SECTION 903 – CONCRETE
903.01 Cement
Use cement, listed on the QPL, that is either portland cement or blended hydraulic cement and conforms to the following: Portland Cement, Type I, II, and Type III ................................ ................................ ........................... ASTM C 150 Blended Hydraulic Cement, Type IS, IP, and IL ................................ ................................ ................. ASTM C 595 Only use Type III portland cement for Class V concrete, prestressed Items, and precast Items. Use portland cement pre-blended with a maximum of 25 percent fly ash, by weight, or a maximum of 5 percent silica fume by weight, or with a maximum of 50 percent slag by weight for blended hydraulic cement Type IS or IP. Use portland cement pre-blended with a minimum of 5 percent limestone content and a maximum of 15 percent limestone content by weight for blended hydraulic cement Type IL. Ensure that a scaling test according to ASTM C 672 is completed on the mix design if more than 30 percent slag is used and that the concrete has a visual rating less than 3 after 50 cycles. Do not add additional mineral admixtures to blended hydraulic cements Type IS or IP at the concrete plant unless approved by the ME. The use of additional mineral admixtures in blended hydraulic cement Type IL at the concrete plant is permitted if the mineral admixture is listed on the QPL Do not mix different brands of cement, the same brand of cement from different mills, or different types of cement. Provide suitable means for storing and protecting the cement against dampness. The ME will reject cement that has become partially set or that contains lumps of caked cement. Ensure that the temperature of the cement at the time of delivery to the mixer does not exceed 160 °F.
903.02 Concrete Admixtures
903.02.01 Air-Entraining Admixtures
Use air-entraining admixtures for concrete that are listed on the QPL and conform to AASHTO M 154, except that the tests for bleeding and volume change are not required. The ME will test for uniformity through the use of infrared spectrophotometry, pH values, solids content, and specific gravity for liquid admixtures. For pH test of non -liquid admixture, dissolve 1.28 grams of powde r in 128 milliliter of distilled water. Keep all bulk storage tanks inside a heated area with an ambient temperature of not less than 32 °F. Do not reuse air-entraining admixture that has been allowed to freeze until it has been agitated and retested.
903.02.02 Chemical Admixtures
Use chemical admixtures for concrete that are listed on the QPL and conform to AASHTO M 194. Use chemical admixtures of the following types:
1.Type A – Water-reducing admixtures
2.Type B – Retarding admixtures
3.Type C – Accelerating admixtures
4.Type D – Water-reducing and retarding admixtures
5.Type E – Water-reducing and accelerating admixtures
6.Type F – Water-reducing, high range admixtures
7.Type G – Water-reducing, high range, and retarding admixtures Do not use chemical admixtures that contain calcium chlorides or any other chlorides that may initiate or promote corrosion of the reinforcement steel. Locate all bulk storage tanks for chemical admixtures inside a heated area with an ambient temperature of not less than 32 °F. Do not use chemical admixtures that have been allowed to freeze until they have been agitated and retested. The ME may require certification from the manufacturer stating that the material is identical to that originally approved and has in no way been changed or altered. The ME will test for uniformity through the use of infrared spectrophotometry, pH values, specific gravity, and solids content.
903.02.03 Mineral Admixtures
A.Fly Ash. Ensure that fly ash for use as a pozzolan in concrete is listed on the QPL and conforms to ASTM C 618, Class C or Class F, except that the loss on ignition shall not exceed 3 percent. Use Class F fly ash to control alkali-silica reactivity. The supplier shall determine conformance to the requirements for loss on ignition and fineness for each truck load of fly ash delivered to the mixing site and shall include the test values on the delivery ticket. Submit certificate of compliance as specified in 106.07.
B.Slag. Slag for use as a cementitious material is ground, granulated blast furnace slag. Use slag that is listed on the QPL and conforms to the requirements of AASHTO M 302, Grade 120. The Contractor may use Grade 100 with the written permission of the ME. The Contractor may use slag as a replacement for cement as specified in 903.01, up to a maximum replacement level of 50 percent by weight of the total cementitious material. If more than 30 percent of cement is replaced, test the concrete mix design f or scaling as specified in ASTM C 672, and ensure that it complies with a visual rating less than 3. Submit certificate of compli ance, as specified in 106.07, indicating that the slag conform s to the requirements of AASHTO M 302, Grade 120.
C.Silica Fume Admixture. Ensure that silica fume admixture for use in concrete is listed on the QPL and conforms to AASHTO M 307. Use only 1 brand of silica fume admixture for the entire duration of the Contract. The Contractor may supply silica fume admixture either in dry or in slurry form. If the slurry form is used, ensure that it is homogeneous and agitated to prevent separation. Submit certificate of compliance as specified in 106.07.
903.02.04 Viscosity Modifying Admixture
Use a viscosity modifying admixture that is listed on the QPL and that, when evaluated according to the test methods and mix design proportions in AASHTO M 194, conforms to the following physical requirements:
1.For initial and final set times, the allowable deviation of the test concr ete from the reference concrete is not more than 1.0 hour earlier or 1.5 hours later.
2.For compressive and flexural strengths, the minimum allowable strength of the test concrete is 90 percent of the reference concrete strength at 3, 7, and 28 days.
3.The maximum allowable length change of the test concrete is 135 percent of the reference concrete. However, if the length change of the reference concrete is less than 0.030 percent, the maximum allowable length change of the test concrete is 0.010 percentage units more than the reference concrete.
4.The minimum allowable relative durability factor of the test concrete is 80 percent.
903.02.05 Corrosion Inhibitor Admixture
When required, use a calcium nitrite based corrosion inhibitor admixture to reduce the potential of corrosion of embedded steel. Use the following guidelines for calcium nitrite:
1.Ensure that the calcium nitrite does not contact other admix tures before entering the concrete mix. Use air-entraining, water reducing, and retarding admixtures that are compatible with the calcium nitrite solution. Thoroughly mix the calcium nitrite solution before incorporating it into the concrete mix.
2.Strictly adhere to the manufacturer’s written recommendations regarding the use of the calcium nitrite admixture including storage, transportation, and method of mixing. The manufacturer of the calcium nitrite admixture shall have a representative available to assist the Contractor.
3.The ME will test for the presence of the calcium nitrite admixture in the plastic concrete as specified in NJDOT C-3. Provide the test kit that is required to perform the plastic test to the ME.
4.Use admixture that is 30 ± 2 percent calcium nitrite by weight of solution. Include a high range water reducing chemical admixture in the concrete when using a calcium nitrate admixture.
5.Add the calcium nitrite at a rate of 3 gallons per cubic yard of concrete.
6.Use a calcium nitrite admixture listed on the QPL.
903.03 Concrete
903.03.01 Composition
Compose concrete of cement, coarse aggregate, fine aggregate, admixtures, and water. Concrete may include fly ash, slag, or silica fume. Provide materials as specified: Aggregates ................................ ................................ ................................ ................................ .................... 901.06 Cement ................................ ................................ ................................ ................................ ......................... 903.01 Admixtures: Air-Entraining ................................ ................................ ................................ ................................ ........ 903.02.01 Chemical................................ ................................ ................................ ................................ ................ 903.02.02 Mineral ................................ ................................ ................................ ................................ .................. 903.02.03 Corrosion Inhibitor ................................ ................................ ................................ ................................ . 903.02.05 Water ................................ ................................ ................................ ................................ ............................ 919.08 Use chemical admixtures according to the admixture manufacturer’s recommendation for the mix design and anticipated field conditions, including the admixture dosage rate and the location and method for introducing it into the mixture. If fly ash is added to control alkali -silica reactivity, use at least 15 percent fly ash by weight of the total cementitious material. If AASHTO T 303 testing results i n an expansion greater than 0.40 percent, use at least 20 percent fly ash. If slag is used to control alkali-silica reactivity, use at least 25 percent slag by weight of the total cementitious material. If a low alkali cement is used to control alkali-silica reactivity, use cement with equivalent alkali of less than 0.60 percent. Use the combined weight of fly ash, slag, silica fume , and cement content to determine compliance with the minimum cement content and water -cement ratio requirements specified in Table 903.03.06 -3. Include free water from the aggregates and the water in the admixtures and additives along with the mixing water when calculating the water-cement ratio.
