SECTION 502 - PORTLAND CEMENT CONCRETE PAVEMENT (Last Revised May, 2024)
502-1 DESCRIPTION. Construct a Portland Cement Concrete (PCC) pavement and shoulders, if
required, as detailed in the contract documents.
502-2 Materials
Portland Cement Concrete 501 Chemically Curing Adhesives for PCC Pavement Applications 701-14 Highway Joint Sealants (ASTM D6690, Type IV) 705-02 Premolded Resilient Joint Filler 705-07 Preformed Elastic Longitudinal Joint Seal 705-10 Preformed Elastic Transverse Contraction and Expansion Joint Seal 705-12 Lubricant for Preformed Elastic Joint Sealer 705-13 Longitudinal Joint Ties 705-14 Transverse Joint Supports 705-15 Wire Fabric for Concrete Reinforcement 709-02 Epoxy-Coated Bar Reinforcement, Grade 60 709-04 Quilted Covers (for Curing) 711-02 Plastic Coated Fiber Blankets (for Curing) 711-03 Polyethylene Curing Cover (White Opaque) 711-04 Membrane Curing Compound 711-05 Form Insulating Materials for Cold Weather Concreting 711-07
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Sections 200 - 599 STANDARD SPECIFICATIONS (USC) January 1, 2026 Volume 2 Water 712-01 If requested, provide the Engineer with any appropriate manufacturer’s details and/or instructions for use of the listed materials before use of the product. In addition to meeting the requirements of §701-14, Chemically Curing Adhesive for PCC Pavement Applications, the material used to anchor longitudinal joint ties, dowels, or other miscellaneous items into hardened concrete must be a pourable, two-component, 100% solid structural epoxy dispensed: • From side-by-side cartridges by manual or pneumatically powered injection guns. • Through a static mixing nozzle that homogeneously mixes the material without any hand mixing.
502-2.01 Performance Engineered Mixes (PEM) Provide a Performance Engineered Mix (PEM) in
accordance with Section 501, Portland Cement Concrete – General. The PEM concrete shall meet the design requirements of Materials Procedure MP502-01 Design and Approval of Performance Engineered Concrete Pavement for 502-PCC Pavements, unless otherwise specified in the contract documents. Obtain approval of the mix design from the Director of the Materials Bureau prior to placing any concrete. Any change to aggregate sources, major proportioning changes, cement type, supplementary cementitious material type or chemical admixture type/brand will require a new mix design. Minor changes in admixture dosages based on environmental conditions will not constitute a new mix design. The Regional Materials Engineer will evaluate changes to determine if a new trial batch is required.
502-2.02 High-Early-Strength (HES) Concrete. Use HES concrete where required in the contract
documents or where the contract documents require the pavement to be open to traffic in 48 hours or less. Design the HES mix to satisfy the opening to traffic time requirements of the project and Table 502-1, High-Early-Strength Concrete Mix Requirements. Submit the HES concrete mix design to the Engineer. Include admixture brands and dosages as well as mixing, transporting, placing, paving, curing, and anticipated strength gain details. Produce and place a 4.0 yd3 (minimum) trial batch at an off-contract location selected by the Contractor and agreed upon by the Engineer. Produce the trial batch using the same materials and processes as those to be used to produce concrete for the contract. Provide the Engineer a 7-day minimum advance notification of trial batch production. Produce and place the trial batch in the presence of the Engineer, the Regional Materials Engineer, and Materials Bureau personnel as per Materials Method MM502-02 Mix Design and Approval Procedure for High Early Strength (HES) Concrete for Portland Cement Concrete (PCC) Pavements. Changes other than minor fluctuations in admixture dosage rates require a new mix design and trial batch. The Engineer will reject the concrete if the specified plastic air content is not achieved. The Engineer may halt paving and order additional trial batches whenever the specified compressive strength requirements are not achieved. TABLE 502-1 HIGH-EARLY-STRENGTH CONCRETE MIX REQUIREMENTS Property Minimum Maximum 28 Day Compressive Strength 3000 psi - Opening Compressive Strength 2500 psi1 - Freeze-Thaw Loss (Test 502-3P, 3% NaCl) - 3.0 % Plastic Air Content 5.0 % 8.0 % Water – Cement Ratio (w/c) - 0.40
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Sections 200 - 599 STANDARD SPECIFICATIONS (USC) January 1, 2026 Volume 2 NOTES:
1.See §502-3.16, Opening to Traffic. Automobile only areas may be opened at 1500 psi.
2.There are no minimum or maximum requirements for slump, however mix must be fluid enough to finish without segregating.
502-2.03 Load Transfer Devices. Refer to 705-14 and 705-15 for load transfer device requirements.
Material requirements as well as the approval and acceptance procedures will be included in the contract documents when load transfer devices other than epoxy coated steel are specified.
502-3 CONSTRUCTION DETAILS. Hold a pre-pave meeting 7 to 14 days before the planned start of
paving with the Engineer, any PCC paving and saw cutting subcontractors, and concrete suppliers to coordinate all aspects of paving and inspection, including equipment review, construction methods, and time and personnel requirements.
502-3.01 Equipment. Provide the Engineer with an equipment list and specifications a minimum of 14
days prior to the planned start of PCC paving. Bring all equipment needed to place, consolidate, finish, texture, cure, saw cut, seal, and test the PCC pavement to the job site a minimum of 1 full workday before its use to allow examination by the Engineer. Repair or replace any equipment found to be defective before or during its use. Discontinue any operation if unsatisfactory results are being obtained. Use of equipment other than described below is subject to the approval of the Director, Materials Bureau.
A.Slipform Paving. Use a self-propelled slipform paver equipped with: • Rigid side forms that laterally support the concrete and minimize edge slumping. • A full width finishing pan. • Attached internal vibrators capable of consolidating the entire concrete placement. Slipform paving consists of a single paver, or a placer/spreader followed by a separate paver, capable of placing, spreading, consolidating, screeding, and finishing the concrete such that hand finishing is kept to a minimum. Use equipment guided by a reference system that ensures the pavement is placed to the specified line, grade, and cross section.
