South Dakota 2015 Standard Specifications for Roads & Bridges — Section 380

380 Page 216PART D RIGID PAVEMENT

380.1DESCRIPTION

This work consists of constructing Portland Cement Concrete Pavement of sufficient quality to serve the purpose for which the concrete pavement was designed on a prepared surface.

380.2MATERIALS

Materials will conform to the requirements specified in the following Sections: A.Cement: Section 750. Type II cement will be used for all concrete pavement. B.Admixtures: Section 751 and Section 752. C.Water: Section 790. D.Fine Aggregate: Section 800. E.Coarse Aggregate: Section 820. F.Reinforcing Steel: Section 1010 . G.Preformed Expansion Joint Filler: Section 860. H.Joint Sealer: Section 870. I.Curing Materials: Section 821. J.Dowel Bar Assemblies: Section 1010 . K.Fly Ash: Section 605 and Section 753. L.Epoxy Resin Adhesive : Epoxy resin adhesive will be of the type intended for horizontal applications, and will conform to the requirements of ASTM C881, Type IV, Grade 3 (equivalent to AASHTO M 235, Type IV, Grade 3) Class A, B, or C. The minimum gel time will be 5 minutes. M.Non-Shrink Grout : Non-shrink grout will be of the type intended for anchoring horizontal dowel bars or reinforcement bars, (AMBEX AAC or an approved equal by the Department’s Concrete Engineer).

380.3CONSTRUCTION REQUIREMENTS

A.Quality of Concrete and Proportioning: The Contractor will design and be responsible for the performance of all concrete mixes used in the pavement. 380 Page 217The Contractor will submit the proposed mix design on a completed Contractor Concrete Mix Design form (DOT-24) for review by the Department. If concrete mix design requirements are not designated in the plans, the Contractor will develop and use a concrete mix design conforming to the following: •Minimum cementitious material content of 600 pounds or 575 pounds if well graded* with a maximum cementitious content of 800 pounds per cubic yard. •The Contractor will substitute a portion of the cement with Class F modified fly ash in accordance with Section 605. The amount of cement to be replaced will be 20% to 25% by weight. •A maximum Water/Cementitious ratio “W/C Ratio” of 0.42. •Minimum coarse aggregate content of 55% by weight of total aggregates. •A water reducer at manufacturer’s recommendations will be used. •Minimum 28 day compressive strength of 4,000 psi. *Well graded concrete mixes are those mixes conforming to the aggregate gradation shown in The Department’s Concrete Engineer will determine if a concrete mix design verification is required. If the Department, in the Department’s discretion, determines a concrete mix design verification is required, the Contractor will submit samples of materials proposed for use, excluding water, to the Department’s Central Materials Laboratory at least 40 calendar days prior to the anticipated paving start date. Aggregate samples will be obtained from stockpiles of material to be used in the work. A maximum of two concrete mix design verifications per contract will be made by the Department without charge. Should the Contractor desire additional concrete mix designs verified, the costs involved will be at the Contractor's expense. The Contractor will produce a concrete paving mix with a uniform consistency. The Contractor will produce a concrete paving mix in accordance with the successfully reviewed mix design and the following: For the stationary side form method, the slump of the concrete will be between 1 inch and 3 inches. For the slip-form method, the slump of the concrete will not be more than 2 inches. The concrete will contain 6.5% entrained air with an allowable tolerance of +1% to -1.5%. Air will be entrained by an approved air-entraining admixture. The concrete will exhibit a minimum compressive strength of 4000 psi at 28 days. The concrete will have a maximum Water/Cementitious ratio “W/C Ratio” as listed on the mix design. The Engineer will be responsible for the sampling, preparing, curing, and testing of all concrete cylinders for concrete compressive strength in accordance with the Department’s Materials Manual. 380 Page 218The 28 day compressive strength will be determined in accordance with Section 460.3 B. If the 28 day compressive strength is less than the specified 28 day compressive strength, the Department’s Concrete Engineer will evaluate the average compressive strength and determine if the concrete is structurally adequate. B.Equipment: Vehicles tracking foreign substances, including but not limited to; soil, rock, vegetation, hardened concrete, partially hydrated concrete, fuel, and oil will not be allowed to drive through or back into fresh mixed concrete. Equipment dropping foreign substances, including but not limited to; soil, rock, vegetation, hardened concrete, partially hydrated concrete, fuel, and oil from the unit will not be allowed over or in contact with the fresh mixed concrete. 