903.03.02 Mix Design and Verification
Design at least 1 mix to equal or exceed the required verification strengths specified in Table 903.03.06-3 for each class of concrete included on the Project. A single mix design may satisfy the requirements for more than 1 class of concrete. Compute and set up the designs according to ACI Standard 211.1 or 211.2, as applicable. At least 45 days before the start of concrete placement, submit each mix design on concrete mix design forms provided by the ME. Identify the sources of materials and test data on the forms. The ME will be present at the time of verification batching to confirm that the proportions and ingredients batched are according to the proposed mix designs. If directed by the ME, mix at least 3 cubic yards of concrete in a central mix plant or transit truck for verification. The ME will direct that the verification batch be mixed in the top half of the allowable slump and air co ntent ranges. Test for and report the slump and air content of the trial batch. The ME will reject the verification batch if the slump, air content, or yield is not acce ptable. Prepare at least six 4 × 8 inch test cylinders from each acceptable batch an d cure according to AASHTO T 23 or AASHTO R 39. Between 2 and 5 days after molding, deliver the cylinders to the ME for testing. The ME will test 3 cylinders at 7 days and 3 cylinders at 28 days to determine the 7 day and 28 day compressive strengths, respectively. At the ME’s option, verification may be done on an annual basis for a concrete plant rather than on a project -to-project basis, provided the properties and proportions of the materials do not change. If the Contractor submits written verification that the same source and character of materials are to be used, the ME may waive the requirement for the design and verification of previously approved mixes. Provide concrete conforming to the approved mix design. If using a previously a pproved mix design, notify the ME at least 1 day before making the change. Do not change the source, type, or proportions of materials until approved and the requirements for design and verification have been satisfied.
903.03.03 Mixing for Central-Plant and Transit Mixing
A.Handling, Measuring, and Batching Materials. Mix concrete at a concrete plant that is listed on the QPL and conforms to the requirements specified in 1011.01. Ensure that the plant’s location, layout, equipment, and provisions for transporting material will ensure a continuous supply of concrete to the work. Stockpile aggregates as specified in 901.02. Separately weigh the fine aggregate and each size of coarse aggregate into hoppers according to the amounts in the job mix design. Measure cement by weight, using separate scales and hoppers with a device to indicate the complete discharge of the batch of cement into the batch box or container. Ensure that the weighing hopper and scale are of adequate size, completely encased, and have provisions for locking. Operate the weighing hopper discharge gate so as to not affect the scale balance. Suspend the discharge chute, boot, or other such device from the encasement, not from the weighing hopper. Discharge the cement so that it does not lodge in the weighing h opper and there is no loss of cement by air currents. Ensure that the required cement content is added to each batch. Store mineral admixtures, unless pre-blended cement is supplied, at the batching plant in a separate storage facility. Batch mineral adm ixtures to tolerances equivalent to those specified for cement. When mineral admixtures are weighed cumulatively with the cement, add the mineral admixtures last in the batching sequence. When silica fume and dyes are added, demonstrate, prior to production, that the batching sequence will produce a uniform mix. If using mineral admixtures packaged in bags, empty the bag into the mix. Do not put degradable bags in the mix. Add chemical, air-entraining, and corrosion inhibiting admixtures to the mixing water or sand. Use a water measuring device that automatically registers and stops the flow of the water when the designated quantity has been delivered into the mixing drum.
B.Batch Tolerances. For individual batches, conform to the following tolerances based on the required scale reading:
1.Cement and Mineral Admixtures: ± 1.0 percent of the r equired weight of material or ±0.3 percent of scale capacity, whichever is greater.
2.Aggregates 1 1/2 inches or smaller: ±2.0 percent of the required weight of material or ±0.3 percent of the scale capacity, whichever is greater.
3.Aggregates larger than 1 1/2 inches: ±3.0 percent of the r equired weight of material or ± 0.3 percent of scale capacity, whichever is greater.
4.Water: ±1.0 percent of the required weight of material.
5.Chemical, Air-entraining, and Corrosion Inhibiting Admixtures: ±3.0 percent of the required weight of material or ±1 ounce, whichever is greater.
C.Delivery Tickets. Supply a delivery ticket for each load of concrete. Ensure that the delivery ticket cont ains the following information:
1.Use tickets that are serially numbered and bear the printed heading of the supplier and the location of the batch plant.
2.Show the name of the Project, the name of the Contractor, the quantity and class of concrete, the batch time as imprinted on the ticket by an automatic clock, the date, and the truck number.
3.After the truck has been discharged, fill in the time when the concrete was completely discharged, the amount of mixing water and the amount of tempering water, if used, and the total number of mixing revolutions for transit mix.
4.An authorized representative of the supplier shall sign each ticket and give copies to the ME and the RE. In addition, for each truck or batch, provide a batching ticket to the ME, indicating the amount, brand name, and type of cementitious material; the amount and source of the fine aggregate; the amount, sizes, and sources of the coarse aggregates; the amount of mixing water; and the amounts, brand names, and types of admixtures.
D.Mixing Requirements. Do not allow the elapsed time from batching to the discharge of all the concrete from the mixer to exceed 90 minutes, except that under conditions contributing to quick stiffening of the concrete or when the temperature of the concrete is above 85 °F, the time limit is changed to 60 minutes. Under very severe conditions, the RE may further reduce the time limits. Measure batching time from the time cement is introduced to the mixer. If the concrete cannot be entirely discharged within 10 minutes, keep the concrete in the drum plastic and workable by revolving the truck drum at the manufacturer’s designated speed for agitation fo r at least 2 minutes in each 10 minute period. Use one of the following mixing methods unless mixing on the Project as specified in 903.03.04:
1.Mixing at a Central-Mixing Plant. For central-mix concrete, proportion and mix concrete at a central-plant and transport to the point of use in an agitator approved by the ME. If approved by the ME, non -agitating vehicles may be used to transport concrete at precast/prestressed concrete fabricators. Use central-mixing plant mixers that are of the type and capacity ca pable of combining the required materials into a thoroughly mixed and uniform mass within the specified mixing time and of discharging the mixture with a satisfactory degree of uniformity. Operate the plant according to N.J.A.C 7:27-6.1 et seq. Mix for at least 1 minute, with mixing time measured from the time all cement and aggregates are in the drum. Charge the batch into the mixer so that sufficient water enters in advance of cement and aggregates to prevent caking. Ensure that all water is in the drum by the end of the first quarter of the mixing time. When the temperature of the mixing water exceeds 100 °F, modify the loading sequence by mixing all the water and the aggregates and then the cement. Begin mixing immediately following the complete ch arging of the drum, and continue for not less than 1 minute. Restrict the volume of mixed concrete in the agitating truck to not exceed the manufacturer’s rating or 80 percent of the gross drum volume, whichever is less. Before acceptance testing, the Contractor may add mixing water, air-entraining agent, or chemical admixture incrementally in order to achieve the proper slump or air content range as specified in Table 903.03.06-1 or Table 903.03.06-2.
