1040CONCRETE BRIDGE DECK REPAIR

1040.1DESCRIPTION—This work is removing and patching unsound bridge deck concrete as indicated

and directed. Unsound concrete is defined as existing bridge deck concrete that is deteriorated, spalled, or determined by the Representative to be unsound. This work applies to approach slabs and barrier when indicated or directed. Concrete Bridge Deck Repair is classified into three types as follows:

bars without exposing the top mat. Type 1 repairs are only performed when a latex overlay is indicated.

extends no deeper than the bottom mat without exposing the bottom mat.

the full depth of the deck is unsound. This includes deck overhang areas; and areas where curb, barrier, or deck ends need to be patched as part of the repair. Type 3 repairs over adjacent box beams extend to the top of the beam.

1040.2MATERIAL—

• Class AAAP Cement Concrete. Section 704, except use No. 8 coarse aggregate.

• Class AA Cement Concrete . Section 704, except use No. 8 coarse aggregate. For use i n barrier repairs only.

• Latex Modified Concrete (LMC). Section 1042.2(f)

• Accelerated Structural Concrete (ASC). Section 704, except use No. 8 Coarse Aggregate. Do not use ASC unless indicated or directed.

• Bag Mix. When the quantity of concrete is smaller than the minimum delivery requirement from a mix supplier, a Bulletin 15 approved bag mix with No. 8 coarse aggregate may be used. Submit the bag mix data sheets for review and do not use until accepted.

• Concrete Bonding Compound. Type II, Grade 2, ASTM C881 epoxy as specified in Section 706

• Wearing Surface Material for Patching. Section 1042.2

1040.3CONSTRUCTION—As shown on the Standard Drawings and as follows:

drops spaced every 6 inches for Department use. Sound the entire bridge deck with the chain drag in the presence of the Representative. When scarification and a latex overlay are indicated without hydrodemolition, sound the entire deck after scarification in the presence of the Representative. The Representative will delineate the repair areas.

final particles of unsound concrete or to provide necessary clearances around reinforcement bars.

• Do not exceed 30 foot-pound hammers.

• Do not exceed 15 foot -pound hammers to remove final particles of unsound concrete, to provide necessary clearances around reinforcement bars, or below the bottom mat of steel overtop of concrete beams.

• Do not operate pneumatic hammers or mechanical chipping tools at an angle in excess of 45 degrees relative to the surface of slab.

• Do not use pointed or narrow chisels overtop of beams, provide 2-inch minimum width chisels.

• Do not place pneumatic hammers in direct contact with reinforcing steel.

5,000 pounds per square inch.

removal operations. During removal for Type 3 repairs, provide shielding to prevent debris from falling below the deck. Prevent damage to underlying beams. Outline the unsound delineated areas with a 3/4 -inch-deep saw-cut. Remove unsound concrete with hand tools and pneumatic hammers. Notify the Representative if unsound concrete extends beyond the delineated areas. Extend repair areas as directed. Remove portions of damaged or heavily corroded reinforcement bars, and replace with the same type of bars, as specified in Section 1002.3 and as directed. For Type 1 repairs, perform Type 1 removal only when scarification and a latex overlay are indicated without hydrodemolition. When a latex overlay is not indicated, perform Type 1 repairs as Type 2 repairs. For Type 2 repairs, remove concrete to a depth that provides a minimum of 3/4 -inch clearance around all reinforcement bars in the top mat, regardless of concrete deterioration. If portions of the bottom mat of reinforcement bars are exposed during removal, remove full-depth and perform a Type 3 repair as directed. Satisfactorily repair damage to the structure beyond the limits of this work due to construction operations at no additional cost to the Department.

concrete removal operations are complete, remove remaining debris and loose materials. Abrasive blast exposed reinforcement bars to clean white metal. Air-blast repair areas with oil-free compressed air, ensure abrasive blast material is removed, and remove contaminants detrimental to the bond of the patching material. Epoxy coat exposed reinforcement bars. Protect cleaned areas from contaminatio n.

coat surfaces to receive a new overlay. Remove concrete bonding compound from surfaces to receive an overlay at no additional cost to the Department.

compound is still tacky to ensure bond between contact surfaces and fresh concrete. Wire brush or sandblast hardened epoxy before recoating with fresh epoxy.

manufacturer's recommended time frame. When recommended time frame has expired, follow manufacturer’s recommendations for recoating contact surfaces.

or ASC if indicated or directed . Patch Type 2 barrier repairs with Class AA cement concrete or ASC if indicated or directed . Vibrate concrete with a pencil vibrator . Finish patches to match the existing deck surface elevation. Before the concrete becomes nonplastic, tine the surface as specified in Section 501.3(k)4. Finish barrier patches to match adjacent barrier contours. Do not tine barrier patches.

formwork of sufficient strength to prevent lateral or vertical deflection. Provide side forms including drip - strip and chamfering.

4.a Type 1. Patch Type 1 repair areas concurrently with the overlay placement with the same material used for the overlay. Place overlay as specified in Section 1042.3.

4.b Type 2, Concurrent with Overlay. Patch Type 2 repair areas up to 4 inches in depth concurrently with the overlay placement with the same material used for the overlay. Place overlay as specified in Section 1042.3.

4.c Type 2, Patching before Overlay Placement. If Type 2 repair areas exceed 4 inches in depth, patch before overlay placement. Perform scarification before patching. If indicated, perform hydrodemolition before patching. Patch repair areas with modified Class AAAP cement concrete, LMC or ASC if indicated or directed. Vibrate concrete with a pencil vibrator. Finish patches to match the scarified or hydrodemolitioned deck surface elevation. Provide a rough texture on patch surfaces. After patches have attained a minimum compressive strength of 3,000 pounds per square inch, remove laitance from patch surfaces by water blasting.

4.d Type 3. Do not place Type 3 patches concurrently with overlay. Perform scarification before patching. If indicated, perform hydrodemolition before patching. Use removable formwork of sufficient strength to prevent lateral or vertical deflection. Provide side forms including drip -strip and chamfering. Patch repair areas with modified Class AAAP cement concrete, LMC or ASC if indicated or directed. Vibrate concrete with a pencil vibrator. Finish patches to match the scarified or hydrodemolitioned deck surface elevation. Provide a rough texture on patch surfaces. After patches have attained a minimum compressive strength of 3,000 pounds per square inch, remove laitance from patch surfaces by water blasting.

barrier patches with curing compound as specified in Section 1001.3(p)3.a or water cure as specified in Section 1001.3(p)3.b.1. After 28 days, remove laitance and contamination on the surface by water blasting. Apply a penetrating sealer after water blasting as specified in Section 1019 and according to the manufacturer’s recommendations . When a latex overlay is indicated, do not apply penetrating sealer to bridge deck patching performed before overlay.

curing compound to bridge deck patching performed before overlay.

cement concrete or LMC for bridge deck patches or modified Class AA cement concrete for barrier patches, cure as specified in Section 1040.3(g)1. When bag mixes are accepted for use as a substitute for ASC, cure as specified in Section 1040.3(g)2.

1040.4MEASUREMENT AND PAYMENT—

For the type indicated.

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