B.Fixed Form Paving
1.Forms. Use straight forms without horizontal joints meeting Table 502-2, Form Requirements, and equipped with: ▪ At least 3 stake pockets spaced 3 feet apart (maximum), each having a positive, nondetachable wedge. ▪ Positive, interlocking devices capable of holding abutting sections together to form neat, tight joints. Flexible, curved, or wooden forms may be used in irregular areas or curved sections having horizontal radii of 100 feet or less. T ABLE 502-2 FORM REQUIREMENTS Characteristic Requirement Material Steel, 1/4 inch thick, minimum. Length 10 feet, minimum.
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Sections 200 - 599 STANDARD SPECIFICATIONS (USC) January 1, 2026 Volume 2
2.Paving Equipment. Use fixed form paving equipment specifically made for placing concrete. The equipment must be capable of placing, spreading, consolidating, screeding, and finishing the concrete to the specified line, grade, and cross section such that hand finishing is kept to a minimum. Use equipment with either attached internal vibrators or in conjunction with handheld internal vibrators.
C.Vibrators. Use paver-mounted internal vibrators capable of consolidating the entire concrete placement that are: ▪ Capable of being shut off without shutting off the paver. ▪ Equipped with frequency controls readily accessible to the paver operator. ▪ Capable of simultaneously operating at the same frequency as the other paver - mounted vibrators. ▪ Capable of operating through a frequency range of 6,000 - 10,000 vibrations per minute. Check vibrator operating frequencies daily when paving begins. Check frequencies under load with the Engineer present. If the paver is not equipped with direct-read frequency gauges for each vibrator, supply the Engineer with a calibrated, hand-held tachometer, including instructions, to monitor vibrator frequencies. The tachometer will remain the Contractor’s property after paving is complete. Use hand-held vibrators capable of operating through a frequency range of 6,000 - 10,000 vibrations per minute in any location that is not consolidated by internal vibrators attached to the paving equipment.
D.Saw Cutting Equipment. Use diamond blade saws capable of making straight cuts to the dimensions depicted in the Standard Sheets that are equipped with cutting guides, blade guards, water cooling systems, dust controls, and cut depth control. Maintain equipment and supplies to ensure uninterrupted saw cutting. Early entry saws require approval from the Director, Materials Bureau. Submit requests to use early entry saws at least 7 calendar days before paving.
E.Curing Compound Applicators. Use atomizing mechanical sprayers capable of exerting consistent pressure without hand pumping that are equipped with tank agitators to continuously Depth Equal to the sum of the edge thicknesses of all pavement layers placed within the form. Base Width Equal to the depth, minimum. Horizontal Top Face 2 inch wide, minimum, and lying in a plane with a maximum variation of 1/8 inch in 10 feet. Vertical Face Maximum variation of 1/4 inch in 10 feet and rounded on the upper corner with a 3/4inch radius, maximum. Flange Bracing Extends outward on the base 2/3 of the form depth, minimum.
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Sections 200 - 599 STANDARD SPECIFICATIONS (USC) January 1, 2026 Volume 2 mix the curing compound. Use nozzles with spray shields to prevent drift. Flush nozzles daily before use. Maintain equipment and supplies, including extra nozzles, to ensure uninterrupted curing compound application. In a multi-lane slip form paving operation, use self-propelled applicators guided by the same reference system as the slip form paver. Otherwise, applicators need not be self-propelled.
F.Drills. Use gang drills with a minimum of 2 independently powered and driven drills. Use tungsten carbide drill bits. Rest and reference the drill rig frame on and to the pavement surface such that the drilled holes are cylindrical, perpendicular to the surface being drilled, and repeatable in terms of position and alignment. Hand-held drills are permitted for drilling holes in longitudinal joints if there is not enough room to use gang drills resting on the pavement surface.
G.Joint Sealing - Highway Joint Sealant. Heat the sealant in a melter constructed either: • As a double boiler with the space between inner and outer shells filled with oil or other heat transfer medium. • With internal tubes or coils carrying the sealant through a heated oil bath and into a heated double-wall hopper. Do not use direct heating. Use a Melter capable of maintaining the sealant’s pouring temperature and providing homogeneous sealant equipped with: • Positive temperature control. • Continuous full sweep mechanical agitation. • Separate thermometers indicating the temperatures of the heat transfer medium and the sealant in the hopper. Do not place any sealant if the thermometers are defective or missing. Provide 2 thermometers having stems 18 inches long and temperature ranges sufficient to meet the requirements of this specification. Use a discharge hose equipped with a controlled heating apparatus or sufficiently insulated to maintain the proper sealant pouring temperature. Use nozzles that apply the joint sealant within the joint confines for the full width and depth of the joint.
H.Air Blasting Equipment. Use equipment with traps or other installed devices that prevent moisture and oil from contaminating the concrete surface. Use a compressor that delivers air at a minimum of 120 cfm and develops a minimum nozzle pressure of 90 psi. Check the compressed air stream purity daily with a clean white cloth.
502-3.02 Weather Limitations
A.Rain. Do not pave in the rain. Supply sufficient quilted covers, plastic coated fiber blankets, or polyethylene curing covers near the paving operation when rain may be expected. Securely cover any concrete exposed to rain that has not reached initial set or will be visibly affected by the rain.
B.Cold Weather. Place concrete when the air temperature is 40°F and rising, or warmer, and when the surface temperature of the area to be paved is 40°F, or warmer. Stop paving when the air temperature falls below 40°F. Measure temperatures in the shade to an accuracy of 1°F. Refer to §502-3.11C, Cold Weather Curing.
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Sections 200 - 599 STANDARD SPECIFICATIONS (USC) January 1, 2026 Volume 2
502-3.03 Subbase Course. Install a subbase course in accordance with Section 304, Subbase Course,
before placing PCC. If the area is available, extend the prepared subbase course at the same line, grade, and cross slope as the area being paved such that it is at least: • 3 feet beyond the longitudinal edges of a slipform pavement. • 1 foot beyond the outside longitudinal edges of the fixed forms. Additional subbase course that is not included in the finished work will be paid for under Section 304 items included in the contract.
