633Conditioning Existing Pavement Prior to Asphalt

633-1 DESCRIPTION. Cleaning, sealing, and filling joints and cracks in the existing pavement,

removal and repair of deteriorated pavement sections, stress-relieving pavement repairs, and cleaning the existing pavement and shoulders prior to the application of a new asphalt course.

633-2 MATERIALS. Use materials conforming to the requirements of the specifications listed below:

Asphalt True & Leveling 401 and 404 Asphalt Shim 401 Asphalt Filler 702-0700 (Table702-2, Miscellaneous Asphalt Cements) Anionic or Cationic Asphalt Emulsion 702 Fine Aggregate 703-01

633-3 Construction Details

633-3.01 Cleaning Existing Pavement and/or Shoulders. Clean existing pavement and shoulder

surfaces to be overlaid, including ruts and depressions, by the use of mechanical sweepers, hand brooms, or other means until the surfaces are free of all material which might interfere with the bond between the overlay material and the existing surfaces. All cleaning equipment shall be approved by the Engineer prior to use. Remove all debris from the pavement and shoulders surfaces and dispose of in an appropriate manner. Keep the pavement and shoulders clean until the overlay operations are completed. Cleaning of shoulders is required only when the shoulder surface is constructed of Portland Cement Concrete (PCC), asphalt or a surface treatment thereon.

633-3.02 Cleaning, Sealing and/or Filling Joints and Cracks. If the existing pavement requires stress

relieving repairs, complete these repairs in accordance with §633-3.05, Stress Relieving Pavement Repairs, prior to joint and crack repair work. Use a compressed air stream of at least 80 psi gage measured at the source, to clean all unsealed and inadequately sealed joints and cracks. Clean all joints and cracks in the pavement of all dirt and loose material to a depth equal to a minimum of twice the crack or joint width, by holding the cleaning jet 1 inch above the pavement surface. Old joint and crack sealer remaining after such cleaning operation need not be removed. Keep the joint and cracks clean until the sealing, filling, and paving operations are completed. Joints and cracks less than 1/4 inch are not required to be cleaned or sealed. Seal joints and cracks in the existing pavement from 1/4 to 1 inch wide with an asphalt filler. To ensure that space will be

633-3 03

NEW YORK STATE DEPARTMENT OF TRANSPORTATION Section 600 STANDARD SPECIFICATIONS (USC) January 1, 2026 VOLUME 3 available for expansion of the asphalt filler when the asphalt is paved over the joint or crack, do not fill the joint or crack completely to the surface. Blot with fine aggregate, if required, to prevent tracking the bituminous material over the pavement surface. Fill joints and cracks greater than 1 inch wide with Asphalt Shim or an approved cold, plant-mixed stockpile patching material.

633-3.03 Removal and Repair of Deteriorated Asphalt Pavement Sections. Remove and dispose of

deteriorated asphalt pavements to sound material, such that all excavated sides are vertical. Use a chipping hammer meeting the requirements of §580-3.02, Removal of Structural Concrete, a milling machine equipped with a means to suppress airborne particles, or by other appropriate means. If a chipping hammer is used, first sawcut the pavement around the perimeter of the designated repair area to the anticipated repair depth. Clean and dry all surfaces exposed from removal operation such that they are clean and free of dust and debris. Uniformly apply asphalt emulsion to these surfaces and place the asphalt mixture in the repair areas only when the ambient temperature is 45°F or greater. The minimum asphalt placement temperature shall be 250°F. If the total depth of the patch is greater than 3 inches, compact the asphalt mixture in multiple lifts of approximately equal thickness with a maximum lift of 3 inches. When placing asphalt in multiple lifts, thoroughly compact the lower lifts with a mechanical tamper. For the top lift, thoroughly compact with a roller meeting the requirements of §404-3.04, Rollers, or a small vibratory roller approved by the Engineer. Slightly overfill the patch with asphalt mixture such that the resulting patch is dense, smooth, and no more than 1/4 inch above the existing surface.

633-3.04 Removal and Repair of Loose, Broken, or Spalled PCC Pavement Sections. Remove loose,

broken, or spalled PCC pavements to sound material, but not exceeding a depth of 3 inches. Use a chipping hammer meeting the requirements of §580-3.02, Removal of Structural Concrete, a milling machine equipped with a means to suppress airborne particles, or by other appropriate means. If a chipping hammer is used, first sawcut the pavement around the perimeter of the designated repair area to the anticipated repair depth not to exceed 3 inches. Dispose of all the removed PCC material in an appropriate manner. Clean and dry all surfaces exposed from removal operation such that they are clean and free of dust and debris. Uniformly apply asphalt emulsion to these surfaces and place the asphalt mixture in the repair areas only when the ambient temperature is 45°F or greater. The minimum asphalt placement temperature shall be 250°F. If the total depth of the patch is greater than 3 inches, compact the asphalt in multiple lifts of approximately equal thickness with a maximum lift of 3 inches. When placing asphalt in multiple lifts, thoroughly compact the lower lifts with a mechanical tamper. For the top lift, thoroughly compact with a roller meeting the requirements of §404-3.04, Rollers, or a small vibratory roller approved by the Engineer. Slightly overfill the patch with asphalt such that the resulting patch is dense, smooth, and no more than 1/4 inch above the existing surface.

