specified in 504.03.02.F.2. Maintain the curing material for 3 days. For Class V, cure the concrete using wet burlap as specified in 504.03.02.F.2 and cover with an insulation blanket to retain the heat from hydration. Ensure that insulatio n blankets are secured to prevent lifting. When the concrete surface temperature exceeds 120 °F, remove the insulating blanket.
F.Sawcutting and Sealing Joints. Sawcutting relief joints may begin as soon as hardened concrete can support operations without spalling, and must be completed within 18 hours of placing concrete and before opening to traffic. Sawcut transverse relief joints abov e joint assemblies. Sawcut 1/8 inch wide relief joints to a depth of 1/3 of the thickness of the concrete repair. 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 all sawing slurry from the sawcut cavity and surrounding pavement surface. Clean sawcuts with a minimum of 150 pounds per square inch water blast to remove remaining debris in the sawcut cavity, and then blow sawcuts with a hot-air lance to provide a dry surface. Seal sawcuts immediately after blowing. Seal joints with joint sealer when the ambient temperature 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 so that the joint sealer is 1/8 to 1/4 inch below the adjacent surface. Do not allow traffic over the sealed joints until the joint sealer has hardened to resist pickup.
G.Opening to Traffic. For Class V concrete, do not open repair to traffic until flexural strength as measured by flexural beams is mor e than 350 pounds per square inch. For Class A and E concrete, do not open repair to traffic until compressive strength as measured by the average of 2 cylinders is more than 3,000 pounds per square inch. If the required strength is not met by the time th e roadway must be opened to traffic, open to traffic. Remove and replace the repair during the next available roadway closure.
453.03.02 Full Depth Concrete Pavement Repair, HMA
A.Preparation. Arrange a project site meeting with the RE to establish the limits of repair. Additional repairs, not delineated by the RE during the project site meeting with the Contractor, may be required if the need for them is established by the RE. If milling and paving is also specified within the areas requiring full depth repair, then perform the repair work first and as a separate operation from the milling and paving. Ensure that the top of the repaired concrete surface is flush with the existing unrepaired pavement. The Contractor may request approval of the RE to perform the repair work, milling and paving as one operation. Sawcut full depth at the limits of the repair. Remove existing concrete or composite pavement using the lift out method. Do not use in-place breaking to remove concrete. Ensure that spalling of the remaining concrete does not occur during the lifting. Reuse removed pavement as specified in 202.03.03.C.1. The Contractor may sawcut the slab and drill the lift out holes up to 5 days before the concrete removal. Only remove concrete that can be replaced during the workday. Repair any damage to remaining pavements. After the existing concrete has been removed, the RE will examine underlying material to determine its condition. If water or excess moisture exists in the area, remove the underlying material to the depth specified by the RE. Place and compact coarse aggregate using the directed method as specified in 203.03.02.B.3. Grade the underlying surface so that the thickness of the repair matches the existing slab thickness.
B.Placing Limitations. Comply with the limitations as specified in 453.03.01.B.
C.HMA Placement. Apply tack coat at an application rate of 0.15 gallons per square yard to the vertical surfaces and base of the opening. Spread and grade HMA surface course mix in the opening as specified for the roadway surface or a HMA surface course mix approved by the RE. Ensure that the temperature of the HMA when placed is at least 250 °F, and compact as specified in 401.03.07.F. Compact areas not accessible to rollers with a flat face compactor. Compact until the top of the repair is flush with, or 1/8 inch higher than, the adjacent pavement surface.
D.Opening to Traffic. Remove all loose material from the repair before opening to traffic. Open repa irs to traffic when the surface temperatures is below 140 °F.
453.04 Measurement and Payment
The Department will measure and make payment for Items as follows: Item Pay Unit FULL DEPTH CONCRETE PAVEMENT REPAIR, CONCRETE CLASS ___ SQUARE YARD FULL DEPTH CONCRETE PAVEMENT REPAIR, HMA SQUARE YARD
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Source: Standard Specifications for Road and Bridge Construction, 2019 (rev. 2022-12-21) Edition. Pages 237–240 of 651. View official source ↗