818Portland Cement Concrete Bridge Deck Repair

818.01 Description.

This work includes removing deteriorated concrete from bridge deck surfaces, erecting formwork, and placing new Portland cement concrete.

818.02 Materials.

Use materials that conform to the following requirements. Concrete. Use concrete that conforms to the requirements for Class HP material as stated in Subsections 601.02.1 and 601.03.1, with the exception to use coarse aggregate gradation that meet s Subsection M02.03 for aggregate size ½ in. or ⅜ in. The size used is at the discretion of the Contractor. Bonding Agent. Use bonding agent that is an all-purpose, high-strength, moisture-insensitive, rigid bonding agent that is listed on the Department ’s A pproved Materials List. E nsure that the material used is compatible with the surfaces to be bonded. Reinforcement. Use reinforcement that conforms to ASTM 615 Grade 60 Reinforcing Steel as presented in SECTION 810.

818.03 Construction Methods.

Removal of Deteriorated Concrete. Remove all loose, deteriorated, or unsound concrete. Make a saw cut to an approximate depth of ¾ in. along all boundaries of the repair patches before removal, except those patches bounded by the bridge curbing. Do not cut into the top mat of bridge deck reinforcing steel. Perform concrete removal so as to not damage reinforcing steel or saw cut areas at the repair boundaries. Remove the concrete to a minimum depth of 1 in. Do not use jackhammers heavier than a nominal 30 lb. Do not use c hipping hammers heavier than a nominal 15- lb class to remove concrete from areas beneath reinforcing bars. Provide hand tools such as hammers and chisels

Part 800 — Bridge Structures August 2025

800-116 SECTION 818 — PORTLAND CEMENT CONCRETE BRIDGE DECK REPAIR for removal of particles of unsound concrete or to achieve the required depth throughout the repair areas, including the saw cut edges. Do not place pneumatic tools in direct contact with reinforcing steel or the surrounding concrete to remain . The Engineer can require other methods if the Engineer determines that the Contractor’s method is damaging the concrete. Where reinforcing steel is surrounded by deteriorated concrete or where at least one -half of its surface area is exposed, ensure that the depth of concrete removal includes all deteriorated concrete but not less than that depth necessary to allow for ¾-in. clearance below the primary reinforcing bars in the top mat of reinforcing steel. If removal extends deeper than 50 percent of the original deck thickness solely for obtaining the ¾-in. clearance, the repair is still considered a partial-depth repair. It is not necessary to remove concrete underneath any temperature and distribution reinforcement that has no more than one half of its surface area exposed . For reinforcing bars that have lost 25 percent or more of their original diameter, supplement the bars with new bars spliced in place while maintain the required cover, especially for dual bars. In splicing new bars, lap sufficiently (30 diameters on both sides of the a ffected areas) to develop the full strength of the bar and, if necessary, provide additional concrete removal for the lap. Dual bars of equivalent or greater section may be used. Perform deck removal by hydrodemolition according to SECTION 840. Use alternative methods only with written approval from the Engineer. Preparation of Sound Concrete and Reinforcing. Clean all exposed reinforcing bars and newly exposed concrete by sandblasting or other mechanical abrasion methods. Ensure that t he exposed concrete and reinforcing steel surfaces are free of rust, oil, solvent, grease, dirt, dust, bitumen, loose particles, and other foreign matter before the application of the bonding agent. Use a large sized vacuum cleaner and/or an air jet to remove dust and other particles before placing the bonding agent. Repair all damage to steel reinforcement coatings. Forms for Full Depth Removal. Ensure that forms used for patching can support the quantity of fresh concrete needed to install the patch. Bonding Agent. Apply bonding agent to the substrate to a thickness of according to the recommendations of the manufacturer. Follow the manufacturer ’s recommendations for curing the bonding agent before placing the concrete. Placing and Finishing Concrete. Hand manipulate t he new concrete and str ike-off the concrete slightly above the final grade. Then, mechanically consolidate and screed to a final grade.

Part 800 — Bridge Structures August 2025

SECTION 818 — PORTLAND CEMENT CONCRETE BRIDGE DECK REPAIR 800-117 Provide a mechanical or hand trowel finish to produce a tight and uniform surface. As soon as the finishing has been completed, seal all vertical joints with adjacent concrete by painting with thinned grout. Apply white pigmented liquid curing compound immediately after the joint application is completed. Use a rate of application 15 sq yd/gal, applied evenly and uniformly over the surface area. If the curing compound is not applied within 10 minutes after the final screeding, cover the finished concrete surfaces with wet burlap until the application of curing compound can be made. Remove the repaired concrete in the rejected areas, and re-repair the areas. Do not allow traffic or external loads from heavy equipment such as pavers on the repaired deck surfaces until the concrete has reached a minimum of 95 percent of its 28-day compressive design strength.