1.Batching Equipment: Batching equipment will be computerized and automatic. Manual operation will be permitted when automatic controls fail provided concrete meeting specified results is produced, however, the automatic operation will be restored before work may commence the day following the failure. The Contractor will provide satisfactory means for obtaining material samples from the batching plant. Batching plant structures will be leveled so the accuracy of the weighing mechanism is maintained. Hoppers will fully discharge without jarring the scales. Clearances between scale parts, hoppers, and bin structure will be maintained to avoid displacement of, or friction between, parts due to material accumulations, vibration, or other cause. Pivot mountings will be designed so the parts will not jar loose and constructed to assure unchanging spacing of knife edges under all circumstances. Exposed fulcrums, clevises, and similar working parts will be kept clean. To maintain accuracy, weighing hoppers and other parts which are affected by wind action will be protected by shelters or wind breaks. The equipment for weighing aggregates, cement, water, and admixtures will be an integral part of the batching equipment. The scales/load cells will be accurate within 0.5% at any point throughout the range of the scale/load cell. Graduations will be not greater than 0.1% of the capacity of the scale/load cell. The scales/load cells will be sensitive to the weight indicated by one graduation. The following controls will apply to the aggregate batching equipment: The batching equipment will operate within a delivery tolerance of 1.5% of the net weight for each aggregate weighed. The hopper inlet mechanism will be interlocked against opening when the discharge gate is open. The hopper discharge mechanism will be interlocked against opening while the hopper is being charged. 380 Page 219The hopper discharge mechanism will be interlocked against opening if any material in the hopper is either overweight or underweight by more than 1.5% of the specified weight. The cement batching equipment will operate within a delivery tolerance of 1% of the net weight of the cement per batch. The cementitious material (cement and fly ash) batching equipment will also operate within a delivery tolerance of 1% of the net weight of the total cementitious material per batch. Water may be measured by volume or weight. The measuring equipment will operate within a delivery tolerance of 1% of the net weight or volume of water. When water is measured by volume, means for determining the accuracy of the measuring device will be provided. Air-entraining or other admixtures may be measured by volume or by weight. The measuring equipment will operate within a delivery tolerance of 3% of the net weight or volume per batch. 2.Ticket Requirements: A printed, computer generated, ticket will be automatically produced for each load of concrete batched. The printed computer ticket will accompany each load of concrete to the project and will be presented to the Engineer prior to discharging the load at the project site unless the Engineer approves an alternate procedure. The printed ticked must contain the following minimum information: Truck Number Date and Time Batched Total volume of the load, in cubic yards DOT Mix Design Number Actual weight (mass) or volume of each component of the mix: Coarse Aggregate Fine Aggregate Cement Fly Ash Water (batch water) Admixtures Air Entraining Admixtures Water Reducers Retarders Accelerators Others % Moisture in Aggregate (either % free moisture or % total moisture) Maximum Water Allowed (maximum water allowed = weight of mix design water - weight of free water) W/C ratio (as batched) 380 Page 220When automatic moisture sensing equipment is used for an aggregate component, the batch ticket will show the percent of moisture for the aggregate component with moisture sensing equipment. The results of the most recent two hour moisture test will be shown for aggregate components without moisture sensing equipment. The final W/C ratio, for acceptance, will be calculated using the following formula and rounded to the nearest 0.01: 𝑊/𝐶 𝑟𝑎𝑡𝑖𝑜 =𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑓𝑟𝑒𝑒 𝑤𝑎𝑡𝑒𝑟 +𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑏𝑎𝑡𝑐ℎ 𝑤𝑎𝑡𝑒𝑟 +𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑎𝑑𝑑𝑒𝑑 𝑤𝑎𝑡𝑒𝑟 𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑐𝑒𝑚𝑒𝑛𝑡 +𝑤𝑒𝑖𝑔ℎ𝑡 𝑜𝑓 𝑠𝑢𝑝𝑝𝑙𝑒𝑚𝑒𝑛𝑡𝑎𝑟𝑦 𝑐𝑒𝑚𝑒𝑛𝑡𝑖𝑡𝑖𝑜𝑢𝑠 𝑚𝑎𝑡𝑒𝑟𝑖𝑎𝑙 % free moisture =% total moisture in aggregate - % absorption of aggregate weight of free water =% free moisture x weight of aggregate weight of batch water =total weight of water added to the batch either at the plant or in the truck weight of added water =total weight of water added after batching process (typically added at point of delivery) The weight of free water will be calculated for both the fine aggregate and the coarse aggregate. The above information must be automatically printed in such a manner that the Engineer may verify the mix adheres to the proportions specified by the mix design. 