502-3.04 Slipform Paving. Establish a reference system to achieve the specified smoothness level. If
string lines are used, set them by survey and use dual lines whenever possible. Maintain uniform concrete quality and head in front of the paver. Coordinate concrete delivery to maintain continuous forward movement of the paver and avoid excessive delivery truck queues. Keep paver tracks clear of concrete and debris before and during paving. Wet the entire subbase surface without forming puddles or mud immediately before placing concrete. Consolidate the entire concrete placement using internal vibrators attached to the paver. Combine paver forward speed, vibrator frequency, and vibrator depth to consolidate the concrete without segregation, vibrator trails, or contacting the joint assemblies. Discontinue vibration and tamping if the paver stops. Determine edge slump by extending a 2 foot (minimum) long straightedge over the longitudinal pavement edges. Immediately correct edge slumps greater than 1/4 inch that are between concrete placements and greater than 3/8 inch at free edges and HMA shoulders.
502-3.05 Fixed Form Paving.
A.Setting Forms. Compact the supporting layer at the form line such that the forms are supported for their full length. Set forms to string lines placed at the pavement elevation, line, and grade and to achieve the specified smoothness. If a form sits above the string line, remove the form and trim the form line to the proper grade. If a form sits below string line, remove the form and fill and compact the low area with granular material at least 6 inches on both sides of the form. Frequently check form grade and alignment while paving. Reset forms as necessary. Set forms to accommodate a full day’s paving before placing concrete. Extend forms beyond construction bulkheads to provide a working platform at the end of a placement. Secure each form with a minimum of 3 pins, each of sufficient length to hold the forms in place without movement during any operation. Lock the forms together such that the form ends are aligned, and the joints are tight and smooth. Run the paving equipment atop the forms before placing any concrete and recheck form alignment. Reset forms as necessary. Align keyway strips in a smooth, horizontal plane, parallel to the top of the form. Match keyway strips on abutting forms such that a nearly seamless keyway results.
B.Paving. Apply oil to forms before placing concrete. Immediately before placing concrete, wet the entire subbase surface without forming puddles or mud. Uniformly distribute the concrete in front of the paver. If concrete is spread by hand, use come-alongs or shovels. Do not use rakes or hand-held vibrators to spread concrete. Maintain uniform concrete quality and head in front of the paver and without running over the screeds. Coordinate concrete delivery to maintain continuous forward movement of the paver and avoid excessive delivery truck queues. Keep form tops clean before and during paving. Consolidate the entire concrete placement using internal vibrators attached to the paver. Combine paver forward speed, vibrator frequency, and vibrator depth to consolidate the concrete without segregation, vibrator trails, or contacting the joint assemblies. Discontinue vibration and tamping if the paver stops.
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Sections 200 - 599 STANDARD SPECIFICATIONS (USC) January 1, 2026 Volume 2 Use hand-held vibrators ahead of the paving equipment to consolidate all concrete not consolidated by machine-mounted internal vibrators. Keep hand-held vibrators perpendicular to the pavement surface. Vibrate between 2 and 4 seconds in each location, overlapping adjacent locations. Do not drag vibrators through the concrete. Do not walk through the consolidated concrete. Mark the midpoint (± ½ inch) of each transverse contraction joint such that the saw cut operator can accurately locate the first-stage saw cut locations.
C.Form Removal. Remove forms after the concrete has developed sufficient strength to allow removal without damaging the pavement. Repair pavement damaged during form removal. Remove forms before making second-stage saw cuts.
502-3.06 Joint Construction. The Engineer will inspect the longitudinal joint ties and transverse joint
supports for compliance to the relevant Materials Details before any joint hardware placement is allowed. Construct joints in accordance with the Standard Sheets and approved Materials Details. Do not stand on joint hardware. Base final joint layout on construction staging and the actual location of utilities, drainage structures, intersections, tapers, and other irregular areas. Submit a proposed joint layout to the Engineer at least 10 calendar days prior to PCC paving. Obtain the Engineer’s approval of the joint layout before paving. Inserting dowels and/or longitudinal joint ties into plastic concrete will be considered. Submit a plan to verify dowel and tie locations, depth, and alignment to the Engineer for consideration. Do not insert dowels or ties until the plan is approved by the Engineer. Make first-stage saw cuts 1/8 inch wide. Make second-stage saw cuts, clean, and seal joints in accordance with §502-3.12, Sealing Joints.
A.Transverse Joints. Transverse joints include contraction, expansion, hinge, and construction joints. Secure joint supports to the subbase as depicted in the Materials Details. Maintain joint supports in their proper position and alignment during paving. Construct transverse joints perpendicular to both the pavement surface and longitudinal joints in the area being paved. Space transverse joints such that the pavement slabs meet the geometric requirements of the 502 Standard Sheets.
1.Transverse Contraction Joints. All transverse joints are contraction joints unless otherwise shown in the contract documents. Contraction joints are constructed in a straight line across the full width of the PCC pavement and shoulders. Contraction joints may also be angled (rather than straight across a pavement) at tied longitudinal joints between lanes placed separately if the placements do not have the same centerline, e.g., where a ramp centerline diverges from parallel to the pavement centerline. Contraction joints may terminate at, or be misaligned at, untied longitudinal joints as discussed in §502-3.06B3, Untied Longitudinal Joints. Store transverse contraction joint support assemblies in inverted stacks at the project site. Cover stored epoxy coated steel such that it is protected from direct sunlight. Handle joint supports such that no twisting or bending occurs during storage and positioning. Supports with bent, twisted, or deformed wires will be rejected. Before placing concrete, position transverse joint supports such that the: • Entire longitudinal axis of each dowel is located at the mid-depth of the pavement slab or up to 1 inch below the mid-depth of the slab.