633-3.05 Stress Relieving Pavement Repairs. Unless indicated otherwise in the contract documents, the

pressure relief joint shall be a minimum of 15 feet longitudinally and the full width of the pavement, including the curb, and gutter, if any. If an existing transverse joint is within the pressure relief joint repair, remove the existing transverse joint by a minimum of 12 inches. Saw cut the transverse lines of the designated repair area full depth to produce a neat cut. Remove the PCC pavements with minimum disturbance to the subbase. Dispose of all the removed PCC material in an appropriate manner. Level and recompact the subbase, prior to the placement of the asphalt. Clean and dry all surfaces exposed from removal operation such that they are clean and free of dust and debris. Uniformly apply asphalt emulsion to these surfaces and place the asphalt mixture in the repair areas only when the ambient temperature is 45°F or greater. The minimum asphalt mixture placement temperature shall be 250°F.

633-4 01

NEW YORK STATE DEPARTMENT OF TRANSPORTATION Section 600 STANDARD SPECIFICATIONS (USC) January 1, 2026 VOLUME 3 Compact the asphalt mixture in multiple lifts of approximately equal thickness with a maximum lift of 3 inches. Thoroughly compact each lift with a roller meeting the requirements of §404-3.04, Rollers, or a small vibratory roller approved by the Engineer. Slightly overfill the patch with asphalt mixture such that the resulting patch is dense, smooth, and no more than 1/4 inch above the existing surface.

633-4 Method of Measurement

633-4.01 Cleaning Existing Pavement and/or Shoulders. The quantity measured will be the number of

square yards of existing pavement and/or shoulder surfaces cleaned.

633-4.02 Cleaning, Sealing, and/or Filling Cracks. The quantity measured will be on a lump-sum basis

for work satisfactorily completed.

633-4.03 Cleaning, Sealing, and/or Filling Joints. The quantity measured will be on a linear feet basis

for work satisfactorily completed.

633-4.04 Removal and Repair of Deteriorated Asphalt Pavement Sections. The quantity measured will

be the number of square yards of existing pavement surface removed and repaired. The quantities of different sized repairs will be calculated separately in accordance with the following:

633-4.05 Removal and Repair of Loose, Broken, or Spalled PCC Pavement Sections. The quantity

measured will be the number of square yards of existing pavement surface removed and repaired.

633-4.06 Stress Relieving Pavement Repairs. The quantity measured will be the number of square yards

of existing pavement surface removed and repaired.

633-5 Basis of Payment

633-5.01 Cleaning Existing Pavement and/or Shoulders. The unit price bid for this work shall include

the cost of all labor, materials, and equipment necessary to complete the work.

633-5 02

NEW YORK STATE DEPARTMENT OF TRANSPORTATION Section 600 STANDARD SPECIFICATIONS (USC) January 1, 2026 VOLUME 3

633-5.02 Cleaning, Sealing, and/or Filling Cracks. The lump sum price bid for this item shall include

the cost of all labor, materials, and equipment necessary to complete the work.

633-5.03 Cleaning, Sealing and/or Filling Joints. The unit price bid for this item shall include the cost

of all labor, materials, and equipment necessary to complete the work.

633-5.04 Removal and Repair of Deteriorated Asphalt Pavement Sections. The unit price bid for this

work shall include the cost of all labor, materials, and equipment necessary to complete the work. A unit cost shall be given for the repair conditions as stated in section 633-4.04 Removal and Repair of Deteriorated Asphalt Sections when specified in the contract.

633-5.05 Removal and Repair of Loose, Broken, or Spalled PCC Pavement Sections. The unit price

bid for this work shall include the cost of all labor, materials, and equipment necessary to complete the work.

633-5.06 Stress Relieving Pavement Repairs. The unit price bid for this work shall include the cost of

all labor, materials, and equipment necessary to complete the work. Payment will be made under: Item No. Item Pay Unit 633.11 Cleaning Existing Pavement and/or Shoulder Square Yards 633.12 Cleaning, Sealing and/or Filling Cracks Lump Sum 633.13 Cleaning, Sealing and/or Filling Joints Linear Foot 633.1401 Removal and Repair of Deteriorated Asphalt Pavement - Less than or equal to 4 Square Yards Square Yards 633.1402 Removal and Repair of Deteriorated Asphalt Pavement – Greater than 4 Square Yards and less than 20 Square Yards Square Yards 633.1403 Removal and Repair of Deteriorated Asphalt Pavement – 20 Square Yards or Greater Square Yards 633.15 Removal and Repair of Loose, Broken, or Spalled PCC Pavement Square Yards 633.16 Stress Relieving Pavement Repairs Square Yards SECTION 634 (VACANT)