2.Transit Mixing. For transit mix concrete, proportion materials, including w ater, into a truck mixer from a 1-stop or 2-stop batching plant and mix in the truck. A 1-stop batching plant is a plant where the dry ingredients for each batch of concrete are loaded into the mixer truck while water is being introduced. A 2-stop batching plant is a plant where the ingredients for each batch of concrete are loaded into the mixer truck at 2 separate locations. When loaded for mixing concrete, restrict the volume of concrete to no more than 63 percent of the gross drum volume of the transit truck mixer. Immediately begin mixing after the complete charging of the drum and continue for not less than 50 or more than 100 revolutions of the drum at the mixing speed recommended by the manufacturer of the transit truck mixer. After completing the minimum number of mixing revolutions at the plant, reduce the speed of the drum to the agitation speed recommended by the manufacturer. When using Type F or G admixtures, mix the load at the minimum specified number of mixing revolutions as recommended by the manufacturer. Before acceptance testing, the Contractor may add mixing water, air-entraining agent, or chemical admixture incrementally in order to achieve the proper slump or air content range as specified in Table 903.03.06-1 or Table 903.03.06-2.
E.Rejection Criteria. The RE will reject concrete for any of the following reasons:
1.The information for batching and delivery tickets is not complete, does not agree with the mix design, or is not supplied to the ME.
2.The mixer fails to maintain the manufacturer’s stated speed of rotation for both mixing and agitation, or is not able to properly discharge the concrete.
3.The RE observes improper batching, lack of uniform distribution of constituents throughout the load, or balling of the cement and aggregates.
4.Water has been added while the truck is en route to the work site.
5.The concrete is not discharged within the specified time limit, or if the revolution counter shows a total of more than the 300 revolutions. However, if the load has been partially discharged and if the concrete yet to be discharged conforms to the specified ranges for slump and entrained air without further additi on of water or admixtures, then the RE may allow the use of the concrete.
6.The slump or air content does not comply with requirements specified in 903.03.05.C.
7.The concrete has been tempered after the ME has performed the final acceptance testing.
8.Water is added after the truck has partially discharged regardless of ME testing.
9.The indicator on the revolution counter shows that the instrument has been turned off or tampered with.
10.The temperature of the concrete does not comply with requirements.
11.The water-cement ratio of the load is greater t han the allowable maximum water-cement ratio for the class of concrete.
903.03.04 Mixing on the Project
A.Mobile Mixers. Mix the concrete in a mixing unit that is part of the truck carrying the dry ingredients and conforms to the requirements for a mobile mixer as specified in 1010.03. Use a mixing unit that is an auger type incorporated in the truck’s discharge chute or other approved mixing mechanism. Produce concrete of uniform consistency and discharge the mix without segregation. Provide a means for storing the additives on the truck and incorporating them into the mix. Include a way to check the rate of flow of the additive into the mix and a meter to register the total volume of additive incorporated into the mix during each mixing operation. The ME will not allow use of trucks not having functional meters on the Project. Handle, measure, and batch materials according to the following:
1.Stockpile aggregates as specified in 901.02.
2.Proportion, measure, and batch cement and aggregates by a volumetric weight equivalent method. Mix the materials in the continuous-mixing-type truck mixer.
3.Provide delivery tickets to the ME for each truckload of ingredients. On the delivery tickets, show the brand name and type of cement, the calibrated cement constant of the mixer in terms of the indicator revolution count, the source of aggregates, and the size of the coarse aggregate. A responsible officer or employee of the concrete supplier shall sign the delivery tickets. For each class of concrete and for each separate mixing operation, the mixer operator shall enter on the tickets the name of the Project, the name of the Contractor, the revolution counter indicator readings indicating the volumetric weight equivalent of cement discharged during that mixing operation, the concrete additive meter reading indicating the total volume of additive discharged into the mix during that mixing operation, the aggregate dial settings, the water and concrete addit ive flow rates, and the class of concrete delivered. The operator shall sign each completed ticket and provide a copy to the ME.
B.Small Mixers. With the RE’s approval, use small mixers only for small quantities of concrete that must be mixed on the Project. Unless provisions are made for accurately weighing bulk cement, use full bags of cement in each batch. Only use pre -blended mineral admixtures. Proportion aggregates and water by weight unless a calibrated volumetric method has been approved by the RE. Use accurate volumetric measuring devices to proportion chemical and air-entraining admixtures. Charge the mixer with the aggregates and part of the mixing water, and begin mixing. Add cement and admixtures with another portion of the mixing water. Mix until uniform. Temper with the remaining allowable mixing water to obtain the necessary consistency. Do not exceed the quantity of water required by the mix design.
903.03.05 Control and Acceptance Testing Requirements
A.Sampling and Testing Methods. Use the sampling and testing methods for concrete as specified in Table 903.03.05-1. Table 903.03.05-1 Sampling and Testing Methods Designation Test Method AASHTO T 221 Compressive Strength of Cylindrical Concrete Specimens (Including the Annex providing for use of neoprene caps) AASHTO T 232 Making and Curing Concrete Test Specimens in the Field AASHTO T 243 Obtaining and Testing Drilled Cores and Sawed Beams of Concrete AASHTO T 97 Flexural Strength of Concrete (Using Simple Beam with Third-Point Loading) AASHTO T 119 Slump of Hydraulic Cement Concrete AASHTO T 121 Weight Per Cubic Foot, Yield and Air Content (Gravimetric) of Concrete AASHTO T 1414 Sampling Fresh Mixed Concrete AASHTO T 152 Air Content of Freshly Mixed Concrete by the Pressure Method AASHTO T 196 Air Content of Freshly Mixed Concrete by the Volumetric Method AASHTO T 303 Accelerated Detection of Potentially Deleterious Expansion of Mortar Bars Due to Alkali-Silica Reaction AASHTO R 39 Making and Curing Concrete Test Specimens in the Laboratory ASTM C 567 Unit Weight of Structural Lightweight Concrete ASTM C 3115 Sampling and Testing Fly Ash or Natural Pozzolans for Use as a Mineral Admixture in Portland Cement NJDOT C-1 Determination of Yield of Concrete Produced by Mobile Truck Mixers
1.Use 4 × 8 inch (diameter × height) compression test cylinders, except use 6 × 12 inch (diameter × height) test cylinders for concrete mixes containing coarse aggregate sizes exceeding a nominal maximum size of 1 inch.
2.Cure compression test cylinders for strength acceptance according to the Standard Cure Method in AASHTO T 23. For determining early strength for form removal, early loading of members, or opening to traffic, cure compression test cylinders according to the Field Cure Method in AASHTO T 23.
3.Obtain and prepare cores for compressive strength testing according to AASHTO T 24, except for the provisions for moisture conditioning. For moisture conditioning, soak cores in a lime bath at 73.4 ± 3 °F for at least 40 hours immediately prior to testing. After making any necessary corrections to the core results for ratio, the ME will divide each core result by 0.85 before reporting the final compressive strength.
4.Sample according to AASHTO T 141, except do not take a composite sample to represent a truck. Take the sample after approximately 1 cubic yard of concrete has been discharged from the truck to be sampled.
5.The Department may modify the sampling rate for individual and composite samples.
B.Quality Control. The concrete supplier shall have a quality control plan approved annually by the ME. The producer shall ensure that the plan conforms to the “Requirements for a Portland Cement Concrete Plant Quality Control Plan”, which may be obtained from the ME. During production of concrete for the Project, the supplier shall perform quality control testing as required in the approved plan . If a concrete supplier does not have an approved plan or does not follow the approved plan, the ME will remove the supplier from the QPL. Ensure that the QC technician, certified by ACI as a Concrete Field Technician, Grade 1, is present at the plant or the Project Limits during production. During production of concrete for the Project, perform quality control testing as required in the approved plan and as needed to ensure compliance with the requirements for the concrete.
