530LONG-LIFE CONCRETE PAVEMENT (LLCP)

530.1DESCRIPTION—This work is the construction of Long-Life Concrete Pavements (LLCP). LLCP is

concrete pavement that is made with high quality materials and processes and is intended to provide a longer service life than conventional concrete pavement.

530.2MATERIAL—Section 501.2 with the following modifications:

Limit thin and elongated coarse aggregate retained on the 3/8-inch sieve to 20% or less with a ratio of 3:1 according to 2010 ASTM D4791, Method B.

All concrete mixtures for slip-form paving are limited to a m aximum cement factor of 611 pounds per cubic yard and a maximum water/cement ratio of 0.42. Limit fixed-form paving mixtures to a maximum cement factor of 611 pounds per cubic yard and a maximum water/cement ratio of 0.45.

completed passing test reports for testing done according to PTM No. 642 (not executive summaries), shop drawings, and LTU samples to the Representative for verification testing at least 45 days before beginning paving operations. Provide one LTU sample that accommodates a minimum of six dowel bars with bond breaker lubricant pre- applied to the dowel bars . Do not begin concrete paving until the Representative approves the LTU documentation and verifies passing test results for the LTU. For High Performance Dowel Bars listed in Bulletin 15, provide one LTU sample that accommodates a minimum of three dowel bars with bond breaker lubricant pre- applied to the dowel bars at least 45 days before beginning paving operations for verification testing. Only one type of dowel bar can be used for Long Life Concrete Paving on a project unless approved. Do not begin concrete paving until the Representative verifies passing test results.

unless approved by the Representative. Store as specified in Section 1002.3(b) to allow air circulation. If field storage is expected to exceed 30 days, cover bars with opaque polyethylene or other protective material. Store stainless steel dowel bars as specified in Section 1002.3(i)3. Provide dowel bars having uniform appearance. Do not use dowel bars with visible corrosion deposits, uncoated spots, or acid, flux , or black spots. Do not place or store dowel bars in contact with uncoated reinforcement bars or other uncoated steel or stainless steel. After placement, inspect the dowel bars and replace dowel bars damaged during placement.

530.3CONSTRUCTION—Section 501.3 with the following modifications:

The “Slip-form” method of construction is the standard construction method. Fixed forms may be used for pavement gaps and nonuniform areas with the approval of the Representative. Use plant mixed concrete except for areas approved by the Representative. Areas that truck mixed concrete would be appropriate for include shoulders, closure pours, and projects with less than 15,000 square yards of mainline concrete paving.

Monitor aggregate gradations during concrete production by performing sieve analysis using plant stockpiled aggregate before beginning daily production and when restocking bins, but no more than daily. From the results of the sieve analysis generate the cumulative percent retained chart. Verify that the daily production plots are within the limits defined by the cumulative percent retained chart in PTM No. 529. If necessary, adjust aggregate proportions during production to maintain the combined percent retained gradation within limits in PTM No. 529. Adjustments to aggregate proportions that also require adjustments to cementitious material or water content will require the development of new mix designs, including trial concrete batches. The DME/DMM may allow combined gradations during production that are less than 5% outside of the required percent retained gradation in PTM No. 529. The DME/DMM will immediately report acceptance of production gradations outside of the limits in PTM No. 529 to CMD QA personnel in writing.

Include a concrete temperature control plan that outlines the actions that will be taken to control concrete temperatures if they exceed 80F at the point of placement. Provide a written QC Plan for Department approval that specifies a method for keeping the LTU assemblies anchored to the foundation. The LTU Quality Control Plan includes the following minimum requirements:

• Proposed type, number, and installation locations of fasteners

• LTU assembly anchoring plan

• A method for measuring proper alignment of LTU before concrete placement as specified in Section 501.3(i)

• Within 18 hours after ending each day’s concrete pavement placement and finishing for quantities greater than 700 SY, verify the LTU vertical and horizontal alignment by a nondestructive verification method acceptable to the Representative. Verify a minimum of the first five transverse joint locations across the full width of the pavement placed and one joint location for each 2,640 LF (1/2 mile) of pavement placed each day.

• An action plan to address dowel bars not meeting the requirements as specified in Section 501.3(i) before or after concrete placement.