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Sections 200 - 599 STANDARD SPECIFICATIONS (USC) January 1, 2026 Volume 2 • Longitudinal axes of the dowels are aligned parallel with the pavement centerline and pavement surface such that the maximum misalignment of one dowel end relative to the other is ¼ inch. • Midpoint of the longitudinal axis of each dowel is at the center of the joint (±1 inch). • Longitudinal axes of the two end dowels are 4 to 12 inches from the longitudinal joints. • Longitudinal axes of the dowels are spaced 12 inches apart. Mark the location of each contraction joint on the subbase before placing concrete such that the assembly is properly positioned. Also mark the longitudinal midpoints of the dowels such that the saw cut operator can accurately locate first-stage saw cuts. In a slipform paving operation, mark the joint support midpoint on the subbase immediately adjacent to the pavement. In a fixed form paving operation, mark the joint support midpoint on the form or such that the saw cut operator can easily locate the joint midpoint. Do not cut the shipping wires. Make first-stage saw cuts as soon as the concrete has hardened sufficiently to permit sawing without causing raveling wider than 1/8 inch. Replace blades if raveling persists. Center first stage saw cuts within 1 inch of the longitudinal midpoints of the dowels. Complete first-stage saw cuts before any uncontrolled cracking occurs. Be prepared to make first-stage saw cuts 24 hours a day to prevent uncontrolled cracking. Provide lighting required to make first-stage saw cuts at night at no additional cost to the State. Sweep or wash first-stage saw cut debris from the pavement before it rains, or before opening the pavement to any traffic, such that debris does not enter the joint.
2.Transverse Expansion Joints. Construct transverse expansion joints as part of the utility and drainage structure isolation systems depicted in the Standard Sheets or where indicated in the contract documents. Handle and position expansion joint supports in accordance with §502-3.06A1, Transverse Contraction Joints. Construct expansion joints using 1/2 inch thick premolded resilient joint filler placed in 1 piece between longitudinal joints. Tightly place and support abutting sections of joint filler such that no concrete infiltrates the joint. Place expansion caps on the dowels as depicted in the Materials Details. Do not tap or hammer the caps onto the dowels. No saw cuts are required in expansion joint construction. Remove the finishing cap, if supplied, after the concrete has developed sufficient strength to prevent damage.
3.Transverse Construction Joints. Construct transverse construction joints wherever there is an interruption of more than 30 minutes in concrete paving operations. Construct these joints as wide as the concrete placement, typically 1 or 2 lanes, but not necessarily the full pavement width. Align construction joints with transverse contraction or construction joints in adjacent lanes. Construction joints may be formed by bulk heads, saw cuts, concrete removal, or any combination thereof. When required, drill and anchor dowels in accordance with §502-3.06D, Drill and Anchor Dowels or Ties, such that they meet the positioning requirements of §502- 3.06A1, Transverse Contraction Joints.
a.Bulkheads. Ensure the bulkhead can support the weight of the plastic concrete. Bulkheads may be slotted or solid. Place a slotted bulkhead over the dowels of an exposed joint assembly such that half of the dowel lengths are embedded within newly
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Sections 200 - 599 STANDARD SPECIFICATIONS (USC) January 1, 2026 Volume 2 placed concrete. Immediately remove plastic concrete in front of the bulkhead and from the exposed joint support. The transverse joint assembly may be omitted and a solid bulkhead may be used. In this case, drill and anchor dowels, if required, into the transverse joint face.
b.Saw Cut. Saw cut full depth construction joints at locations that satisfy the minimum and maximum slab length requirements of the 502 Standard Sheets. Saw cut when the concrete has obtained sufficient strength to be saw cut without damage to concrete to remain in place. Do not cut within 12 inches of a longitudinal joint tie. Remove the hardened concrete ahead of the saw cut. Drill and anchor dowels, if r equired, into the saw cut face such that they meet the positioning requirements. Do not drill into longitudinal joint ties. In lieu of drilling holes, the contractor may use transverse joint supports fabricated with closed-end, hollow plastic cylinders instead of dowels. Use hollow cylinders with outer diameters equal to the drilled hole diameters described in §502- 3.06D, Drill and Anchor Dowels or Ties. Position cylinders as required in §502- 3.06A1, Transverse Contraction Joints. Saw cut the newly placed concrete full depth and full width through the midpoint of the longitudinal axis of each cylinder (± 1 inch). Remove hardened concrete and the joint assembly ahead of the saw cut. Remove the hollow cylinder embedded in the concrete that remains and anchor the dowels in accordance with §502-3.06D, Drill and Anchor Dowels or Ties, to the required alignment in §502-3.06A1, Transverse Contraction Joints.
c.Removal. Remove all concrete to the midpoint of the preceding transverse joint without damaging the dowels, dowel coatings, or the pavement to remain in place.
4.Transverse Hinge Joints. Do not place hinge joints without the Engineer’s approval. Construct transverse hinge joints when a slab length exceeds the geometric requirements of the 502 Standard Sheets. Construct hinge joints in accordance with §502-3.06A1, Transverse Contraction Joints, except the positioning requirements do not apply. Instead, position transverse hinge joint supports such that the: • Entire longitudinal axis of each deformed bar is located at the mid-depth of the pavement slab or up to 1 inch below the mid-depth of the slab. • Longitudinal axes of the bars are aligned parallel with the pavement centerline and pavement surface such that the maximum misalignment of one bar end relative to the other is 1 inch. • Midpoint of the longitudinal axis of each bar is at the center of the joint (±1 inch). • Longitudinal axes of the two end bars are 4 to 10 inches from the longitudinal joints. • Longitudinal axes of adjacent bars are spaced 4 to 18 inches apart.
B.Longitudinal Joints. When a longitudinal joint item is specified, select tie type, size, spacing, and positioning in accordance with the 502 Standard Sheets and contract documents. Provide a minimum clearance of 3 inches between the end ties in a slab and any part of the transverse joint support. Keep ties free of materials that inhibit bonding to concrete or anchoring material. Maintain ties in their proper position during paving.
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Sections 200 - 599 STANDARD SPECIFICATIONS (USC) January 1, 2026 Volume 2 It is highly desirable to align longitudinal joints with the permanent pavement markings. Tied longitudinal joints located in the wheel paths of the completed pavement will require ties placed 24” on center.
1.Longitudinal Joints Between Lanes Paved Simultaneously. Use one-piece ties fabricated into assemblies capable of securely holding 2 or more ties. Secure the assemblies to subbase prior to paving in accordance with the Materials Details. Make first-stage saw cuts parallel to the pavement centerline and perpendicular to the pavement surface before uncontrolled cracking occurs. Use equipment specified in §502-3.01D, Saw Cutting Equipment. Replace saw blades if raveling wider than 1/8 inch occurs. Center first- stage saw cuts within 1 inch of the longitudinal midpoint of the ties. Sweep or wash first-stage saw cut debris from the pavement before it rains, or before opening the pavement to any traffic, such that debris does not enter the joint.