C.Acceptance Testing Procedures for Slump and Air Entrainment. The ME will perform sampling and testing for slump (AASHTO T 119) and air entrainment (AASHTO T 152 or T 196), except for precast, prestressed co ncrete Items, for which the Contractor shall perform sampling and testing for slump and air entrainment. For pumped concrete, take the sample of concrete at the point of discharge and deliver it to the ME. At a minimum, the ME will perform slump and air -entrainment tests at the rate specified for strength tests in Table 903.03.06-4 and on the same samples of material from which the compressive tests cylinders are molded. The ME will perform additional slump and air-entrainment tests as necessary to ensure the quality of the concrete. While these tests are being performed, halt discharge from the truck. Discharge from other trucks not scheduled for testing may proceed unless otherwise directed by the ME. If the measured value of either slump or air entrainment exceeds the upper limit, the ME will perform a second test on a different portion of material from the same load. If the average of the 2 test results for either slump or air entrainment exceeds the upper limit, the ME will reject the load. Remove rejected loads from the Project Limits. If neither of the measured values of the slump or air entrainment exceeds the upper limit, the Contractor may temper the concrete once, prior to discharge into the work. Temper by addition of water, air-entraining agent, or any chemical admixture included in the mix design as recommended by the manufacturer. Ensure that quantities added will result in slump and percent air entrainment within the specifie d ranges throughout the duration of discharge of the load. After tempering, rotate the drum at the recommended mixing speed for a minimum of 30 revolutions. Meet the specified maximum water-cement ratio and comply with the time and revolution limits specified in 903.03.03. Report quantities added to the ME. Following any allowed tempering, the ME will disregard the original test results and perform a single test for slump and air entrainment. If the measured values for slump and air -content are not within the ranges specified in Table 903.03.06-1 or Table 903.03.06-2, the RE will reject the load of concrete. Do not make additions to the load after the acceptance testing has been completed. For loads not scheduled for acceptance testing, make additions as specified in 903.03.03 before discharge into the work.
D.General Acceptance Testing Requirements for Strength. The ME will perform sampling and testing for strength, except for precast, prestressed concrete Items for which the Contractor shall perform sampling and testing for strength. For pumped concrete, take the sample of concrete at the point of discharge and deliver it to the ME. Provide, for the sole use of the ME, a sufficient number of curing facilities for the storage and curing of concrete test cylinders within the Project Limits for the first 24 hours according to AASHTO T 23. Ensure that the curing facilities are provided with minimum-maximum thermometers and are securable with lock and key. During the period from May 1 through October 31, provide water tanks or tubs of sufficient capacity and rigidity to hold the cylinders in an upright position, fully submerged and without contact between cylinders. During the remaining months of the year, or as directed by the RE, provide securable, insulated boxes, of similar capacity and r igidity. During the initial 24 hours, ensure that the test specimens are undisturbed and maintained within the specified temperature range. If, within 10 days of the RE’s request, the facilities are not provided, do not place any concrete. The ME will cure concrete test specimens that are to be used for determination of early strengths for removing forms, opening to traffic, or o therwise placing the concrete into service according to the fi eld curing provisions in AASHTO T 23. An initial strength test result is defined as the average strength of two 4 × 8 inch compression test cylinders, cured for 28 days, and tested by the ME. The Contractor may have cylinders for precast concrete tested at the fabricator’s plant under the supervision of the ME. The ME will sample and test at the rate specified in Table 903.03.06-4. If either of the cylinders comprising a test shows definite evidence (other than low strength) of improper sampling, molding, handling, curing, or testing, the ME will discard it and use the strength of the remaining cylinder as the test result. If the difference in compressive strength between 2 cylinders comprising a test equals or exceeds 600 pounds per square inch, the ME will disregard the lower value and use the higher value as the test result. If both cylinders comprising a test are discarded, the ME will evaluate the lot on the basis of the reduced number of tests. If the ME takes additional unscheduled compression cylinders, as specified in 106.05, the ME will include the results with the regularly scheduled compression cylinder results and will evaluate the lot on the basis of the increased number of tests.
E.Acceptance Testing for Strength for Pay Adjustment Items. The Special Provisions will identify the concrete Items, if any, that are subject to pay adjustment and their base prices. The ME will test the cylinders in the lot of concrete and compute the pay adjustment in the following steps:
1.Compute Average Lot Strength (ALS) and Standard Deviation (S). If only a single test result is available, the standard deviation (S) is assumed to equal 200 pounds per square inch. ALS = ∑ Xi N S = √∑(Xi − ALS)2 N − 1 Where: = Summation Xi = Individual test result (average strength of a test cylinder pair) N = Number of test results for the lot
2.Compute Quality Index (Q). Q = ALS − CDS S Where: CDS = Class design strength in pounds per square inch from Table 903.03.06-3 for the specified class of concrete.
3.Determine Percent Defective (PD). Using NJDOT ST for the appropriate sample size, the ME will determine PD associated with Q calculated in the previous step.
4.Compute Percent Pay Adjustment (PPA). Quality Percent Pay Adjustment Equation 1 PD < 50 PPA = 3.0 − 0.3 PD Equation 2 PD 50 PPA = 26.0 − 0.76 PD The amount of pay adjustment in dollars is the product of the Item base price times the lot quantity times the percent pay adjustment (expressed as a decimal) given by Equation 1 or 2. For lots having percent defective (PD) levels less than 10 percent, Equation 1 provides positive adjustments to the contract price. For lots having exactly 10 percent defective, there is no adjustment to the contract price. For lots having greater than 10 percent defective, Equations 1 or 2, as appropriate, subtract progressively larger amounts from the contract price. If, based on the initial series of tests, the lot quality of a pay adjustment item is estimated to be PD = 50 or greater, the ME may reevaluate by coring or other suitable means. When this provision is applied to precast/prestressed concrete, the ME will evaluate each item in the bed separately. If the re-evaluation is accomplished by a method other than coring, the ME will use the results only to determine what further action is to be taken. If all non-core test results equal or exceed the class design strength, the ME may elect to accept the lot at 100 percent payment. If the Department elects not to core, the Contractor may accept the PPA calculated by Equation 1 or 2, as appropriate, or, when approved by the Department, the Contractor may take cores as specified in Table 903.03.06-4. Take the cores within 90 days from the date of concrete placement. The Department will not award a positive pay adjustment based on core samples taken more than 90 days from the date of concrete placement. If electing to core, perform the coring as directed by the ME, and provide the cores to the ME for testing. If cores are taken, the Department will use the core results to determine the final disposition of the lot. If, based on the core results, the lot is determined to be at a quality lev el of PD < 75, the Department will compute the pay adjustment by Equation 1 or 2, as appropriate. If the lot is confirmed to be at a quality level of PD ≥ 75, the ME will reject the lot and the RE may do one of the following:
1.Require the Contractor to remove and replace the defective lot.
2.Allow the Contractor to leave the defective lot in place and receive a PPA computed by Equation 2.
3.Allow the Contractor to submit a plan, to the RE for approval, for corrective action.