The QC Plan must require that the first truck in each lot be sampled for plastic air and state that trucks that do not meet the requirement of 7.0%, plus or minus 1.5%, will not be incorporated. Each truck after any failing plastic air test will be tested until three consecutive passing test results are obtained. The QC plan must include the method proposed to be used to cure and protect joints during the curing period, to prevent moisture loss from concrete in and adjacent to joints during and following joint sawing. Submit an organizational chart listing names and telephone numbers of individuals and alternates responsible for mix design, process control administration, and quality control. Post the organizational chart in the Contractor's on-site field office. Assign a QC Supervisor to manage all testing and plant operations. The QC Supervisor must be on site at all times during LLCP placement or have a mobile device in their possession and must be able to arrive at the project or plant site within 1 hour.

Provide a slip-form paver with the following characteristics:

• Automatic controls to control line and grade.

• A positive interlock system to stop all vibration and tamping elements when forward motion of the machine stops.

• A mechanical device that accurately spaces and positions the required tie bar reinforcement that allows satisfactory mechanical or manual tie bar insertion, and a non-oscillating extrusion plate with an adjustable angle of entry.

Provide an electronic monitoring device meeting the following characteristics and requirements to display the operating frequency of each individual internal vibrator for concrete pavement placed by the slip-form method:

• Contains a readout display near the operator’s controls, visible to the operator and the Representative.

• Operates continuously as the paving machine operates.

• Displays all the vibrator frequencies with manual and automatic sequencing for each of the individual vibrators.

• Records the following at least every 25 feet of paving or at least every 5 minutes:

ͦ Clock time ͦ Station location ͦ Paver track speed ͦ Operating frequency of individual vibrators

Do not operate equipment, other than sawing equipment or a lightweight profiler, on the new pavement slab as specified in Section 530.3(q). Do not operate equipment wheels or tracks within 4 inches of the slab edge.

When tie bars are mechanically inserted, verify location of tie bars every 500 feet in tangent sections and 100 feet through horizontal curves to confirm that tie bars are inserted no closer than 24 inches from the transverse joint.

Finish the surface of all travel and passing lane pavements with a longitudinal texture as specified in Section 501.3(k)4.a. Finish all other pavement surfaces as specified in Section 501.3(k)4.a or Section 501.3(k)4.b.

include but are not limited to any full width lane used for travel, passing, climbing, center turn, acceleration, deceleration, and ramps.

include but are not limited to approach slabs, bridge decks, tapers, shoulders, medians, or other pavement surfaces as directed.

The Representative will determine when pavement may be opened to traffic. D o not open pavement to traffic or operate heavy equipment on it until the concrete has reached a minimum compressive strength of 3,000 pounds per square inch. Estimating concrete compressive strength by the maturity method according to AASHTO T 413 may be used as an alternate method of determining the compressive strength of the finished pavement. Perform operations on new pavement as approved by the Representative and according to the following:

• When moving on and off the pavement, construct a ramp to prevent damage to the pavement slab.

• Take positive action to prevent damage to the pavement surface and joints.

• Before placing the protective mats, sweep the pavement surface free of debris.

• Operate equipment on a slab without causing damage. If damage results, suspend operations, and take corrective action as approved.

• New pavement will not be opened to any traffic until all joints have been sealed unless an acceptable method to protect joints from damage and keep non- compressible materials from entering the joint is approved.

The Representative will determine lots and sublots as specified in Section 530.3(u). Complete any surface corrective work before testing for pavement depth. Test pavement depth by obtaining one core or one N on-Destructive test in each sublot. The Representative will determine the location of each depth test according to PTM No. 1. If the drilled core measurement method is used for depth measurement submit the first sublot core and every tenth core thereafter, as an information core, immediately to the Representative. If the non- destructive depth measurement method is used, drill one information core in the first sublot placed and one information core for every tenth sublot thereafter. Verify the depth of all drilled cores as specified in Section 530.3(s)1. The Representative will determine sublot and core locations according to PTM No. 1. For a partial lot the Representative will randomly select one core or core location according to PTM No. 1. The Representative will immediately submit the information cores to the LTS for an evaluation of entrained air content according to PTM No. 623. If the entrained air content is below 3.5% or above 8.5% provide a written evaluation of the problem and proposed solution to the Department within 5 days. If positive action is not taken to address hardened entrained air results below 3.5% or above 8.5% within 5 days, the District Executive may require that paving operations be stopped until an acceptable solution is agreed upon.

Drill cores at each sublot location, according to PTM No. 606, in presence of the Representative. Thoroughly clean the vertical surface of the core hole of laitance and loose and foreign material. Fill the holes with the mixture used to construct the course and consolidate. As an alternative, use a premixed, non-shrink grout. Provide a measuring apparatus according to PTM No. 614. The Representative will:

• determine the core length according to PTM No. 614,

• determine the average lot pavement thickness by averaging the individual sublot core thicknesses,

• accept concrete as specified in Section 530.3(u), and

• determine price adjustments as specified in Section 530.4(a).