2.Tied Longitudinal Joints Between Lanes Paved Separately. In a slip form operation, construct a butt joint and drill and anchor one-piece ties into the hardened concrete in accordance with §502-3.06D, Drill and Anchor Dowels and Ties. The use of push-in type ties will be considered. Submit a plan to verify tie locations, depth, and alignment to the Engineer for consideration. Do not insert push-in type ties until the plan is approved by the Engineer. Use # 6 ties, 22 inches (minimum) long between travel lanes and 18 inches (minimum) long between a travel lane and a PCC shoulder. Anchor ties between travel lanes 10 inches into the previously placed concrete, leaving 12 inches (minimum) projecting from the joint face. Anchor ties between a travel lane and a PCC shoulder 8 inches (minimum) into the previously placed concrete, leaving 10 inches projecting from the joint face. Place end ties in a slab 14 to 18 inches from the transverse joint. Typically, space ties between the end ties 36 inches apart, maximum. Pavements having 4 or more tied lanes, or 3 lane pavements 12 inches (or more) thick, may require a decreased spacing in accordance with the contract documents. In a fixed form operation, construct either a butt or a keyed joint. Drill and anchor one-piece ties as discussed above, or use multiple-piece ties. Apply a corrosion inhibiting coating to the threads of all multiple-piece tie components before assembly. Bolt the female portion of the tie to the form prior to paving as depicted in the Standard Sheets. Insert and tighten the male ends before paving the adjacent lane. Ensure all threaded connections are tight. First-stage saw cuts are not required between lanes paved separately.
3.Untied Longitudinal Joints. Construct untied longitudinal joints at utilities and/or drainage structures, at intersections, between adjacent lanes having non-parallel center lines (such as ramps), or where indicated in the contract documents. Form as depicted in the Standard Sheets. Transverse joint type, location, and alignment may be changed when a transverse joint intersects an untied longitudinal joint. Patch honeycombing along the untied longitudinal joint face to achieve a smooth surface prior to applying the bond breaker and placing the adjacent concrete. First-stage saw cuts are not required.
C.Utility and Drainage Structures and Telescoping Manholes. Detail jointing around each utility and drainage structure in the proposed joint layout submitted to the Engineer for approval. Refer to the Standard Sheets for jointing and reinforcement around utilities and drainage structures. When possible, do not isolate, or “box out,” utilities and drainage structures from the pavement. Instead, set and center utilities and drainage structures between transverse joints and pave the slab with the structure at the same time as the surrounding pavement. Use a minimum slab length, Lmin, as defined
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Sections 200 - 599 STANDARD SPECIFICATIONS (USC) January 1, 2026 Volume 2 in the 502 Standard Sheets. Reinforce the slab that contains the structure. Select reinforcement size and spacing such that: As ≥ 0.0018(s)(t) where: As = Area of a steel bar (in2) s = Spacing of steel bars (in). Minimum 3” clearance between bars. t = Slab thickness (in) Use mat reinforcement with steel in both directions. Use top and bottom double mat reinforcement for slabs thicker than 10”. Refer to the Standard Sheet for mat reinforcement placement locations. When using telescoping manholes, remove temporary support bolts from the telescoping manhole casting as soon as the concrete hardens.
D.Drill and Anchor Dowels or Ties. Do not drill holes until the concrete has developed sufficient strength to withstand drilling without damage. Damage from drilling shall be addressed in accordance with §502-3.14, Damaged or Defective Concrete. Drill such that the hole diameters are in accordance with the anchoring material manufacturer’s written recommendations. Replace worn bits when necessary to ensure the proper hole diameter is drilled. Follow the anchoring material manufacturer’s written recommendations for cleaning the holes. As a minimum, clean the drilled holes with compressed air. Insert the nozzle to the back of the hole to force out all dust and debris. When using new cartridges of anchoring material, ensure the initial material exiting the nozzle appears uniformly mixed. If it is not uniformly mixed, waste the material until uniformly mixed material extrudes. Place the anchoring material in the back of the hole using a nozzle with sufficient reach. Push the dowel or tie into the hole while twisting such that the air pocket within the hole is heard to burst and the anchoring material is evenly distributed around the bar. Use sufficient amounts of anchoring material such that it slightly extrudes out the hole as the bar is inserted.
502-3.07 Paving Adjacent to Existing Concrete. Wherever paving equipment operates on existing PCC
pavement that is to remain, install bolt-on track covers or rubber tired, flangeless wheels. Remove all debris on the existing PCC pavement in the equipment track. Immediately remove any concrete that spills onto the existing concrete. When paving from (or to) a transverse construction joint or intersecting pavement, use hand-held vibrators to thoroughly consolidate any concrete inaccessible to the paving equipment vibrators. Hand finish these areas with the minimum effort required to produce an acceptable surface. Do not dump the grout box head into the pavement concrete when approaching a construction joint.
502-3.08 Plastic Thickness Determination. Provide the Engineer with a round, rigid, nonaluminum
probe, having a 1/8-inch diameter. The Engineer will determine the plastic concrete thickness by inserting the probe and measuring the insertion depth. The Engineer will check thickness at least every 150 feet of paving and at least 2 feet from the placement edge. Keep several probes at the project. The minimum measured plastic thickness must be equal to (-1/4 inch) or greater than the thickness required in the contract documents. Areas not meeting minimum thickness will be treated in accordance with §502-3.14, Damaged or Defective Concrete. If 2 consecutive measurements do not meet minimum thickness, stop paving and reestablish the paving operation to achieve acceptable thickness. No additional payment will be made for concrete placed in excess of:
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Sections 200 - 599 STANDARD SPECIFICATIONS (USC) January 1, 2026 Volume 2 • ¼ inch of the designed pavement thickness when placing an overlay on an existing pavement. • ½ inch of the designed pavement thickness when placing directly on subbase.