F.Acceptance Testing for Strength for Non-Pay Adjustment Items. Non-pay adjustment Items are those concrete Items not specifically designated as pay adjustment Items, as specified in 903.03.05.E, but may be accepted by pay adjustment under certain circumstances. Such an Item is eligible for 100 percent payment (PPA = 0) if each individual test result in a lot meets the retest limit specified in Table 903.03.06-4. If any individual test value (average of a cylinder pair) falls below the retest limit for non-pay adjustment concrete in Table 903.03.06-4, the ME may reevaluate by coring or other suitable means. When this provision is applied to precast/prestressed concrete, the ME will evaluate each item in the bed separately. If the re -evaluation is accomplished by a method other than coring, the ME will use the results only to determine what further action is to be taken. If all non-core test results equal or exceed the class design strength, the ME may elect to accept the lot at 100 percent payment. If the Department elects not to core, the Department may allow the Contractor to take cores as specified in Table 903.03.06-4. Take the cores within 90 days from the date of concrete placement. If electing to core, perform the coring as directed by the ME, and provide the cores to the ME for testing. If cores are taken, the Department will use the core results to determine the final disposition of the lot. If, based on the core results, the lot is determined to be at a quality level of PD < 75, the Department will compute the pay adjustment as specified in 903.03.05.E. The Department will not award positive pay a djustment for non -pay adjustment Items. If the lot is confirmed to be at a quality level of PD ≥ 75, the ME will reject the lot and the RE may do one of the following:
1.Require the Contractor to remove and replace the defective lot
2.Allow the Contractor to leave the defective lot in place and receive a PPA computed by Equation 2.
3.Allow the Contractor to submit a plan, for approval, for corrective action. If retesting is not performed by the Department or the Contractor, the Department will calculate the PPA as for a pay adjustment Item as specified in 903.03.05.E, except that the Department will use the Item bid price instead of an Item base price in the computation of the pay adjustment. When computing a pay adjustment for any of the Items listed in Table 903.03.05-2, which are only partially composed of concrete, the ME will multiply the amount of pay adjustment, if any, by th e Estimated Percentage of Concrete (expressed as a decimal) as shown in Table 903.03.05-2. Table 903.03.05-2 Estimated Percentage of Concrete in Items Item Estimated Percentage of Concrete INLET, TYPE ___ 30 INLET, TYPE ___, USING EXISTING CASTING 30 MANHOLE, ___' DIAMETER 30 MANHOLE, USING EXISTING CASTING 30 MANHOLE, SANITARY SEWER 30 MANHOLE, SANITARY SEWER, USING EXISTING CASTING 30 GRANITE CURB 25 RESET GRANITE CURB 25 BEAM GUIDE RAIL TERMINALS AND ANCHORAGES 25 CHAIN-LINK FENCE, ___' HIGH 25 CHAIN-LINK FENCE, ALUMINUM-COATED STEEL, ___' HIGH 25 CHAIN-LINK FENCE, PVC-COATED STEEL, ___' HIGH 25 GATE, CHAIN-LINK FENCE, ___' WIDE 25 GATE, CHAIN-LINK FENCE, ALUMINUM-COATED STEEL, ___' WIDE 25 GATE, CHAIN-LINK FENCE, PVC-COATED STEEL, ___' WIDE 25 TEMPORARY CHAIN-LINK FENCE, ___' HIGH 25 GUIDE SIGN, TYPE GA, BREAKAWAY SUPPORTS 20 GUIDE SIGN, TYPE GA, NON-BREAKAWAY SUPPORTS 20 The amount of pay adjustment for Items not listed in Table 903.03.05-2 is the product of the unit bid price times the lot quantity times the percent pay adjustment determined according to Equation 1 or 2.
903.03.06 Tables
Table 903.03.06-1 Requirements for Roadway Concrete Items Class Slump1 (inch) Percent Air Entrainment for Coarse Aggregate1 No. 57 and No. 67 No. 8 Cast-in-Place Items Surface Course, Base Course B 2 ± 1 6.0 ± 1.5 7.0 ± 1.5 Inlets, Manholes, Headwalls, Sidewalks, Driveways, Islands B 3 ± 1 6.0 ± 1.5 7.0±1.5 Slope Gutters, Vertical Curb, Sloping Curb, Barrier Curb, Concrete Islands B 4 ± 1 6.0 ± 1.5 7.0 ± 1.5 Foundations for: Inlets, Manholes and Electrical Items B 3 ± 1 7.5 max 8.5 max Signs B 3 ± 1 6.0 ± 1.5 7.0 ± 1.5 Footings for: Fence Post, Beam Guide Rail Terminals, and Anchorages B 3 ± 1 7.5 max 8.5 max Culverts A 3 ± 1 6.0 ± 1.5 7.0 ± 1.5 Monuments A 3 ± 1 7.5 max 8.5 max Slope Protection B 2 ± 1 6.0 ± 1.5 7.0 ± 1.5 Pipe Bedding, Thrust Blocks, Pipe Plugs, Encasements, Saddles B 3 ± 1 7.5 max 8.5 max Precast Items Culverts P 3 ± 1 6.0 ± 1.5 7.0 ± 1.5 Inlets, Manholes, Junction Boxes, Headwalls, Reinforced Concrete End Sections B 3 ± 1 6.0 ± 1.5 7.0 ± 1.5 Concrete Barrier Curb B 3 ± 1 7.0 ± 2.0 8.0 ± 2.0 Slip-Form Items Surface Course, Base Course B 1-1/2 ± 1 6.0 ± 1.5 7.0 ± 1.5
1.When using a Type F or G admixture, change the requirements for Slump and Air Content for the given concrete item as follows: 1.1 Slump: 6 ± 2 inches 1.2 Air Content: Increase both the target value and tolerance percentages by 0.5. Table 903.03.06-2 Requirements for Structural Concrete Items Class Slump1 (inches) Percent Air Entrainment for Coarse Aggregate1 No. 57 & No. 67 No. 8 Cast-in-Place Items Bridge Approach A 3 ± 1 6.0 ± 1.5 7.0 ± 1.5 Footings, Piles B 3 ± 1 7.5 max 8.5 max Abutments, Wing Walls, Pier Shafts, Retaining Walls B 3 ± 1 6.0 ± 1.5 7.0 ± 1.5 Drilled Shafts2 A 7 ± 12 – 7.5 ± 1.5 Concrete Barrier Curb, Bridge B 4 ± 1 7.0 ± 2.0 8.0 ± 2.0 Pier Columns and Pier Caps, Arch Spans, Culverts A 3 ± 1 6.0 ± 1.5 7.0 ± 1.5 Decks, Sidewalks, Curbs, Parapets, Concrete Patch A 3 ± 1 6.0 ± 1.5 7.0 ± 1.5 Seal (Tremie) Concrete S 7 ± 2 7.5 max 8.5 max Prestressed Items Beams P, P-1 & P-2 2 ± 1 5.0 ± 1.5 5.0 ± 1.5 Piles P 2 ± 1 6.0 ± 1.5 7.0 ± 1.5 Precast Items Piles B 3 ± 1 6.0 ± 1.5 7.0 ± 1.5 Culverts, Parapet P 3 ± 1 6.0 ± 1.5 7.0 ± 1.5 Modular Bin Units, MSE Wall Panels, Leveling Pads P 2 ± 1 6.0 ± 1.5 7.0 ± 1.5 Slip-Form Items Parapet A 1 ± 1/2 6.0 ± 1.5 7.0 ± 1.5
1.When using a Type F or G admixture, change the requirements for Slump and Air Content for the given concrete item as follows: 1.1 Slump: 6 ± 2 inches 1.2 Air Content: increase both the target value and tolerance percentages by 0.5.
2.For drilled shaft concrete, use Type F or G admixture to achieve the required slump. If concrete in the drilled shaft is placed under a drilling fluid, the required slump is changed to 8 ± 1. Table 903.03.06-3 Mix Design Requirements Class A Class B Class S Class P Class P-1 Class P-2 Class Design Strength2 (28 days, psi) 4600 3700 2000 5500 6000 6500 Verification Strength2 (28 days, psi) 5400 4500 – 6000 6500 7000 Maximum Water-Cement Ratio3 (lb/lb) 0.443 0.488 0.577 0.400 0.400 0.400 Minimum Cement Content (lb/cy) 611 564 658 1 1 1
1.According to PCI MNL-116.