3.Mixing and Hauling Equipment: Mixers and agitators will have attached in a prominent place, the manufacturer's plate showing the various uses for which the equipment is designed and the capacity of the drum in terms of volume of mixed concrete. The pick-up and throw-over blades in the drum will be restored or replaced when any part or section is worn 3/4 inch or more below the original height of the manufacturer's design. The Contractor will maintain a copy of the manufacturer's design, showing dimensions and arrangement of blades in reference to the original height and depth. Mixers that have an accumulation of hard concrete or mortar will not be used. Mixers, except truck mixers, will be equipped with a timing device to track the total mixing time of the concrete batch. Truck mixers will be equipped with counters to record the number of revolutions of the drum or blades. Mixers will be capable of combining the concrete ingredients into a thoroughly mixed and uniform mass and will uniformly discharge the concrete. The hauling bodies of non-agitating equipment will be smooth, mortar-tight metal containers equipped with gates and vibrators that will permit uniform control of the discharge of the concrete. 4.Spreading and Finishing Equipment: The spreading equipment will consist of a mechanized device to place and provide a rough strike off of the concrete. The concrete will be unloaded into an approved mechanical concrete spreader and deposited uniformly 380 Page 221across the subgrade or subbase as close as possible to its final position. The use of a mechanical spreader may be waived provided the concrete hauling equipment is equipped with a discharge system capable of distributing the concrete uniformly without segregation across the width of paving and meets the approval of the Engineer. Slipform paving equipment will have the direction of forward motion and grade (vertical elevation) controlled by an electronic sensing device. The electronic sensing device will either follow a taut string line or will be controlled by a GPS/Total Station system capable of meeting the alignment, grade, surface test, and cross slope requirements. The paving equipment will spread, consolidate, screed, and finish the freshly placed concrete to provide a dense and homogenous pavement with a minimum amount of hand finishing. The paving equipment will not cause flotation of aggregate particles or show evidence of an accumulation of laitance on the surface of the concrete either during or after placement. 5.Vibrators : Vibrators will be either the surface pan type or the internal type. They may be attached to the spreader, the finishing machine, or mounted on a separate carriage. Vibrators will be interlocked with the machine's travel mechanism, so vibration is stopped when the forward motion stops. Vibrators will not come in contact with the joints, load transfer devices, reinforcement, subgrade, subbase, or side forms. The frequency of the surface vibrators will not be less than 3,500 impulses per minute. The frequency of the internal vibrators will not be less than 7,000 impulses per minute. When spud type internal vibrators are used adjacent to forms, they will have a frequency of not less than 3,500 impulses per minute. Vibrators will not be operated in excess of this frequency to such a degree that flotation of aggregate particles is caused and is evident or visible either during or after placement or that it causes an accumulation of laitance on the surface of the concrete. A vibrating reed tachometer, hand type, will be provided with each paver. The vibrating reed tachometer will have a range from at least 4,000 to 10,000 vibrations per minute (VPM). For a contract which has a minimum of 50,000 square yards of pavement that is 12 feet or more wide, an electronic internal vibrator monitoring device will be provided. The device will be capable of displaying the operating frequency of each internal vibrator and will be visible to the paving operator. The vibrator monitoring device will have a range from at least 4,000 to 10,000 VPM. Vibrators will not be used to level or spread the concrete but will be used only for purposes of consolidation. 6.Concrete Saw: The Contractor will provide sawing equipment, adequate to complete the sawing to the required dimensions and at the required rate. The Contractor will also provide at least one standby saw in good working order. 380 Page 222If an early entry saw is used, the early entry saw will use a dry cutting operation with up cutting blade rotation and a skid plate straddling the blades to minimize raveling and tearing of the concrete at the joint. 