502-3.09 Finishing. Provide an ACI certified concrete flatwork finisher to supervise finishing. Provide
proof of ACI flatwork certification to the Engineer. Mechanically finish the pavement after consolidation and strike off. Use machine mounted finishers such as full-width finishing pans, transverse oscillating screeds, longitudinal floats, pan floats or separate pieces of equipment such as tube floats. Correct bumps with a 16-foot straight edge or bump cutter specifically made for finishing concrete. After mechanical finishing, hand finish the pavement to correct and seal minor imperfections. Hand finish with magnesium floats, lutes, and/or trowels. Use work bridges to hand finish concrete inaccessible from the pavement edge. Keep hand finishing to a minimum. Do not use excess mortar or discarded concrete to fill low areas. Do not add water to the concrete surface to close imperfections. Do not trowel bleed water into the surface. Stop paving or reformulate the concrete mix if surface imperfections that require additional water to close routinely occur. Ensure the saw cut operator can locate joint sealant locations between separate, adjacent placements. This may be accomplished with a small radius (1/4 inch) edger along the edge of the second placement.
502-3.10 Texturing. Immediately after finishing and prior to applying the curing compound, texture the
concrete surface using one of the following procedures in accordance with the contract documents. Apply longitudinal tining if no texturing method is designated in the contract documents. Additional requirements, such as Mean Texture Depth measured by a sand patch test or a profiler may be performed to check texturing adequacy. For a closed drainage system, provide an 8 - 12-inch blank in the texture along the pavement edges to enhance drainage to catch basins.
A.Longitudinal Tining. Texture the concrete parallel to the pavement centerline with a set of evenly spaced spring steel tines. Use rectangular tines 1/8 inch wide, 1/32 inch thick, and approximately 5 inches long at a center-to-center spacing of 3/4 inches. Operate the tine head manually or mechanically. In either case, hold the tines as near an angle of 45° to the concrete surface as possible to minimize mortar dragging. Produce tine texture 1/16 - 1/8 inch deep with minimal dislodging of aggregate. Do not make multiple tine passes in the same area. Keep tines 2 - 4 inches from the placement edges. Keep the tines free of hardened concrete.
B.Artificial Turf Drag. Use a seamless strip of artificial turf drag appearing on the Department's Approved List entitled “Turf Drag” under “Equipment, Concrete Related.” Produce a consistent texture, free of ridges or gouges, parallel to the pavement centerline either by hand or by attaching a weighted strip to the paver, texture/cure machine, or work bridge. Periodically replace or clean the drag to remove hardened concrete paste that compromises texture.
502-3.11 Curing. Apply curing compound no later than 5 minutes after texturing. The Engineer may stop
paving if curing lags beyond the time limits noted. Cure concrete until it is eligible to open to construction traffic as per Table 502-3, Pavement Opening Requirements, based on the Contractor-submitted mix design and the trial batch evaluation.
A.White Pigmented Membrane Curing Compound. Cure concrete with white pigmented membrane curing compound. Mix the curing compound before each use and continuously agitate during use. Uniformly coat all exposed surfaces (including slipformed edges and formed edges immediately after form removal) at a minimum rate of 150 sf/gal such that the coated surfaces are completely white. Check the application rate after every paving day, including exposed vertical slab
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Sections 200 - 599 STANDARD SPECIFICATIONS (USC) January 1, 2026 Volume 2 faces in the calculations. Apply the curing compound in 2 direction passes with no longer than 15 minutes between passes. Immediately reapply curing compound to any damaged coating areas. During curing equipment breakdown, cure the pavement in accordance with §502-3.11B, Curing Covers. Do not apply curing compound in the rain. If rain damages the curing compound before it sets, reapply curing compound after the pavement surface dries.
B.Curing Covers. Use of curing covers is subject to the approval of the Engineer. Use quilted covers, plastic coated fiber blankets, or polyethylene curing covers. Do not use covers with tears or holes. Cover all exposed surfaces and extend the covers a minimum of 12 inches beyond the pavement edges or beyond the forms, when used. Overlap successive covers 12 inches, minimum. Secure the covers to keep them in contact with the entire surface and maintain the overlap. Wet the entire surface of quilted covers and maintain them in a wetted condition until pavement is eligible to be opened to construction traffic.
C.Cold Weather Curing. Supply form insulating materials for winter concreting when the air temperature is going to fall below 40°F at any time until pavement is eligible to be opened to construction traffic. Use material capable of maintaining a surface temperature of 55°F and being easily removed and replaced to accommodate first-stage saw cuts. Apply the insulating material to prevent newly placed concrete from being exposed to air temperatures below 35°F for the curing period. Secure the insulation tight to the concrete surface to prevent air intrusion beneath the insulation. Extend the insulation 12 inches beyond the newly placed concrete. Insulate the pavement vertical edge and/or forms as well. Place recording surface thermometers between the pavement surface and insulating material 12 inches from one of the placement edges wherever insulation is used. Use 4 equally spaced thermometers for each day’s paving. Do not subject the concrete to a temperature drop in excess of 50°F during the first 24 hours after removing the insulation.
502-3.12 Sealing Joints. Seal joints in accordance with the Standard Sheets.
First-stage saw cuts may be temporarily left unfilled if a placement is only subjected to occasional construction traffic, such as pickup trucks or cars. In this case, ensure debris does not enter the joints. Temporarily fill unsealed first-stage cuts with jute or backer rod if a placement is: • Subjected to consistent construction traffic. • Used as a haul road for subsequent concrete placements. • Temporarily opened to general traffic while final sealing has been delayed. Before cleaning, remove any temporary fillers and repair damaged joints in accordance with §502- 3.14, Defective or Damaged Concrete, including chipped joints resulting from debris accumulation in an unfilled or unsealed joint.
