SECTION 503 — REPAIRING DETERIORATED/DAMAGED JOINTS BETWEEN 1 INCH AND 8 INCHES WIDE IN FINISHED PORTLAND CEMENT CONCRETE PAVEMENT — REPAIRING DETERIORATED/DAMAGED JOINTS BETWEEN 1 INCH AND 8 INCHES WIDE IN FINISHED PORTLAND CEMENT CONCRETE PAVEMENT
503.01 Description.
This work includes performing all operations required for cleaning, saw cutting, concrete removal, rebuilding, and sealing joints in existing Portland cement concrete pavement that are between 1 in. and 8 in. wide at designated locations.
503.02 Materials.
a.Joint Seal. Use a joint seal material that conforms to ASTM D6690 and Subsection M02.09.2.
b.Epoxy Resin Bonding Agent. Select an agent that is on the AML.
c.Fast Set Repair Mortar. Select an agent that is on the AML. Ensure that the use of the material meets the manufacturer’s recommendations. If the Contractor proposes a repair material not previously accepted by the Department, and the Department approves its use through the Shop Drawing procedure, provide a field representative of the manufacturer or distributor at the work site before any mi xing of components. Ensure that the field representative instructs the work crews in the proper mixing and application procedures and remains at the job site until he/she and the Engineer are satisfied that the crew has mastered the technique of installin g the system. Provide the service at no additional cost to the Department.
d.Preformed Asphalt Joint Filler . Use preformed asphalt joint filler that conforms to Subsection M02.09.1.
e.Storage. Store materials according to the manufacturer’s recommendations.
503.03 Construction Methods.
Removal of Existing Concrete.
a.Saw Cutting. Provide a ¾-in. deep saw cut parallel to the joint on both sides of the joint a distance of 3 in. back from the edge of the deteriorated concrete. Do not damage the freshly saw cut edge and the slab reinforcing during the concrete removal operations.
b.Removal. Remove the concrete to the full depth of the existing pavement and to a minimum width of 3 in. by a method approved by the Engineer. Do not use jack hammers heavier than the nominal 30 -lb class. Do not use chipping hammers heavier than the nominal 15-lb class to remove concrete from beneath any reinforcing bar. Use hand tools such as hammers and chisels for removal of final particles of unsound concrete or to achieve the required depth. Do not place pneumatic tools in direct contact with reinforcing steel. For any load transfer devices encountered, clean and leave in place, if the device
Part 500 — Concrete Pavements August 2025
SECTION 503 — REPAIRING DETERIORATED/DAMAGED JOINTS BETWEEN 1 INCH AND 8 INCHES WIDE IN FINISHED PORTLAND CEMENT CONCRETE PAVEMENT 500-5 is still a competent part of the concrete slab. If the load transfer device has failed as determined by the Engineer, remove and dispose of the device. Preparatory Work. Just before sealing, clean each joint or crack to the full depth of the concrete pavement to remove all foreign material. Ensure that the exposed concrete and reinforcing steel surface is free of rust, oil, solvent, grease, dirt, dust, bitumen, loose particles, and other foreign matter before the application of the epoxy bonding agent. Correct any disturbance of the gravel su bbase or any undermining of the existing concrete slab at no additional cost to the Department. Joint Filler Placement. Before placement of the fast -set repair mortar, install one 1 -in. or two ½ -in. thick lengths of a preformed asphalt joint filler in a straight line, perpendicular to the reinforcing steel for the full width of the existing concrete slab(s). Extend the preformed asphalt joint filler in a plumb vertical direction from the gravel subbase to the surface of the existing concrete slab. Application of the Epoxy Bonding Agent. For cracks greater than 1 in., apply an epoxy bonding agent to the prepared concrete surface to be repaired to a thickness of approximately 20 mils or according to the manufacturer’s recommendations. Do not coat the reinforcing steel with epoxy. Follow the manufacturer’s recommendations for curing the epoxy bonding agent before placing the concrete repair material. Do not place the repair material if the bonding agent has passed the manufacturer’s recommended contact time. If the time has been e xceeded, follow the manufacturer’s recommendations for re-application. Use an epoxy bonding agent with an extended contact time if required by the timing of concrete placement and/or weather conditions. Application of Fast Setting Mortar.
a.Application, Mixing, and Batching. Perform the application, priming, curing, clean-up, and protection of freshly patched areas according to the manufacturer’s recommendations. Mix no more material than can be placed within the specified working time recommended by the manufacturer. Ensure that the mix conforms to AASHTO M43, Size 8. Do not use crushed limestone.
b.Weather Limitations for Application of the Epoxy Bonding Agent and Fast Setting Mortar. Do not apply concrete repair mortar when the ambient temperature is below 45°F and/or when not recommended by the manufacturer.
Part 500 — Concrete Pavements August 2025
500-6 SECTION 503 — REPAIRING DETERIORATED/DAMAGED JOINTS BETWEEN 1 INCH AND 8 INCHES WIDE IN FINISHED PORTLAND CEMENT CONCRETE PAVEMENT Sealing Joints. Upon placement and proper curing of the fast set concrete repair mortar, remove the top 1 in. of preformed asphalt joint filler and replace with a joint sealer. Clean and dry each joint before placing the sealing compound. Perform any required cleaning by blowing out all dirt, dust, or deleterious matter. Do not place the hot extruded joint sealing material unless approved by the Engineer. Remove all material and debris exiting from the joint from the pavement surface. Apply the joint seal by hot extrusion with a wand type instrument. Use a system that includes a flow control valve that fills all cracks to refusal. Fill all cracks to refusal to eliminate all voids or entrapped air. Ensure that the hot seal completely fills the joint so that, after cooling, the level of the sealer is flush with the pavement surface. Raise all depressions in the seal to the surface with additional hot seal. Seal the joints so that the final appearance presents a neat fine line. Do not overfill the joints and avoid spillage of the sealer. Remove and discard all excess or spilled sealer from the pavement. Do not seal joints if frost, snow, or ice is present. Store materials according to the manufacturer's recommendations.
503.04 Method of Measurement.
Repairing Deteriorated/Damaged Joints Between 1 Inch and 8 Inches Wide in Finished Portland Cement Concrete Pavement will be measured by the number of cubic feet of fast set concrete repair mortar placed in the repaired joints.
503.05 Basis of Payment.
The Department will pay for the completed and accepted quantities as follows. Pay Item Pay Unit Repairing Deteriorated/Damaged Joints 1 to 8 Wide in Finished PCC Pavement CF Payment at the Contract unit price is full compensation for all resources, labor, materials, equipment, and incidentals required to finish the work, complete and accepted.
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Source: Standard Specifications for Road and Bridge Construction (Blue Book), 2022 (Aug 2025 compilation) Edition. Pages 277–279 of 951. View official source ↗