7.Forms: Forms will have a depth not less than the prescribed edge thickness of the pavement. Built up forms with horizontal joints will not be used. When staked in place, forms will withstand the pressure of the concrete and the impact, vibration and loading of any equipment they are required to support, without significant springing, settlement, or lateral displacement meeting the following requirements: The top face of any form will not vary from a true plane by more than 1/8 of an inch in 10 feet, nor will the contact face of a straight form vary from a true plane by more than 1/4 inch in 10 feet. Bent, twisted, or broken forms and those with battered top surfaces will be removed from the work. Repaired forms will not be used until inspected and approved. Flexible or curved forms of proper radius will be used for curves of 100 foot radius or less. Flexible or curved forms will be of an acceptable design. 8.Profilograph/Profiler: When specified in the Contract, the Contractor will furnish and operate an approved computerized 25 foot California style profilograph or profiler. a.Profilograph: The profilograph will consist of a 25 foot frame supported upon a multiple system of wheels at both ends. The profile will be recorded from the vertical movement of a wheel, attached to the frame at midpoint, in reference to the mean elevation of the points of contact established by the support wheels. The profilogram (trace) will be recorded on a scale of 1 inch is equal to 25 feet longitudinally and 1 inch equal to 1 inch vertically. b.Profiler: The Contractor may opt to use a laser-based profiler that conforms to ASTM E2133 and E950M. The profiler must be capable of measuring and analyzing the Profile Roughness Index (PRI). The computer will smooth the profile with a third-order Butterworth filter with a cutoff wavelength of 2.0 feet. The computer will generate a profile index using a zero-width blanking band. The computer will also use a 0.3 inch bump threshold to identify “must grind” locations. Prior to use on the project and periodically thereafter, the calibration of the profilograph/profiler will be checked. The vertical and horizontal scales will be checked. The horizontal scale will be checked by running the profilograph/profiler over a known distance. The cause of incorrect scales will be determined and corrected prior to using the profilograph/profiler. C.Preparation: 1.Insert Steel Bar in PCC Pavement : When specified in the plans and at the locations specified in the plans, the Contractor will insert steel bars into drilled holes in the existing 380 Page 223concrete pavement. An epoxy resin adhesive or a non-shrink grout must be used to anchor the steel bar in the drilled hole. The Contractor will adhere to the manufacturer’s recommendations for mixing and placing the materials. When opening to traffic times are less than 3 days, the Contractor will provide the Engineer with a letter from the manufacturer stating the required minimum cure times of the epoxy resin adhesive or non-shrink grout used to anchor either the dowel bars or reinforcement bars comply with the early opening times. The Contractor will not allow construction equipment or traffic on the affected area until the manufacturer’s recommended minimum cure times are met. Epoxy resin adhesive will conform to Section 380.2 L. Non-shrink grout will conform to Section

The diameter of the drilled holes in the existing concrete pavement for the steel bars will not be less than 1/8 inch nor more than 3/8 inch greater than the overall diameter of the steel bar. Holes drilled into the existing concrete pavement will be located at mid-depth of the slab and true and normal. The drilled holes will be blown out with compressed air using a device that will reach to the back of the hole to ensure that all debris and loose 380 Page 224material has been removed prior to installation of the anchoring material. The drilled holes will be dry when the anchoring material is installed. 2.Stationary Side Form Method: Forms will be set to line and grade. The granular surface will be final graded and dowel assemblies, if required, accurately placed in advance of concrete placement. The foundation under the forms will be compacted and true to grade. The form will be firmly in contact with the granular surface for the entire length of the form. Forms will be staked into place with not less than three pins for each 10 foot section. A pin will be placed at each side of every joint. Form sections will be tightly locked and free from play or movement. Forms will be cleaned and oiled prior to placing concrete. Alignment and grade elevations of the forms will be checked and corrections will be made before placing concrete. When forms have been disturbed or the grade has become unstable, the forms will be reset and rechecked. After side forms have been set to line and grade and securely fastened, the surface on which the concrete paving is to be placed will be brought to final grade by a subgrader or subgrade plainer. High areas will be trimmed to proper elevation. Low areas will be filled and compacted to a condition similar to that of surrounding grade or filled with concrete integral with the pavement. An automatic subgrader operating from a preset grade line or automatic grade control may be used prior to setting of the side forms. After grading has been completed by the automatic subgrader, the forms will be set, the surface checked, and high and low areas corrected. The finished subgrade surface will be maintained in a smooth and compacted condition until the pavement is placed. 