A.Highway Joint Sealant. Widen joints to 1/4 - 3/8 inch for a depth of 1 inch to allow full-depth sealing. Immediately wash the widening cut slurry from the pavement such that it does not reenter the joint. Clean the joints by abrasive blasting before sealing. Keep the nozzle within 2 inches of the joint surfaces. If the project does not allow abrasive blasting, The Engineer may allow pressure washing as an alternate preparation method. When pressure washing, use a 900 psi minimum pressure and a maximum pressure such that no damage occurs to the concrete. Manually dislodge debris remaining in the joint after cleaning, and reclean the joint. Immediately after pressure washing, air blast the joint to remove any debris from the cut and dry
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Sections 200 - 599 STANDARD SPECIFICATIONS (USC) January 1, 2026 Volume 2 the exposed faces. Ensure the joint is completely dry before sealing. Do not allow any traffic on the pavement between cleaning and sealing. Reclean the joint if it rains between cleaning and sealing or if any traffic is on the placement between cleaning and sealing. Provide the Engineer a copy of the sealant Manufacturer's written recommendations for heating and application at least 1 work day before sealing. Follow those recommendations. Unless stated otherwise, the recommended pouring temperature is 40°F below the manufacturer's designated safe heating temperature, with an allowable variation of 40°F. Prior to sealing, discharge sealant from the applicator wand into a vessel and measure the sealant temperature. The temperature must be equal to or above the Manufacturer’s recommended minimum pouring temperature and equal to or below the Manufacturer’s recommended safe heating temperature. Do not use sealant heated above the safe heating temperature. Sealant may be reheated or heated in excess of 6 hours if allowed by the Manufacturer’s heating and application recommendations. In these cases, recharge the melter with fresh sealant amounting to at least 20% of the sealant volume remaining in the melter. Seal joints immediately after cleaning. Seal the joint from the bottom of the cut to within 1/2 inch of the pavement surface. Seal when the: • Air and surface temperatures are 40°F or warmer. • Air temperature is above the dew point. • Pavement surface and all joint surfaces are dry. Open to traffic after the sealant has cured to prevent tracking. Do not blot with fine aggregate.
B.Sealing Joints - Preformed Joint Sealers. Make second-stage saw cuts and/or bevels in accordance with the Standard Sheets. Extend the second-stage saw cut vertically down the free concrete edges. Wash the resulting slurry from the pavement and joint immediately after making second-stage saw cuts and/or bevels. Second-stage saw cuts may be delayed for convenience, but do not leave second-stage saw cuts unsealed or unfilled while open to any traffic. Temporarily fill second-stage saw cuts with jute or backer rod if: • The joints are exposed to any traffic before cleaning and sealing • Weather conditions are not favorable for timely (within 2 calendar days) cleaning and sealing, regardless of if they are exposed to any traffic. Clean the joints by pressure washing before sealing. Use a 900 psi minimum pressure and a maximum pressure such that no damage occurs to the concrete. Manually dislodge debris remaining in the joint after cleaning, and reclean the joint. Within 24 hours of pressure washing, air blast the joint to remove any debris from the cut and dry the exposed faces. Reclean the joint if it rains between cleaning and sealing. Do not allow any traffic on the pavement between cleaning and sealing. Install the sealant in accordance with the Manufacturer’s written instructions. Lubricate the concrete, the sealer, or both before installation such that the lubricant fully covers the sealer/concrete interface, but not the top of the sealer. Install one piece of transverse joint sealer in a compressed condition across the full pavement width, including concrete shoulders, and down the vertical saw cut at the free edge. Cut the longitudinal sealer where it crosses a transverse joint. Do not splice the longitudinal sealer between transverse joints. Seal the intersection between longitudinal and transverse sealers with lubricant. Install the sealer such that it is not stretched more than 5%, nor compressed more than 2%, of the minimum theoretical length. Check the installation for stretch and compression by installing sealers in 5 transverse joints and removing the sealer immediately after installation and checking the length.
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Sections 200 - 599 STANDARD SPECIFICATIONS (USC) January 1, 2026 Volume 2 An alternate method for checking stretch and compression, where applicable, may be performed by premarking or precutting the sealer to length prior to installation. If the measurement of any of these 5 sealers exhibits stretching in excess of 5% or compression in excess of 2%, modify the installation method to meet the requirements or discontinue installation. Once sealing operations begin, remove 1 joint per 100 in the presence of the Engineer to check stretch and compression. If the sealer is found to be stretched in excess of 5% or compressed in excess of 2%, remove the sealer material from successive joints in both directions until sealers are found that meet the stretch and compression requirements. Replace all joints sealers found with excess stretch or compression. Replace joint sealers removed and found to meet the stretch and compression requirements.
502-3.13 Pavement Protection. Protect the pavement and appurtenances from traffic and construction
operations. Protect the work and provide for traffic as indicated in the contract documents.
502-3.14 Damaged or Defective Concrete. The Engineer will identify all areas of damaged and
defective concrete. The Contractor shall submit a repair plan for the damaged or defective concrete to the Engineer for approval. Repair or replace all damaged or defective concrete in accordance with the approved repair plan. Damage and defects include, but are not limited to, cracking, spalling, poor consolidation, out of specification materials, or imperfections caused by inadequate pavement protection, traffic, and/or construction practices. Slipformed concrete with inadequate plastic thickness as described in §502-3.08, Plastic Thickness Determination, will be rejected in 150 foot segment lengths.
502-3.15 Hardened Surface Tolerance. After the concrete has hardened sufficiently, test each travel
lane, including ramps, with straight edges laid both longitudinally and transversely. Do not measure transverse deviations across longitudinal joints. The Engineer will mark longitudinal deviations in the pavement surface exceeding 1/4 inch in 15 feet and transverse deviations exceeding 1/4 inch in 10 feet. Diamond grind these deviations in accordance with §505-3.02, Bump Grinding, such that they do not exceed these parameters when retested. Shoulders and other areas not routinely exposed to traffic must meet 1/4 inch in 10 feet both longitudinally and transversely.
502-3.16 Opening to Traffic Open concrete pavements to construction traffic or general traffic based on
the requirements of Table 502-4, Pavement Opening Requirements, and if the joints have been addressed in accordance with §502-3.12, Sealing or Filling Joints using one of the following.