2.Record all concrete test results to the nearest 10 psi.
3.When a Type F or G water-reducing, high range admixture is used as specified in Table 903.03.06-1 and Table 903.03.06-2, reduce the maximum water-cement ratio by 0.043 for all classes of concrete except for Classes P, P-1, and P-2. Table 903.03.06-4 Lot Sizes, Sampling Rates, and Retest Limits Class A Class B Class S Class P Class P-1 Class P-2 Lot Size1, 2 (maximum) Day’s Production Day’s Production of a Single Steam Bed Pay Adjustment Items Initial Sampling Rate3, 4 5/Lot 5/Lot – 5/Lot 5/Lot 5/Lot Retest Sampling Rate5 (minimum) 5/Lot 5/Lot – 5/Unit or Load Test Non-Pay Adjustment Items Initial Sampling Rate 3, 4 3/Lot 2/Lot 1/Lot 5/Lot 5/Lot 5/Lot Retest Limit (psi) 4400 3600 2000 5400 5900 6400 Retest Sampling Rate5 5/Lot 5/Lot 5/Lot 5/Lot 5/Lot 5/Lot
1.The lot sizes are maximums. The ME may subdivide a lot into 2 or more smaller lots. When a subdivision is made, the specified sampling rate applies to each of the smaller lots.
2.The ME will not include more than 1 class of concrete in a lot.
3.An initial sample is defined as 2 cylinders taken from a concrete sample.
4.The ME will sample at the specified sampling rates except that no more than 1 test per truckload or batch of concrete will be required (except for air and slump tests when retempering). The ME may accept nonstructural concrete lots consisting of 20 cubic yards or less without strength tests.
5.A retest sample is defined as 1 core.
903.04 Pavement Repair Mixes Class V and E
903.04.01 Composition
Use Class V or E concrete for concrete pavement repair and replacement. Ensure that the composition of Class V and E concrete complies with 903.03.01 except that Class V concrete is required to use an accelerating admixture and a high range water-reducing admixture. Ensure that the composition of Class V or E concrete conform to the composition requirements specified in 903.03.01, except use an accelerating admixture and a high range water-reducing admixture for Class V concrete.
903.04.02 Mix Design and Verification
Design and verify Class V and E concrete as specified in 903.03.02, except for the following:
1.Design Class V and E concrete to conform to the requirements in Table 903.04.02-1.
2.Include 6.5 hour flexural beam testing in the verification testing for Class V concrete. Test two 6 6 21 inch flexural beams according to AASHTO T 97. The ME will witness the flexural beam testing. The ME will approve the mix design if both beams meet the verification strength.
3.Include 72 hour compressive strength testing in the verification testing for Class E concrete. Table 903.04.02-1 Mix Design Requirements Class V Class E Class Design Strength 28 day Compressive Strength, psi 3700 3700 6.5 Hour Flexural Strength, psi 350 – 72 Hour Compressive Strength, psi – 3000 Verification Strength 28 day Compressive Strength, psi 4500 4500 6.5 Hour Flexural Strength, psi 390 – 72 Hour Compressive Strength, psi – 3700 Maximum Water-Cement Ratio (lb/lb) 0.40 0.40 Minimum Cement Content (lb/cy) 611 611
903.04.03 Mixing
Mix Class V and E concrete as specified in 903.03.03 or 903.03.04.
903.04.04 Control and Acceptance Testing Requirements
A.Sampling and Testing Methods. Use the sampling and testing methods specified in 903.03.05.A.
B.Acceptance Testing Procedures for Slump and Air Entrainment. The ME will perform acceptance testing for slump and air entrainment as specified in 903.03.05.C.
C.Acceptance Testing Procedures for Strength. The ME will test Class V and E concrete to ensure conformance to the requirements specified in 903.03.05.D and 903.03.05.F for control and acceptance testing of non-pay adjustment Class B concrete for 28 day compressive strength. For each day’s production of Class V concrete, the ME will field cure two 6 × 6 × 21 inch beams according to AASHTO T 23 and will test the beams’ 6.5 hour flexural strength according to AASHTO T 97. If either beam is below the required strength of 350 pounds per square inch at 6.5 hours, the ME will perform a retest on 2 beams at 8 hours. If either beam is below the required strength of 350 pounds per square i nch at 8 hours, the ME will reject the day’s production. For Class E concrete, the ME will field cure cylinders according to AASHTO T 23 for use in 72 hour compressive strength testing. The ME will sample for 72 hour compressive strength testing at the sa me rate as for the 28 day compressive strength. The ME will perform compressive strength testing to ensure that the required 72 hour compressive strength of 3,000 pounds per square inch is in compliance. Each test is comprised of 2 cylinders.
903.05 High Performance Concrete (Hpc)
903.05.01 Composition
Produce HPC conforming to the composition requirements specified in 903.03.01, except for the following:
1.When using more than 1 admixture, ensure that they are compatible. If using admixtures from different manufacturers, submit letters from each manufacturer certifying that their admixtures a re compatible with all others in the mix design.
2.Pozzalonic material maximum percentage limitations specified in 903.01 and 903.02.03 are waived for HPC mix designs.
3.In the design of HPC, in order to achieve the desired resistance to chloride penetration, provide an appropriate pozzalonic or other cementitious material, such as silica fume, fly ash, or slag in the mix design.
4.Do not use silica fume as a sole material to achieve the desired resistance to chl orides. Do not use more than 5 percent of silica fume by weight of the total cementitious material. If using fly ash in conjunction with silica fume, use 10 to 15 percent fly ash by weight of the total cementitious materials. If using slag in conjunction with silica fume, use up to 40 percent slag by weight of the total cementitious materials.
903.05.02 Mix Design and Verification
Design an HPC mix that conforms to the requirements in Table 903.05.02-1. Submit a report documenting these results to the ME. Obtain the results of these standard tests from an AASHTO accredited testing agency that is accredited for the test being performed. Design mixes according to the HPC-1 criteria for use in bridge decks, parapets, and bridge sidewalks. Design mixes meeting the HPC-2 criteria for use in pier column protection. Table 903.05.02-1 Design and Verification Requirements for HPC Performance Characteristic Test Method Requirements HPC-1 HPC-2 Scaling Resistance1@ 50 cycles (visual rating of the surface, maximum) ASTM C 672 3 – Abrasion Resistance (average depth of wear in inches, maximum) ASTM C 944 – 0.04 Freeze-Thaw Durability (relative dynamic modulus of elasticity after 300 cycles, minimum) ASTM C 666 Proc. A 80% 80% Surface Resistivity2 @ 56 days (kΩ-cm, minimum) AASHTO T 358 36 36 Compressive Strength3 @ 56 days (pounds per square inch, minimum) AASHTO T 22 5,400 5,400 Water-Cement Ratio (maximum) – 0.40 0.40
1.For the scaling resistance testing, moist cure specimens for 14 days and then air cure for 14 days.
2.If the surface resistivity requirement has been achieved in 28 days, consider the surface resistivity acceptable. If the required surface resistivity is not achieved in 28 days, test the HPC sample at 56 days.
3.If the compressive strength requirement has been achieved in 28 days, consider the strength acceptable. If the required compressive strength is not achieved in 28 days, test the HPC samples at 56 days. At least 90 days before the planned start of the concrete placement, submit the mix design to the ME for approval and verification as specified in 903.03.02. Include the results of the required performance testing in the submission. In addition to verifying the compressive strength of the HPC mix, the ME will verify the surface resistivity according to AASHTO T 358. Submit 4 additional cylindrical samples, having a 4 inch diameter and a length of at least 8 inches, to the ME for this verification testing. The ME will average the values of tests on 4 specimens for each mix design.