3.Slip Form Method: The surface, on which the concrete is to be placed, will be brought to final grade by an automatic subgrader operating from a preset grade line or automatic grade control. The finished subgrade surface will be maintained in a smooth and compacted condition until the pavement is placed. D.Handling, Measuring, and Batching Materials: The separate aggregate components will not become intermixed prior to being weighed. Aggregates will be transported from stockpiles or other sources to the batching plant in a manner that maintains a uniform grading of the material. The use of track-type dozing equipment will not be permitted in handling coarse aggregates from stockpiles. Aggregates that have become segregated or mixed with earth or foreign material will not be used. If the aggregates contain non-uniform moisture, storage or stockpile periods will be required to equalize the moisture content. 380 Page 225The separate aggregate components for each batch may be weighed cumulatively in a single hopper or weighed separately in individual hoppers. A separate scale and hopper will be used for weighing cementitious materials. The amount of batch water and aggregates added to the mix will be adjusted accordingly using the results of the most recent two hour moisture tests. If automatic moisture sensing equipment is used, the Engineer may allow the use of the automatic moisture sensing results to make adjustments. E.Mixing Concrete: Concrete will be mixed at a central stationary plant. Truck mixing will be permitted only when approved by the Engineer. Mixing and agitating speeds will be as designated by the manufacturer of the equipment. Mixers may not be charged in excess of their rated capacity. Manual operation of the central plant will be permitted only in case of failure of the automatic control. Automatic operation must be restored before work may commence the day following the failure. Mixing water will not be heated above 160F. Aggregates will not be heated above 100F and will be free of frozen lumps, ice, and snow. A portion of the mixing water will be charged into the drum in advance of the cement and aggregates. The flow of water will be uniform, and all water will be in the drum by the end of the first 15 seconds of the mixing period. Concrete mixed less than the specified time will be disposed of at the Contractor's expense. When a concrete batch is 60% or less of the rated capacity of the drum on a central plant, drum on a truck mixer, or agitator; the Contractor may pre coat the drum or agitator or incorporate additional cementitious materials to the batch. 1.Central Plant Mixing: Concrete will be mixed not less than one minute after all materials, excluding water, are in the mixer. 2.Truck Mixing: Original mixing time for truck mixed concrete will not be less than 70 or more than 100 revolutions of the drum at mixing speed after all ingredients, including water, are in the drum. Additional revolutions beyond 100 will be done at agitating speed. The mixing water will be added at the time of batching. When approved by the Engineer, additional water, admixtures, and cement may be added to the batch after completion of the original mixing, in which case the batch will be mixed an additional 30 revolutions at mixing speed. The Contractor will provide means to accurately measure the amount of additional materials added. F.Delivery Requirements: The rate of delivery of concrete will be uniform. When concrete is continuously agitated in the hauling unit, the concrete will be discharged within 90 minutes after the cement has been placed in contact with the aggregates and discharged and screeded within 105 minutes. When the concrete temperature is 85F or 380 Page 226above, the time limitation will be reduced to discharged within 45 minutes and discharged and screeded within 60 minutes. When concrete is not continuously agitated in the hauling unit, the concrete will be discharged within 45 minutes after the cement has been placed in contact with the aggregates and discharged and screeded within 60 minutes. When the concrete temperature is 80F or above, the time limitation will be reduced to discharged within 30 minutes and discharged and screeded within 45 minutes. The hauling unit will be thoroughly cleaned and flushed with water as necessary to insure hardened concrete will not accumulate in the concrete hauling compartment. All wash water will be completely discharged before recharging the hauling unit with fresh concrete. G.Placing Concrete : Placement of concrete on a