When indicated or when requested in writing and approved by the District Executive test the depth of the finished pavement as specified in Section 501.3(s)2.

Unless otherwise directed in writing, as specified in Section 110.10(d)1., by the District Executive, remove and replace pavement determined defective as follows:

design thickness (D) minus 0.5 inch or more than one individual sublot core depth is less than the design thickness minus 0.5 inch.

than 55%, as specified in Section 530.3(u)2.

from rain, improper joint construction, improper curing procedures, improper final finish, cracking, or honeycombing that cannot be satisfactorily repaired as determined by the Representative.

pavement contains depressions or high points as specified in Section 506.3(o) that cannot be satisfactorily corrected as determined by the Representative.

501.3(g)5 are not met.

Remove and replace a minimum of an entire panel of LLCP pavement as shown on the Standard Drawings. Longitudinal edge spall repairs are not considered satisfactory repairs for edge slumping or spalling between adjacent lanes or outside pavement edges.

Lots and sublots for the combined pavement characteristics of depth and compressive strength will be determined based on the full width of pavement placement. Lots and sublots will begin at the starting point of paving and continue until 5,600 square yards are placed. Lots and sublots will be calculated as the work progresses and will include any pavement designated as LLCP pavement. Do not combine pavement with different depths into any lot or sublot. A full lot is defined as 5,600 square yards of pavement of the same constant depth and consists of 4 equal sublots of 1,400 square yards each. Combine partial lots with the last full lot or make a separate lot according to the following procedure:

• If less than 4,200 square yards remain, combine the remaining pavement with the last full lot.

• If the remaining pavement is equal to or greater than 4,200 square yards, consider the remaining pavement as a separate lot.

• Determine sublots for the last pavement lot by establishing a number of equal size sublots.

• Determine the number of sublots by dividing the area of the combined lot or partial lot by 1,400 square yards and then rounding to the nearest whole number.

• Determine the equal size of each sublot by dividing the combined lot or partial lot quantity by the number of whole sublots calculated.

• Determine lots and sublots based on the full width of pavement placement.

for depth if the average core depth of the lot is more than the design thickness (D) minus 0.5 inch and not more than one individual sublot core depth is less than the design thickness minus 0.5 inch.

concrete for compliance with the specification requirements , for compressive strength, on a lot - by-lot basis, as specified in Section 105 and Section 106. The Representative will determine locations where acceptance samples of plastic concrete will be taken, according to PTM No. 1. Make one set of compressive strength specimens and one test for percentage of plastic air content on samples from each sublot. All sampling and testing must take place before the concrete in the truck being tested is placed on grade. Trucks selected for acceptance testing with plastic air results that are outside specification limits will not be placed. If a truck is discarded because of low plastic air content, test consecutive trucks as specified in Section 704.1(d)4 .a. Discard all concrete with failing plastic air results. Provide a testing station within 1 mile of the final concrete placement location unless an alternate location is approved by the Representative. Mold acceptance cylinders at the determined sublot location. The average of the test results from two cylinders, made from the same sample, tested according to PTM No. 604, will constitute the 28-day compressive strength. Cure test specimens according to Subsection 12.1 of PTM No. 611. The Representative will accept concrete based on the adequacy and uniformity of compressive strength at the age of 28 days, when the PWL is 55% or greater. For compressive strength, c alculate the value of Q L by the following equation, where X�4 is the average of the sublot test results. QL is the lower quality index, and “s” is the Standard Deviation as specified in Section 106.03(a)3.a.4.

2.a For Class AA 28-day concrete compressive strength,

QL = X�4 − 3,300psi s

Determine the percentage of material within specification limits as specified in Section

106.03(a)3

Provide and place concrete with a W/C ratio between 0.37 and 0.42. Do not add water or finishing aids to the surface of the concrete to aid in finishing. The Department will determine the W/C ratio for concrete hauled in dump or agitator trucks according to the following (concrete hauled in truck mixers is not eligible for W/C ratio incentives):

location for each sublot as specified in Section 530.3(u)2. The Representative will compute the average W/C ratio for each lot of material established as specified in Section 530.3(u) as follows:

1.a Water Content Determination. For plant mixed cement concrete, use a Representative approved electronic meter that is capable of recording and printing on the batch ticket the total amount of water added to the mix including temper water. The amount of temper water may be handwritten on the delivery ticket if the District provides inspection personnel to certify the hand written information. All temper water must be from a metered and calibrated source.

The Representative will determine the water content for calculating the water/cement ratio for each sublot and lot.