903.05.03 Mixing
Mix HPC concrete as specified in 903.03.03. During production, do not change the components of the mix in any way from the approved mix design. If the components must be changed, redesign and re-verify the mix.
903.05.04 Control and Acceptance Testing Requirements
With the exception that the ME may perform compression testing at 56 days, the ME will enforce the requirements specified in 903.03.05 for control and acceptance testing of non-pay adjustment Class A concrete in the fabrication of the HPC elements. Produce HPC that conforms to the acceptance testing criteria in Table 903.05.04-1. Table 903.05.04-1 Acceptance Requirements for HPC Performance Characteristic Test Method Requirement Percent Air Entrainment1 AASHTO T 152 6.0 ± 1.5 (No. 57/67 Aggregate) 7.0 ± 1.5 (No. 8 Aggregate) Slump (inches)1, 2 AASHTO T 119 3 ± 1 Surface Resistivity @ 56 days3, 4 (kΩ-cm, minimum) AASHTO T 358 19 Compressive Strength @ 56 days5 (pounds per square inch, minimum) AASHTO T 22 4,400
1.If using a Type F or G admixture, change the Slump and Air Content values for the HPC as follows: 1.1 Slump: 6 ± 2 inches. 1.2 Air Content: increase both the target value and tolerance percentages by 0.5.
2.For slip-formed parapet, design and produce a mix with a slump of 1 ± 1/2 inch.
3.The ME will not test for the surface resistivity requirements for HPC used for Items other than bridge decks.
4.For surface resistivity, the ME will mold 4 additional cylinders, taking 2 cylinders each from 2 randomly selected delivery trucks for testing at 56 days.
5.For compressive strength testing, the initial rate for the HPC is 6 per lot. The retest limit is 4,400 pounds per square inch. The ME will test 2 specimens for surface resistivity and will average the results of the 2 specimens to determine the test result. The ME will perform 2 tests on each lot from samples taken from 2 randomly selected delivery trucks. The lot is eligible for 100 percent payment provided that the test results are equal to or above 19 kilo-ohm centimeter. If, upon testing at 56 days, one or more individual test results is below 19 kilo-ohm centimeter, the RE may do one of the following:
1.Require that the Contractor remove and replace the defective lot.
2.Allow the Contractor to submit a corrective action plan for approval.
903.06 Self-Consolidating Concrete (Scc)
903.06.01 SCC for Drilled Shafts
A.Composition. Produce SCC conforming to the composition requirements specified in 903.03.01, except use a Type F admixture and a viscosity modifying admixture (VMA). Use Type F and VMA admixtures , as specified in
903.02.02 and 903.02.04, at a dosage to produce a flowable concrete that does not require vibration for consolidation.
Proportion the aggregates so that the fine aggregate is less than 50 percent by weight of the total aggregate.
B.Mix Design and Verification. Design the mix as specified in 903.03.02 to conform to the strength requirements, water-cement ratio, and cement content for a Class A concrete and the requirements specified in Table 903.06.01-1. Table 903.06.01-1 Requirements for SCC for Drilled Shafts Property Test Method Requirement Air Content Coarse Aggregate No. 57 AASHTO T 152 6.5 ± 2.0 percent Coarse Aggregate No. 67 6.5 ± 2.0 percent Coarse Aggregate No. 8 7.5 ± 2.0 percent Slump Flow NJDOT C-4 21 ± 3 inches Visual Stability Index Plastic Concrete NJDOT C-4 1 maximum Hardened Concrete NJDOT C-5 1 maximum Perform mix design verification as specified in 903.03.02. For the verification batch, ensure that the air content is in the top half of the allowable range and the slump flow is between 21 and 24 inches. Perform air content, slump flow, and visual stability index (plastic concrete) testing on the verification batch. Make concrete cylinders for compression testing as specified in 903.03.02 and make 2 additional 4 × 8 inch cylinders for evaluation of the visual stability index of the hardened concrete. Saw the additional cylinders length-wise according to NJDOT C-5. The ME will perform the compressive strength testing and the visual evaluation to assign a visual stability index in order to approve the mix.
C.Verification of Pumpability. Verify pumpability at least 10 days before pouring the SCC concrete in the drilled shaft. Demonstrate the pumpability of the SCC to the ME by pumping a trial batch through the pump proposed for placing the SCC into the drilled shaft. Use the proposed methods for mixing the concrete including any anticipated time delays. The ME will test the SCC before and after pumping to verify that the SCC meets the requirements of Table 903.06.01-1 after pumping.
D.Mixing. Mix SCC as specified in 903.03.03.
E.Control and Acceptance Testing. Perform quality control testing as specified in 903.03.05. The ME will perform acceptance testing as specified in 903.03.05 for a non-pay adjustment Class A concrete, except that the provisions for slump testing are replaced with requirements for slump flow testing and visual stability index on the plastic concrete. The ME will perform the slump flow testing and the visual stability index according to NJDOT C-4, at the sampling rate specified for slump testing of Class A concrete. The ME will perform visual stability index on the hardened concrete according to NJDOT C-5 at a rate of at least 1 per day. If the visual stability index on the hardened concrete does not conform to the criteria in Table 903.06.01-1, the ME will require redesign of the mix. In the performance of quality control or acceptance testing, fill cylinder molds, slump flow cones, and air buckets in one lift. Do not vibrate, rod, or tap to consolidate the SCC.
903.06.02 SCC For Precast Concrete
A.Composition. Produce SCC conforming to the composition requirements specified in 903.03.01, except use a Type F admixture or a combination of a Type F and a viscosity mo difying admixture (VMA). Use Type F and VMA admixtures, as specified in 903.02.02 and 903.02.04, at a dosage to produce a flowable concrete that does not require vibration for consolidation. Proportion the aggregates so that the fine aggregate is less than 50 percent by weight of the total aggregate.
B.Mix Design and Verification. Design the mix, as specified in 903.03.02 or 903.05.02, to conform to the strength, water-cement ratio, and air content requirements for the specified class of concrete for the item that is being cast. In addition, ensure that the SCC conforms to the requirements specified in Table 903.06.02-1. Table 903.06.02-1 Requirements for SCC for Precast Concrete Property Test Method Requirement Slump Flow NJDOT C-4 16 to 24 inches Visual Stability Index Plastic Concrete NJDOT C-4 1 maximum Hardened Concrete NJDOT C-5 1 maximum Perform mix design verification as specified in 903.03.02 or 903.05.02. For the verification batch, ensure that the air content is in the top half of the allowable range and the slump flow is between 22 and 24 inches. Perform air content, slump flow, and visual stability index (plastic co ncrete) testing on the verification batch. Make concrete cylinders for compression testing as specified in 903.03.02 or 903.05.02 and make 2 additional 4 × 8 inch cylinders for visual stability index on the hardened concrete. Saw the additional cylinders length-wise according to NJDOT C-5. The ME will perform the compressive strength testing and the visual evaluation to assign a visual stability index in order to approve the mix.
C.Mixing. Mix SCC as specified in 903.03.03.
D.Control and Acceptance Testing. Perform quality control testing as specified in 903.03.05. The ME will perform acceptance testing as specified in 903.03.05 for specified class of concrete for the item, except that the provisions for slump testing are replaced with requirements for slump flow testing and visual stability index on the plastic concrete. The ME will perform the slump flow testing and the visual stability index according to NJDOT C-4, at the sampling rate specified for slump testing for the specified class of concrete. The ME will perform visual stability index on the hardened concrete according to NJDOT C-5 at a rate of at least 1 per day. If the visual stability index on the hardened concrete does not conform to the criteria specified in Table 903.06.02-1, the ME will require redesign of the mix. In the performance of quality control or acceptance testing, without remixing the sample, fill cylinder molds, slump flow cones, and air buckets in one lift. Do not vibrate, rod, or tap to consolidate the SCC.