frozen surface will not be permitted. The surface temperature of forms, steel, and adjacent concrete which will come in contact with the concrete will be raised to a temperature above freezing prior to placement. Concrete temperature at time of placement will not be less than 50F or more than 90F. The subgrade surface will be uniformly moist when the concrete is placed. Moisture will be applied without forming pools of water. The concrete will be deposited on the grade so as to require as little rehandling as possible. Free fall of concrete will not exceed 5 feet. Necessary hand spreading will be done with shovels. Rakes or vibrators will not be used for spreading concrete. Workmen will not be allowed in the freshly mixed concrete with boots or shoes coated with foreign substances. The concrete will be consolidated against and along the faces of all forms by vibrators. Vibrators will not come in contact with a joint assembly, the grade, or a side form. The vibrator will not be operated longer than 10 seconds in any one location. All concrete material which falls on or is worked into the surface of a completed slab will be removed immediately. H.Test Specimens: The Contractor will furnish concrete from the mixture for making test specimens. I.Placement of Reinforcement and Dowel Bar Assemblies: The reinforcement will be free from dried concrete, dirt, oil, paint, grease, mill scale, and rust which could impair bond with the concrete. Epoxy coated dowel bars and tie bars will meet the requirements of Section 480.3 A. The reinforcement will be positioned on approved supports in advance of the concrete placement. No hand placement will be allowed. Automatic dowel bar inserters will not be allowed. The use of an automatic tie bar inserter mounted at the back of the paving pan will only be allowed on the vertical edge of longitudinal construction joints. The Concrete will be consolidated around the tie bar. The use of an automatic tie bar inserter will not be allowed on sawed longitudinal joints. 380 Page 227Tie bars will be held in the specified position parallel to the slab surface and perpendicular to the centerline by a supporting device. Tie bars or tie bar baskets will be securely staked to the roadbed and will hold the bar at the correct spacing, alignment, and elevation. Tie bars will be tied to at least one stake or supporting device. Tie bars will not require supports if inserted into the side of the pavement during slip form paving of the longitudinal construction joint operation. Failure to acquire the correct tie bar locations or position in the construction joint will require the bars to be corrected and a change made to the operation which may include drilling and epoxying bars or other methods as approved by the engineer. The final position of each tie bar will be within the following tolerances: Vertical Placement: ±T/6 for any part of the tie bar (T = slab thickness) Transverse Placement (side shift): ±3 inches when measured perpendicular to the longitudinal joint line If the tie bar does not meet the requirements and tolerances specified, corrective action will be performed at the Contractor’s expense to the satisfaction of the Engineer. Dowel bar assemblies will be installed where specified. Anchor pins for the dowel bar assemblies will be installed as detailed in the plans. Dowel bar assemblies will be fabricated in single units for the appropriate lane prior to being placed on the subgrade. After the dowel bar assembly is staked and prior to concrete installation, it is the Contractor’s option to cut and bend spacer wires that pass through the contraction joint. The free ends of the epoxy coated dowel bars [minimum of 1/2 of the dowel length plus 2 inches] will be given a thin uniform coating of form oil or multipurpose grease. This coating will be applied within two hours of being covered by concrete. In lieu of this manual coating, dowel bar assemblies may be pre-coated by dipping the complete assembly in a bond breaker meeting the requirements of Section 1010 . Dowel bar assemblies will be pre-coated on projects which have quantities of Portland cement concrete pavement of 50,000 square yards or greater. Pre-coated dowel bar assemblies must be free of foreign materials at the time of placement. Dowel bars will be placed parallel to the subgrade and parallel to the centerline of the pavement as specified in the plans. The final position of each dowel bar will be within the following tolerances: Vertical Placement: ±1/8 inch for any part of the dowel bar Transverse Placement (side shift): ±1/2 inch when measured parallel to the longitudinal joint line If the dowel bar does not meet the requirements and tolerances specified, corrective action will be performed at the Contractor’s expense to the satisfaction of the Engineer. 