1.b Cementitious Content Determination. The Representative will use the sum of all cementitious material weights printed on the plant delivery slip for each sublot to determine cementitious content of each sublot.

1.c Water Content Verification. Provide the microwave oven and the ancillary equipment required by the Representative to perform this test. The Representative will use PTM No.1 to select sample locations from the first sublot and every tenth sublot placed thereafter. Take verification samples from the same truck load of concrete as specified in S ection 530.3(v)1. Plastic concrete samples will be taken at the plant . The Representative will determine the water content of the plastic concrete mixture according to AASHTO T 318. The Representative will begin the test within 45 minutes after the water has contacted the cement. The representative will compare the W/C ratio from the AASHTO T 318 verification testing results to the W/C ratio results computed from the plant delivery tickets. If more than one sublot within a lot is tested according to AASHTO T 318, the av erage of the tested sublots will be compared to the average of the corresponding W/C ratios computed from plant delivery tickets. If the W/C ratio computed from the delivery tickets is not within ± 0.03 of the W/C ratio from the AASHTO T 318 verification testing results, the lot is not considered verified, and no incentive will be paid for the lot. In addition, perform water content verification tests a minimum of one sublot for each lot placed according to AASHTO T 318. If the W/C ratio computed from the delivery tickets is not within ± 0.03 of the W/C ratio from the AASHTO T 318 verification testing results, the lot is not considered verified, and no incentive will be paid for the lot. The Representative will continue verification tests as described herein.

530.4MEASUREMENT AND PAYMENT—Square Yard

The Department will pay on a lot-by-lot basis at the contract price, adjusted for pavement characteristics relative to depth, and compressive strength. The lot payment will be determined according to the multiple characteristic formula specified in Section 530.4(a)3.

characteristic percentage for depth will be determined using Table A. The characteristic percentage for depth will be placed in the multiple characteristic formula as Pd specified in Section 530.4(a)3 to determine the lot payment.

specified in Section 530.3(u)2. The characteristic percentages for compressive strength will be determined by using Table B. The characteristic percentage for compressive strength will be used as Ps in the multiple characteristic formula specified in Section 530.4(a)3 to determine the lot payment.

Multiple Characteristic Formula No Incentive / Disincentive

L p = Cp �2Ps + 2Pd 400 �

Multiple Characteristic Formula With Incentive

Lp = Cp �2Ps + 2Pd 400 � WC

Lp = Lot Payment Cp = Contract price per lot (contract price times lot size) Ps = Characteristic Percentage of Compressive Strength—(Table B) Pd = Characteristic Percentage for Depth—(Table A) WC = Incentive Pay Factor (Table C)

TABLE A Characteristic Percentages for Concrete Pavement Depth (Pd) Relative to Specification Limits

15-inch Design Thickness 14.5-inch Design Thickness Characteristic Characteristic Average Percentage Average Percentage Thickness, inches Pd Thickness, inches Pd

15.00or greater 100.0 14.50 or greater 100.0

14.9014.99 97.1 14.40 - 14.49 96.9

14.8014.89 94.4 14.30 - 14.39 94.0

14.7014.79 91.4 14.20 - 14.29 90.9

14.6014.69 88.0 14.10 - 14.19 87.3

14.5014.59 86.4 14.00 - 14.09 85.5

Less than 14.50 * Less than 14.00 *

14-inch Design Thickness 13.5-inch Design Thickness Characteristic Characteristic Average Percentage Average Percentage Thickness, inches Pd Thickness, inches Pd

14.00or greater 100.0 13.50 or greater 100.0

13.9013.99 96.7 13.40 - 13.49 96.5

13.8013.89 93.6 13.30 - 13.39 93.2

13.7013.79 90.3 13.20 - 13.29 89.8

13.6013.69 86.5 13.10 - 13.19 85.8

13.5013.59 84.6 13.00 - 13.09 83.7

Less than 13.50 * Less than 13.00 *

13-inch Design Thickness 12.5-inch Design Thickness Characteristic Characteristic Average Percentage Average Percentage Thickness, inches Pd Thickness, inches Pd

13.00or greater 100.0 12.50 or greater 100.0

12.9012.99 96.3 12.40 - 12.49 96.1

12.8012.89 92.8 12.30 - 12.39 92.4

12.7012.79 89.2 12.20 - 12.29 88.7

12.6012.69 85.0 12.10 - 12.19 84.8

12.5012.59 82.8 12.00 - 12.09 81.9

Less than 12.50 * Less than 12.00 *

12-inch Design Thickness 11.5-inch Design Thickness Characteristic Characteristic Average Percentage Average Percentage Thickness, inches Pd Thickness, inches Pd