903.07 Quick-Setting Patch Materials
Use quick -setting patch material that is listed on the QPL and is ready for mixing according to the ma nufacturer’s recommendations. Follow the manufacturer’s recommendations regarding the required water demand for the patching material. Use patching material that is concrete gray in color and contains no calcium chloride or other ingredients that cause corrosion to steel reinforcement. If adding coarse aggregate to patching material, use broken stone conforming to
901.03.01 Ensure that the material is quick -setting for use in concrete patchi ng where fast setting, rapid strength gain,
non-shrink, and high bond strength characteristics are needed. The ME will add products to the QPL only after testing and evaluation in the field, after service for 1 year. The classifications for quick-setting patch materials are as follows:
1.Type 1. Suitable for use above water. Type 1 products are used neat or with up to 15 pounds of coarse aggregate size No. 8 added to a 50 pound bag of material. The ME will test the patch material neat. At the work site, the Contractor may add up to 15 pounds of coarse aggregate size No. 8 to a 50 pound bag of the patch material to increase yield, provided that the product properties are not adversely affected.
2.Type 1A. Suitable for use above water. Type 1A products have manufacturer specified mix proportions with aggregates that would preclude it from being classified as a Type 1. The ME will approve the mix proportions before adding the material to the QPL. The manufacturer shall provide mixing proportions, including the required type and size of aggregate and the proportion of patching material, aggregate/sand, and water. At least 10 d ays before the start of placement, propose aggregates for verification trial batching based on the manufacturer’s pre-approved proportions. The ME will verify that the proposed quick setting patch mixture meets the required physical properties.
3.Type 1B. Suitable for use above water. Type 1B products are those products that have coarse aggregate, sand, or both pre-packaged with the cementitious material. The ME will test this material, including a field trial, prior to adding it to the QPL. The manufacturer shall designate the amount of aggregate and shall maintain the total aggregate within ±10 percent of this stated amount. The ME will randomly test the aggregate to ensure that the overall percentage of aggregate is within ±10 percent of the total and that the gradation on individual sieves does not vary more than ±10 percent from the gradation of the originally approved sample. The manufacturer shall use an aggregate supplier that is listed on the QPL. The ME will disapprove quick-setting patch material that fails to comply with the aggregate consistency requirements. If the manufacturer makes any changes to the formulation, the ME will require that the material be resubmitted for approval. Do not add additional aggregate in the field.
4.Type 2. Suitable for vertical and overhead repairs that are not formed and poured. The ME will test the patch material neat. If liquid activator, other additives, adhesive, or bonding agents are integral to the performance of the patch material, the manufacturer shall provide the material so that 1 package of additive, activator, adhesive or bonding agent is required for 1 package of patch material. Mix patch material as specified in 903.03.04. Use quick setting patch material that meets the requirements in Table 903.07-1 when tested according to NJDOT C-2. Mix quick-setting patch according to the manufacturer’s recommendations. Table 903.07-1 Requirements for Quick Setting Patch Material Type 1, 1A, 1B Type 2 Bond Strength 7 day (minimum) 1,000 psi 1,000 psi 28 day (minimum) 2,000 psi 2,000 psi Expansion/Shrinkage Cured in Water (maximum) +0.20% +0.20% Cured in Air (maximum) −0.20% −0.20% Difference (maximum) 0.30% 0.30% Durability Retained strength at 50 cycles (minimum) 90% 90% Visual condition rating at 50 cycles (maximum) 3 3 Permeability (maximum chloride content at 2 inches) 2.5 lbs/yd3 2.5 lbs/yd3 Compressive Strength 3 hour (minimum) 2,000 psi – 1 day (minimum) 3,000 psi 1,000 psi 7 day (minimum) 4,000 psi 2,000 psi 28 day (minimum) 4,500 psi 3,000 psi Time of Set in minutes (minimum) 15 15
903.08 Mortar and Grout
903.08.01 Mortar
To produce mortar, mix 1 part cement to 2 parts fine aggregate. Add water to form the proper consistency. Do not temper or use mortar after it has begun to set. Provide materials as specified: Fine Aggregate ................................ ................................ ................................ ................................ ......... 901.06.02 Cement ................................ ................................ ................................ ................................ ......................... 903.01 Water ................................ ................................ ................................ ................................ ............................ 919.08
903.08.02 Grout
A.Non-Shrink Grout. Use non -shrink grout of a plast ic consistency that is listed on the QPL and conforms to ASTM C 1107 with the following amendments:
1.Ensure that the grout has a working time of at least 30 minutes from the time the water is added.
2.Match the color of the hardened grout, where visible, to the color of the adjacent hardened concrete.
3.Include 1 day strength tests as part of the performance requirements of ASTM C 1107.
4.Ensure that the grout contains no more than 0.05 percent chlorides or 5.0 percent sulfates by weight.
B.Epoxy Grout. Use epoxy grout that is listed on the QPL and conforms to the requirements of ASTM C 881, Type 1, Grade 3, Class B or C.
903.08.03 Grout for Undersealing of Concrete Pavement
A.High-Density Polyurethane Grout. Submit to the RE for approval all materials proposed for use. Include in the submittal a certification of physical and chemical analysis by an AASHTO accredited testing la boratory. Provide certification that the materials will not shrink or deteriorate for a period of 10 years from the date of injection. Ensure that the high-density polyurethane conforms to the requirements specified in Table 903.08.03-1. Table 903.08.03-1 Requirements for High-Density Polyurethane Grout Property Test Method Requirements Density (pcf) ASTM D 1622 5.65 to 5.90 Compressive Strength (psi)1 ASTM D 1621 65 to 95 Tensile Core (psi) ASTM D 1623 70 to 100 Shear Strength (psi) ASTM C 273 40 to 85 Closed Cell Content % ASTM D 2858 85 to 95 Percent Volume Change Humid - 28 Days (158 °F, 95% Humidity) ASTM D 2126 +5.0 to +11.0 Freeze - 5 Days (−20° F, Dry) −0.1 to −0.9
1.Ensure high-density polyurethane grout reaches 90 percent of the full compressive strength within 15 minutes of injection.
903.09 Controlled Low Strength Material (Clsm)
Provide materials as specified: Fine Aggregate ................................ ................................ ................................ ................................ ........ 901.06.02 Cement ................................ ................................ ................................ ................................ ......................... 903.01 Chemical Admixtures................................ ................................ ................................ ............................... 903.02.02 Water ................................ ................................ ................................ ................................ ............................ 919.08 Use CLSM that consists of a mixture of cement, water, fine aggregate, and admixtures. Proportion the CLSM mixture to provide a backfill material that is self-compacting and capable of being excavated with hand tools at a later date. Proportion the CLSM to produce a 28 day compressive strength of 50 to 150 pounds per square inch. If fast-setting CLSM is required, use an accelerating admixture to produce a fast setting flowable mixture. Ensure that the CLSM for backfilling of conduit and piping has a permeability of 1.7 × 10−3 0.2 × 10−3 centimeters per second when tested according to ASTM D 5084. At least 45 days before the start of any CLSM placement, prepare trial batches of CLSM of the same materials an d proportions proposed for use i n the Contract. Submit each mix design on concrete mix design forms provided by the Department, naming the sources of materials and test data.
Referenced in this section
Concrete in other states
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Source: Standard Specifications for Road and Bridge Construction, 2019 (rev. 2022-12-21) Edition. Pages 468–488 of 651. View official source ↗