ITEM 255 FULL DEPTH PAVEMENT REMOVAL AND RIGID REPLACEMENT
255.01 Description. This work consists of full depth removal of existing pavement; compacting
the subgrade or subbase; furnishing and placing dowel bars, deformed bars, tiebars, and reinforcing steel where specified; placing, consolidating, finishing, and curing new portland cement concrete to the level of the adjacent portland cement co ncrete pavement or wearing course; replacing wearing course where required; and restoring affected shoulders.
255.02 Materials. Furnish materials conforming to:
Concrete, Class QC 1, QC MS, QC RS 499 Curing materials, Type 2.................. 705.07 Non-shrink non-metallic grout ......... 705.20 Reinforcing steel ............................. 709.10 Preformed elastomeric joint sealer... 705.11 Deformed bars and Tiebar 705.01 or 709.00 Dowel bars and basket assemblies ......... 705.01 or 709.13 Expansion shield anchors Type A.... 712.01 Use epoxy coated hook bolt, wiggle bolt, and coupling. Select and furnish grout from the Qualified Product List issued by OMM that firmly anchors the dowel bars, deformed bars, and tiebars within 30 minutes.
255.03 Removal of Existing Pavement. The Engineer will locate and mark all areas for repair
before the start of diamond sawing. Provide the Engineer with aerosol spray paint to outline those areas for repair. Saw cut the existing rigid pavement to the full depth at the limits of the area designated by the Engineer using a diamond saw blade. For Type 1 repairs where there is an existing asphalt concrete overlay on top of the concrete pavement to be removed, the Contractor may make either a full depth saw cut through the asphalt concrete overlay and the concrete pavement, or make an offset saw cut through the asphalt concrete overlay. If making an offset saw cut through the asphalt concrete overlay, remove the overlay as necessary to provide clearance for the full depth saw cut through the concrete pavement. Do not make offset saw cuts with Type 2 repairs. The Contractor may elect to make additional cuts to facilitate the removal of the pavement. Remove pavement in the repair area by the lift -out method without damaging or undermining the remaining pavement. After the repair area is isolated by full depth saw cuts, drill holes through the deteriorated slab, and install lift pins. Vertically lift the pavement out of the repair area. Remove loose debris left behind after lift-out using hand methods. Dispose of removed pavement according to Item 202. Do not break the pavement and clean out the material using a backhoe unless the Engineer determines that the lift-out method is not feasible due to deteriorated pavement or existing asphalt concrete repairs. If the bottom face of the adjacent concrete pavement is deteriorated for a height greater than one - fourth (1/4) the thickness of the rigid pavement, make additional full depth saw cuts as directed by the Engineer along the full width of the lane or lanes to remove the deteriorated areas. Repair pavement damaged during the pavement sawing or pavement removal according to Item 255 or Item 256.
255.04 Correction of Subgrade or Subbase. After removing the pavement full depth and before
installing dowel bars, deformed bars, or tiebars , shape and re-compact the subgrade or subbase to the satisfaction of the Engineer. Use concrete to replace any subgrade or subbase material removed as part of the rigid pavement replacement.
255.05 Placing Dowel Bars, Deformed Bars, and Tiebars. Drill dowel bar, deformed bar, and
tiebar holes using hydraulic, electric, or pneumatic percussion drills without spalling or damaging the existing concrete. Provide drills capable of independent adjustment of each drill shaft in the horizontal and vertical direction. When drilling for dowel bars, use a device capable of drilling a minimum of three holes at a time. For repairs 10 feet (3 m) or greater in length, provide tie bars or wiggle bolts of the size and spaced as shown on the standard construction drawings along the longitudinal joint(s). Blow all drilled holes clean with oil -free compressed air. Maintain holes dry and f rost free before grouting the bars. Pneumatically inject grout starting at the rear of the drilled holes and drawing a bead of material towards the front. Inject a sufficient amount of grout to fill all voids around the bars. Use a grout retention disc with a radius slot as shown in the standard drawings to retain the grout within the drilled holes. Place the grout retention disc on the bars at the end to be inserted in the hole. Insert bars in the holes and rotate them approximately one full revolution. Ensure a small amount of grout extrudes through the radius slot in the grout retention disc when the bars are installed. Hold dowel bars in proper alignment until the grout has hardened.