12.00or greater 100.0 11.50 or greater 100.0

11.9011.99 95.9 11.40 - 11.49 95.7

11.8011.89 92.0 11.30 - 11.39 91.6

11.7011.79 88.1 11.20 - 11.29 87.6

11.6011.69 84.5 11.10 - 11.19 83.8

11.5011.59 81.0 11.00 - 11.09 80.1

Less than 11.50 * Less than 11.00 * 11-inch Design Thickness 10.5-inch Design Thickness Characteristic Characteristic Average Percentage Average Percentage Thickness, inches Pd Thickness, inches Pd

11.00or greater 100.0 10.50 or greater 100.0

10.9010.99 95.5 10.40 - 10.49 95.3

10.8010.89 91.2 10.30 - 10.39 90.8

10.7010.79 87.0 10.20 - 10.29 86.5

10.6010.69 83.0 10.10 - 10.19 82.3

10.5010.59 79.2 10.00 - 10.09 78.3

Less than 10.50 * Less than 10.00 *

10-inch Design Thickness 9.5-inch Design Thickness Characteristic Characteristic Average Percentage Average Percentage Thickness, inches Pd Thickness, inches Pd

10.00or greater 100.0 9.50 or greater 100.0

9.90 - 9.99 95.1 9.40 - 9.49 94.6 9.80 - 9.89 90.4 9.30 - 9.39 89.9 9.70 - 9.79 85.9 9.20 - 9.29 85.2 9.60 - 9.69 81.5 9.10 - 9.19 80.6 9.50 - 9.59 77.4 9.00 - 9.09 76.3 Less than 9.50 * Less than 9.00 * 9-inch Design Thickness 8.5-inch Design Thickness Characteristic Characteristic Average Percentage Average Percentage Thickness, inches Pd Thickness, inches Pd 9.00 or greater 100.0 8.50 or greater 100.0 8.90 - 8.99 94.0 8.40 - 8.49 94.0 8.80 - 8.89 89.3 8.30 - 8.39 88.7 8.70 - 8.79 84.4 8.20 - 8.29 83.5 8.60 - 8.69 79.6 8.10 - 8.19 78.5 8.50 - 8.59 75.1 8.00 - 8.09 73.8 Less than 8.50 * Less than 8.00 *

8-inch Design Thickness Characteristic Average Percentage Thickness, inches Pd 8.00 or greater 100.0 7.90 - 7.99 93.9 7.80 - 7.89 88.1 7.70 - 7.79 82.6 7.60 - 7.69 77.3 7.50 - 7.59 72.4 Less than 7.50 * * Defective work, as specified in Section 530.3(t).

TABLE B Characteristic Percentages for Concrete Pavement Compressive Strength (Ps) Relative to Specification Limits Percent Within Specification Limits Characteristic Percentage 90 - 100 100 85 - 89 99 75 - 84 94 65 - 74 83 55 – 64 66 Below 55 * * Defective work, as specified in Section 530.3(t).

in Section 530.3(v). The Incentive Pay Factor will be determined using Table C. The Incentive Pay Factor will be placed in the W/C Ratio formula as WC as specified in Section 530.4(a)3 to determine the lot payment.

TABLE C Adjustments for W/C Ratio Incentive W/C Test Result Incentive Pay Factor 0.38 to ≥ 0.37 +0.04 0.39 to > 0.38 +0.03 0.40 to > 0.39 +0.02 0.41 to > 0.40 +0.01 ≤ 0.42 to >0.41 0.00

4.a. Evaluation of Lot Pay Factor and Payment of W/C Ratio Incentive. Dollar. If the W/C ratio incentive is indicated, the proposal will include a contract item and a predetermined amount of money for Evaluation of the Lot Pay Factor and Payment of W/C Ratio Incentive. The contract item will have a unit of measure of DOLLAR, a unit price of $1.00, and a quantity equal to the predetermined amount. Because of the incentive status of the payment being made, the provisions of Section 110.02(d) are not applicable to this item. The Evaluation of Lot Pay Factor and Payment of W/C Ratio Incentive contract item will be measured and paid as follows:

• Incentive. When concrete pavement evaluation indicates that an incentive adjustment is applicable and when specified, the appropriate amount will be paid under this contract item.

unless otherwise directed in writing by the District Executive. When the District Executive directs that defective pavement be left in place, final payment for this pavement will be at 50% of the contract unit price.

The contract unit price includes measuring apparatus, which remains the Contractor's property upon completion of the project.