380 Page 228The Contractor will accurately mark the location of doweled contraction joints to assure accurate placement of the weakened plane of the joint during subsequent operations. The marks must be within 1 inch of the center of the dowel bars as placed. Reinforcement for continuously reinforced concrete slabs will be supported on chairs and the entire slab poured in one operation. The chairs meeting the requirements of Section 480 will hold the reinforcement in position without displacement during concrete placement. In addition to other inspection methods for reinforcement and dowel bar assemblies, the Department may use a Ground Penetrating Radar (GPR) to verify reinforcement and dowel bar locations in the hardened concrete. The GPR may be used any time prior to the Acceptance of Field Work being issued. All costs related to corrective measures, including but not limited to concrete removal or cutting of reinforcement, price deducts, and delays to the project schedule will be the responsibility of the Contractor. J.Final Strike-Off, Consolidation, and Finishing: 1.Sequence: The sequence of operations will be the strike-off and consolidation, floating and removal of laitance, straight edging, and final surface finish. The addition of water to the surface of the concrete to assist in finishing operations will not be permitted. In isolated areas where extreme conditions exist, the Engineer may determine the addition of water would be beneficial if applied with an approved fog sprayer. Concrete will be finished before initial set has occurred. Concrete not finished before initial set has begun will be wasted. Retempering of concrete will not be allowed. Concrete will not be mixed and placed unless natural light is sufficient for finishing operations. The Contractor will remove and replace concrete placed that is not workable or able to be finished properly. The concrete will be struck off, consolidated, and finished, so the surface of the pavement conforms to the cross section and elevation specified. The Contractor will consolidate the concrete in a manner that results in a dense homogenous mass without segregation, holes, voids, or layers. Concrete shoulders will not be constructed above or more than 1/8 inch lower than adjacent concrete pavement. 2.Finishing at Joints: The concrete adjacent to joints will be placed without voids or segregation against the joint material, under and around all load transfer devices, joint assembly units, and other features designed to extend into the pavement. Concrete adjacent to joints will be mechanically vibrated as per Section 380.3 G. 3.Machine Finishing: Vibrators meeting the requirements of Section 380.3 B.5 will be used for full width vibration of concrete paving slabs. Immediately after placement, the concrete will be struck off and screeded by an approved finishing machine. The machine will go over each area of pavement as many times and at the intervals necessary to produce a surface of uniform texture, to provide proper 380 Page 229consolidation, and to provide a dense homogenous mixture free of segregation, holes, voids, and layers. The Contractor will be responsible to remove and replace pavement that is not properly consolidated or contains segregation, holes, voids, and layers. Excessive finishing over a given area will be avoided. The top of the forms will be kept clean by an effective cleaning device attached to the machine. The travel of the machine on the forms will be maintained true without lift, wobbling, or other variation affecting the precision finish. During the first pass of the finishing machine, a ridge of concrete will be maintained ahead of the front screed for its entire length. The finishing machine will be operated with a continuous forward movement. All operations of mixing, delivering, spreading, and vibrating concrete will be coordinated to provide uniform progress and minimize the stopping and starting of the paver. Except in an emergency, no tractive force will be applied to the machine, except that which is controlled from the machine. 4.Hand Finishing: Hand finishing methods will not be permitted except when narrow widths or irregular areas that cannot be finished with mechanical equipment are encountered. In the event of mechanical equipment breakdown, the concrete already deposited on the grade will be hand finished, and additional concrete placement will be terminated. Hand finishing will be done in a manner that produces an acceptable finished surface. 5.Floating: Long handled floats will be used to smooth and fill open-textured areas in the pavement. The use of long-handled floats will be kept to a minimum and will not be used to float the entire surface of the pavement. Care will be taken so the crown is not worked out of the pavement during the operation. Excess water and laitance will be removed from the surface of the pavement by a straightedge 10 feet or more in length. Successive drags will be lapped 1/2 the length of the straightedge. 