255.06 Placement of Portland Cement Concrete. Place concrete for Type 1 repairs to the level
of the adjacent portland cement concrete and replace the wearing course where applicable. Place concrete for Type 2 repairs to the level of the adjacent wearing course. Do not place any portland cement concrete until the grout around the bars has hardened. Coat dowel bars with bond breaking material conforming to 451.09.B. Place portland cement concrete according to 451.07. Use forms when placing portland cement concrete against any unbound material and if necessary, when placing against asphalt concrete. Cast each repair in one continuous operation. Consolidate the concrete around the perimeter of the repair and within the limits of the repair area using an internal type vibrator. Use approved internal type vibrators capable of visibly affecting the concrete for a distance of 12 inches (0.3 m) from the vibrator head. When using QC RS concrete, if a maturity curve exists, the Contractor may install maturity sensors to measure the maturity of each day’s placement according to Supplement 1098. If QC RS placement from one location to another is delayed by more than 1 hour treat the delayed placement as a new day’s placement and install additional maturity sensors according to Supplement 1098. Ensure that batch tickets of the delivered QC RS conform to the accepted mix design. Provide batch tickets in accordance with 499.07. Ensure the delivered QC RS mix is workable and produced without balling or clumping of the macro- fibers. A demonstration of the mix may be required by the Engineer prior to placing any of the mix on the project. While the concrete is still in a plastic state, test the surface for trueness and for being flush with the edges of the adjacent slabs using a 10 -foot (3 m) straightedge. Place the straightedge parallel to the pavement centerline with half of the straighte dge resting on the adjacent pavement, and draw the straightedge across the repair to test the repair edges. Check areas within the repair length in a similar manner. Where the straightedge shows deviations, correct all high or low areas exceeding 1/8 inch in 10 feet (3 mm in 3 m). Recheck the concrete surface after making corrections to ensure conformance to the above tolerance. Make additional checks and corrections until repair is within tolerance. Texture Type 1 repairs like that of the surrounding pavement. Texture Type 2 repairs according to 451.10. Apply the liquid membrane-forming curing compound at a minimum rate of 1 gallon (1 L) of material for each 150 square feet (3.7 m²).
255.07 Wearing Course Replacement. Trim the limits of the repair to form a vertical face 1.5
inches (38 mm) deep from the surface. Replace the removed asphalt concrete overlay with material as shown on the plans. Compact the material as approved by the Engineer using any of the roller types specified in 449.02. Apply Item 407 tack coat to the surface of the portland cement concrete and between any lifts of asphalt concrete. Before opening the rigid replacement to traffic, restore the shoulders to the original line and grade. Use either aggregate or asphalt concrete as shown on the plans or as the Engineer directs. Fill the low areas and compact them flush with the surrounding shoulder. Seal the perimeter surface of the repaired areas by applying a 2 to 4 inch (50 to 100 mm) wide strip of approved 705.04 material or 702.01 approved PG binder.
255.08 Opening to Traffic. Do not open the rigid replacement to traffic until the concrete meets
the requirements of Table 255.08-1 based on beam testing on the project or maturity testing. TABLE 255.08-1 OPENING TO TRAFFIC Repair Thickness, in (mm) Modulus of Rupture, psi (MPa) Greater than or equal Less than 8 (200) 400 (2.8) 8 (200) 9 (225) 350 (2.4) 9 (225) 10 (250) 300 (2.1) 10 (250) 250 (1.7) If maintaining traffic in adjacent lanes, schedule work to place the concrete in the prepared repair area within 48 hours after removing pavement. In accordance with standard drawing MT-101.90, drums may be used as a separator to the adjacent traveled lane for repairs 60 feet (18 m) or less in length. If unable to complete placement of the concrete in the exposed repair area by the end of a daily work shift, fill or cover repair areas less than 4 feet (1.2 m) from the traveled lane. Fill using a temporary patch material suitable to the Engineer or cover unfilled repair areas 10 feet (3 m) or less in length with a steel plate. Do not leave repair areas unfilled with concrete when work is suspended on weekends or holidays. If unable to complete placement of the concrete in the exposed repair area before suspending work for a weekend or holiday or within the 48 -hour time specified above, fill the repair area with an asphalt concrete mixture or other suitable temporary patch material with a durable surface as the Engineer directs. Maintain the temporary patches while they are in service.
255.09 Method of Measurement. The Department will measure the quantity of Full Depth
Pavement Removal and Rigid Replacement by the number of square yards (square meters) repaired in the complete and accepted work. The Department will measure the quantity of Full Depth Pavement Sawing by the number of feet (meters) of perimeter full depth saw cuts in the complete and accepted work. The Department will not measure offset saw cuts. The Department will not measure additional cuts made to facilitate the removal of the pavement.
255.10 Basis of Payment. Payment is full compensation for furnishing all materials, including
paint; developing and testing the concrete mix, removing pavement by any method; compacting subbase and subgrade; placing rigid pavement, including concrete necessary to replace removed subbase or subgrade; furnishing and placing dowel bars, deformed bars, tiebars, and reinforcing steel; performing maturity testing and acceptance; placing, maintaining, removing, and disposing of temporary patches, and restoring the shoulders. The Department will not pay for additional concrete sawing and removal depths within 1 inch (25 mm) greater than those shown on the plans. The Department will not pay for additional work to repair damage caused by pavement sawing, pavement drilling or pavement removal. The Department will include tack coat in the cost of the asphalt concrete. The Department will pay for asphalt concrete according to Item 301, Item 441, or Item 442. The Department will pay for accepted quantities at the contract prices as follows: Item Unit Description 255 Square Yard Full Depth Pavement Removal (Square Meter) and Rigid Replacement, Type 1, Class ___ 255 Square Yard Full Depth Pavement Removal (Square Meter) and Rigid Replacement, Type 2, Class ___ 255 Foot (Meter) Full Depth Pavement Sawing
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