SECTION 584 - SPECIALIZED OVERLAYS FOR STRUCTURAL SLABS
584-1 DESCRIPTION. Prepare the surfaces that will be in contact with slab reconstruction concrete and
place slab reconstruction concrete. Prepare the structural slab surface and place a specialized concrete overlay.
584-1.01 Scope. Concrete removal work will be paid for under the appropriate item(s). Minimum
thickness of overlay concrete is 1 1/2 inches. Include the cost of any grade changes necessitated by this requirement in the unit bid price for overlay concrete. Use only one type of overlay concrete on any one structure. All concrete will be Performance Engineered Mixture (PEM) Portland Cement Concrete designed to meet the requirements of §501- Portland Cement Concrete Production and the appropriate mix design requirements specified in Table 2 of Materials Procedure (MP) 501-2 Mix Design and Approval Procedure for Performance Engineered Mixtures – Structural Concrete.
584-1.02 Definitions
A.Overlay Concrete. Concrete placed over existing and slab reconstruction concrete.
B.Slab Reconstruction Concrete. Concrete placed completely around the exposed top mat of bar reinforcement or to the level of surrounding concrete.
C.Positive Tie-Downs. Anchors drilled into the structural slab and connected to the reinforcing steel.
584-1.03 Placement Methods. When 100% of the top mat of bar reinforcement is exposed, overlay
concrete and slab reconstruction concrete may be placed in a single lift. If less than 100% of the top mat of bar reinforcement is exposed, slab reconstruction concrete and overlay concrete shall be placed separately. Use only one type of slab reconstruction concrete on each placement.
584-2 Materials
584-2.01 General. All materials listed in §557-2.
584-2.02 Equipment.
A.Finishing Machine. A finishing machine capable of self propulsion in forward and reverse, raising the screeds above the screeded surface when traveling in reverse, and meeting one of the two sets of requirements below.
1.Roller Screed. Must be equipped with a power driven strike-off auger, power driven finishing roller, vibrating pan or roller producing 3000 to 7000 vpm, and pan float.
2.Dual Oscillating Screed. Must be equipped with at least 2 oscillating screeds producing between 3000 and 7000 vpm, strike-off auger, and control of each screed's vertical position and tilt angle. The specific method and equipment used for finishing will be approved by the Regional Construction Engineer before use. Provide access to the machine at the work site for one working day, for inspection by the Engineer. Have a qualified Finishing Machine Operator present at the time of inspection. Two weeks prior to the inspection date, provide the Engineer with a copy of the operating manual for their exclusive use. Use supporting rails with no bends or kinks. Support the rails with fully adjustable supports (no shims), spaced a maximum of 12 inches on center. When placing
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Sections 200 - 599 STANDARD SPECIFICATIONS (USC) January 1, 2026 Volume 2 concrete adjacent to a completed placement, set the supporting rails for one side of the finishing machine on the completed placement.
B.Recording Thermometer. A continuous recording thermometer capable of measuring temperatures in the range of 30 F to 100 F for a minimum of 24 hours. Include the cost of calibration in the unit price bid.
584-3 Construction Details
584-3.01 Limitation of Operations
A.No structural concrete removal work is permitted in areas adjoining new concrete during the new concrete's specified curing period.
B.No loads, other than construction loads which are less than 2 tons and approved by the Engineer, are permitted on areas of the structural slab where concrete has been removed.
C.No loads are permitted on concrete until completion of the specified curing period.
584-3.02 Blast Cleaning
A.Blast clean all surfaces to be in contact with new concrete. Remove all grease and dirt. Remove all rust and mortar which is not firmly bonded to the surface being cleaned. Rust and concrete deposits which are firmly bonded and cannot be removed by blast cleaning may remain. A light coating of orange rust, that forms on steel surfaces after blast cleaning, is not considered detrimental to bond and may remain. Remove all debris created by blast cleaning.
B.Place reinforcing steel supports and positive-tie-downs at a maximum spacing of 4 feet.
C.Repeat blast cleaning if more than 48 hours pass before concrete placement begins.
584-3.03 Preplacement Wetting. After blast cleaning has been accepted, thoroughly wet the structural
slab surface and all porous surfaces to be in contact with new concrete for at least 12 hours immediately prior to placement. Remove all standing water with oil-free compressed air, and protect the deck from drying, so the concrete remains in a saturated surface dry condition.
584-3.05 Handling and Placing Concrete. §557-3.05 and §557-3.12 with the following:
A.Place concrete only when the ambient air temperature and deck surface temperature (after wetting) will be below 85 F during the entire placement.
B.Place overlay concrete only if preplacement wetting has been completed on an area large enough to require one working day for placement, at least one span length.
C.When using concrete transporting devices on a prepared surface, protect exposed reinforcing steel from deformation and prevent contamination of the surface.