A.Project Strength Determination. Perform testing in accordance with §501-3.07A Early Loading Applications/ High Early Strength Mixtures. The pavement may be opened to construction (or general) traffic if all the cylinders meet the requirements of Table 502-3 Pavement Opening Requirements and if the joints have been addressed in accordance with §502-3.12, Sealing or Filling Joints. TABLE 502-3 PAVEMENT OPENING REQUIREMENTS All the Following Must Apply: Construction Equipment General Traffic Minimum Average compressive strength of all cylinder sets 2500 psi 3000 psi Minimum Average compressive strength of each cylinder set 2000 psi 2500 psi Note: Automobile only areas may be opened at 1500 psi.
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Sections 200 - 599 STANDARD SPECIFICATIONS (USC) January 1, 2026 Volume 2
B.Maturity. ASTM C1074, Standard Practice for Estimating Concrete Strength by the Maturity Method, may be used to open the pavement to traffic. Inform the Engineer of the intent to use this method at least 28 days before producing any pavement concrete. Submit a maturity curve development plan to the Engineer that includes an equipment list, the date and time of batching, the testing facility name and address and any variations to ASTM C1074. Perform all batching and testing related to developing the maturity curve with the Engineer and Regional Materials Engineer present. Open to traffic at the strengths identified in Table 502-3, Pavement Opening Requirements.
502-4 METHOD OF MEASUREMENT. The Engineer will measure the following quantities for items
incorporated into the finished pavement:
502-4.01 PCC Pavement, Unreinforced. The work will be measured for payment as the number of
cubic yards of unreinforced PCC pavement placed to the nearest cubic yard. Deductions will be made for catch basins, manholes, or other similar pavement obstructions requiring either mesh reinforced or heavily reinforced placements.
502-4.02 PCC Pavement, Mesh or Heavily Reinforced. The work will be measured for payment as the
number of cubic yards of reinforced concrete placed. No deductions will be made for drainage and utility structures or other similar pavement obstructions within the placement.
502-4.03 Transverse Joints. The work will be measured for payment as the number of feet of transverse
joints constructed that contain load transfer devices.
502-4.04 Longitudinal Joints. The work will be measured for payment as the number of feet of
longitudinal joints satisfactorily constructed that contain longitudinal joint ties.
502-4.05 Sealing Transverse Joints. The work will be measured for payment as the number of feet of
transverse joints sealed, excluding preformed sealers turned down at the pavement edges.
502-4.06 Sealing Longitudinal Joints. The work will be measured for payment as the number of feet of
longitudinal joints satisfactorily sealed.
502-5 Basis of Payment
502-5.01 PCC Pavement, Unreinforced. Include the cost of all labor, material, and equipment necessary
to perform the work, including first-stage saw cuts, in the unit price bid for PCC Pavement, Unreinforced. No payment will be made for areas that do not meet minimum plastic thickness requirements. No additional payment will be made for concrete placed in excess of the tolerances described in §502-3.08, Plastic Thickness Determination.
502-5.02 PCC Pavement, Mesh or Heavily Reinforced. Include the cost of all labor, material, and
equipment necessary to satisfactorily perform the work, including first-stage saw cuts, in the unit price bid for PCC Pavement, Mesh or Heavily Reinforced. No payment will be made for areas that do not meet minimum plastic thickness requirements. No additional payment will be made for concrete placed in excess of the tolerances described in §502-3.08, Plastic Thickness Determination.
502-5.03 Transverse Joints. Include the cost of all labor, material, and equipment necessary to perform
the work in the unit price bid for Transverse Joints.
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Sections 200 - 599 STANDARD SPECIFICATIONS (USC) January 1, 2026 Volume 2
502-5.04 Longitudinal Joints. Include the cost of all labor, material, and equipment necessary to perform
the work in the unit price bid for Longitudinal Joints. No additional payment will be provided for the additional number of longitudinal joint ties associated with constructing longitudinal joints in wheelpaths.
502-5.05 Sealing Transverse Joints. Include the cost of all labor, material, and equipment necessary to
perform the work, including second stage saw-cuts, in the unit price bid for Sealing Transverse Joints.
502-5.06 Sealing Longitudinal Joints. Include the cost of all labor, material, and equipment necessary to
perform the work, including second stage saw-cuts, in the unit price bid for Sealing Longitudinal Joints.
502-5.07 Quality Units for PEM Concrete Pavement Payment of Quality Adjustments for Performance
Engineered Mixtures will be made based on the number of Quality Units calculated in accordance with §501-5, Determination of Quality Adjustment. No Quality Units will be calculated for High Early Strength mixes. Payment will be made under: Item No. Item Pay Unit 502.0RCF PCC Pavement Cubic Yard R- Pavement Reinf. C- Concrete Class F- Friction Type 0 - Unreinforced 2 - Performance 1-Type 1 1-Mesh Reinforced 4-HES 2-Type 2 2-Heavily Reinforced 3-Type 3 9- Type 9 502.910L Transverse Joints Linear Foot 502.911L Longitudinal Joints Linear Foot L- Load Transfer 0- Epoxy Coated 1- ASTM A934 Epoxy Coated 2- Stainless Steel 3- Other 502.9201 Sealing Transverse Joints-Preformed Elastic Joint Sealer Linear Foot 502.9210 Sealing Transverse Joints- Highway Joint Sealant Linear Foot 502.9301 Sealing Longitudinal Joints -Preformed Elastic Joint Sealer Linear Foot 502.9310 Sealing Longitudinal Joints-Highway Joint Sealant Linear Foot 502.99 Performance Concrete Quality Adjustment - PCC Pavement Quality Unit
Referenced in this section
Sections that cite this one
Portland Cement Concrete Pavement in other states
- Indiana 502 · PORTLAND CEMENT CONCRETE PAVEMENT, PCCP
- Missouri 502 · Portland Cement Concrete Base and Pavement
- Alabama 450 · PORTLAND CEMENT CONCRETE PAVEMENT
- Arkansas 501 · PORTLAND CEMENT CONCRETE PAVEMENT
- Colorado 412 · PORTLAND CEMENT CONCRETE PAVEMENT
- Delaware 501 · PORTLAND CEMENT CONCRETE PAVEMENT
- Georgia 430 · Portland Cement Concrete Pavement
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Source: Standard Specifications (US Customary Units), 2026 (Jan) Edition. Pages 402–418 of 1,489. View official source ↗