D.If operations are delayed for more than 30 minutes, install a construction dam or bulkhead. If placement operations are delayed for more than 60 minutes or if the concrete attains initial set, discontinue placement for at least 48 hours. This restriction does not prohibit continuation of the placement provided a gap is left in the placement. This gap is to be sufficient in length to allow the finishing machine to clear the previously placed concrete. Prepare the gap area for concrete
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Sections 200 - 599 STANDARD SPECIFICATIONS (USC) January 1, 2026 Volume 2 placement in accordance with this specification, after the previously placed concrete, on both sides of the gap, has cured for 48 hours.
584-3.06 Finishing and Curing
A.Slab Reconstruction Concrete - Separate Placement. §557-3.09 and §557-3.11 with the following:
1.For areas less than 25 sf, hand finishing of slab reconstruction concrete is acceptable. For areas greater than 25 sf, use either a manually driven vibrator equipped power screed from the Department’s Approved List or the same machine to be used to finish the overlay.
2.Screed to the level of the surrounding concrete. When 100% of the reinforcing steel is exposed, screed to a minimum 3/8 inch above the reinforcing steel. Roughen the screeded surface with a tining rake or similar device.
3.Cure concrete with wet burlap for 3 days. Provide uniform continuous wetting until concrete curing is complete. The wet burlap and curing cover option is not allowed.
4.Blast clean the surface, according to §584-3.02, after the curing period is over, but prior to wetting. Expose approximately 50% of the surface coarse aggregate, and leave an irregular texture.
B.Overlay Concrete. §557-3.07, §557-3.11, and §557-3.12 with the following:
1.Finish overlay concrete to a minimum depth of 1 1/2 inches and a minimum total cover over top mat of bar reinforcement of 2 3/8 inches. Use a finishing machine meeting the requirements of this specification.
2.Machine finish the concrete within 10 minutes of its deposition onto the deck. If the machine cannot finish the concrete within the 10 minute time limit, stop all further placement, immediately cover the fresh concrete with plastic curing covers, and keep the unfinished concrete covered until it is machine finished. Once concrete being placed can be machine finished within the 10 minute time limit, resume placing concrete.
3.Apply curing within 10 minutes after machine finishing. Cure concrete with wet burlap, protected from displacement for seven days. Provide uniform continuous wetting for the duration of the curing period. The wet burlap and curing cover option is not allowed.
584-3.07 Construction Joints. For the purpose of this specification, construction joints provide for
interruptions in overlay concrete placement. At transverse and longitudinal construction joints, place the overlay concrete a distance at least equal to the depth of the overlay, beyond the intended joint location. After the overlay concrete has cured for 48 hours, sawcut along the joint to a depth of 3/4±1/8 inch. Chip the extra overlay concrete to the level of the original prepared surface at a 45° angle. Do not undercut existing concrete.
584-3.08 Defective or Damaged Concrete. §557-3.16 with the following:
A.Defects and damage, for the purposes of this specification, are imperfections caused by the Contractor's operations, including, but not limited to: cracking, tearing, and open areas. Repair all defective or damaged concrete at no cost to the Department, using the same concrete mixture originally placed.
B.Make all repairs rectangular in plan shape and as close to square as possible. Sawcut the perimeter of the repair to a depth of 3/4 ± 1/8 inch. Chip out the damaged or defective concrete to the level of the original prepared surface. Angle the walls of the repair cavity at 45° toward the center of the repair. Do not undercut existing concrete. Prepare the surfaces of the repair cavity to
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NEW YORK STATE DEPARTMENT OF TRANSPORTATION Sections 200 - 599 STANDARD SPECIFICATIONS (USC) January 1, 2026 Volume 2 achieve a rough bondable surface exposing at least 50 percent of the coarse aggregate and place new concrete in accordance with this specification. Prior to placing repair concrete, all surfaces shall be wetted to a saturated surface dry condition.
584-4 METHOD OF MEASUREMENT. For placements with 100% exposure of the top mat of bar
reinforcement, the number of square yards of slab reconstruction concrete will be equal to the number of square yards of overlay concrete. For placements with less than 100% exposure of the top mat of bar reinforcement, measure slab reconstruction concrete prior to overlay concrete placement. Overlay concrete will be measured separately as the number of square yards of plan area of overlay concrete placed.
584-5 BASIS OF PAYMENT. Include the cost of all labor, materials, and equipment necessary to
complete the work in the unit bid price. The Performance Concrete Quality Units will be calculated in accordance with §501-5, Determination of Quality Adjustment. Payment will be made under: Item No. Item Pay Unit 584.030Fnn Overlay Concrete, Performance Square Yard F - Friction Type 1 - Type 1 2 - Type 1 3 - Type 1 9 - Type 1 584.0320nn Slab Reconstruction Concrete Square Yard 584.9901 Performance Concrete Quality Adjustment – Quality Unit NOTE: nn denotes a serialized pay item.
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Source: Standard Specifications (US Customary Units), 2026 (Jan) Edition. Pages 636–639 of 1,489. View official source ↗