6.Final Finish: Before the concrete has attained its initial set, the surface will be given a final finish with a carpet drag drawn over the surface in a longitudinal direction. The drag will be mounted on a bridge and will be sized so that a strip of the carpet at approximately 2 feet wide is in contact with the pavement surface while the drag is operated. The condition of the drag will be maintained so the resultant surface is of uniform appearance with corrugations approximately 1/16 inch in depth. Drags will be maintained clean and free of encrusted mortar. Drags that cannot be cleaned will be discarded and replaced. 380 Page 230The carpet will meet the following requirements: Facing Material ....................................................... Molded polyethylene pile face Blade Length ............................................................................. 7/8 inch, ±1/8 inch Total Fabric Weight ..................................... 70 ounces per square yard minimum The backing will be of a strong, durable material, not subject to rot, which is adequately bonded to the facing. Plain jointed concrete pavement will be either longitudinally or transversely tined as specified in the plans. Continuously reinforced concrete pavement will be longitudinally tined. Tining depth and spacing will be determined according to SD 418. Brooming may be used on irregular areas in lieu of the carpet drag and tine finish. The broom will be drawn transversely across the pavement with adjacent strokes slightly overlapping. Brooming will be uniform in appearance and will produce grooves approximately 1/16 inch deep. Texturing will be completed while the concrete surface can be broomed without being torn or unduly roughened by the operation. The finished surface will be free from rough and porous areas, irregularities, and depressions resulting from improper handling of the broom. a.Transverse Tining: Immediately following the carpet drag, the surface of the concrete pavement will be given a transverse metal-tine finish with a separate self-propelled mechanical device. The metal-tine finish will provide a groove width of 1/8 inch and a groove depth of 6/32 inch ± 2/32 inch. The spacing between the individual tines will meet the following: Inches (ten foot tining rake) 2-5/16, 2-15/16, 1-1/4, 2-7/16, 2-1/16, 1-1/4, 13/16, 1, 1-5/16, 1-1/8, 2-5/16 2-1/2, 2-7/8, 2-3/4, 1-1/8, 2-3/4, 2-1/8, 1-15/16, 13/16, 7/8, 2-5/8, 3-1/16 3-1/16, 7/8, 9/16, 9/16, 1-5/8, 2-3/8, 1, 1-1/4, 1-9/16, 2-15/16, 1-1/8 1-15/16, 2-3/16, 2, 2-13/16, 1, 2-11/16, 13/16, 1-7/8, 9/16, 2-5/16, 1-7/8 2-1/2, 1-5/16, 3-3/16, 1-3/8, 15/16, 7/8, 1-5/8, 9/16, 1-3/4, 2-7/8, 3 1-5/8, 1-5/8, 7/8, 9/16, 5/8, 2-13/16, 1-5/8, 2-7/16, 13/16, 1-1/4, 11/16 2-3/4, 2-5/16, 1-1/8 Successive passes of the tining will not overlap. Each location, where transverse joint saw cuts are to be made, will be protected from tining by covering with a metal strip from 4 inches to 6 inches or by other methods that produce acceptable results. Brooming may be used on irregular areas in lieu of the carpet drag and tine finish. The broom will be drawn transversely across the pavement with adjacent strokes slightly overlapping. 380 Page 231Brooming will be uniform in appearance and will produce grooves 1/16 inch deep. Texturing will be completed while the concrete surface can be broomed without being torn or unduly roughened by the operation. The finished surface will be free from rough and porous areas, irregularities, and depressions resulting from improper handling of the broom. b.Longitudinal Tining: Immediately following the carpet drag, the surface of the concrete pavement will be given a longitudinal metal-tine finish with a wire broom or comb attached to a separate self-propelled mechanical device. Transverse joints will not be protected from longitudinal tining; the tining will be continuous across the joints. The slab will not be tined within 3 inches of the edge of the slab, centerline, or rumblestrip. The longitudinal tining equipment will have the ability to be raised and lowered and will have vertical and horizontal controls to ensure straight grooves that are parallel to the longitudinal joint. The tine bar will have a single row of tines and will provide a groove width of 1/8 inch ±1/64 inch and a groove depth of 6/32 inch ± 2/32 inch. The spacing between the individual tines will be uniformly spaced at 3/4 inch intervals. 7.Edging at Forms and Joints: After the final finish, and while the concrete is still plastic, the edges of the pavement along each side of the slab, and on each side of transverse construction joints, will be worked with an approved tool and rounded to the specified radius. Edging will be permitted along longitudinal construction joints provided the radius does not exceed 1/4 inch. A well-defined and continuous radius will be produced and a smooth, dense mortar finish obtained. The surface of the slab will not be unduly disturbed by tilting of the tool during use. Any tool marks appearing on the slab adjacent to the joints will be eliminated by brooming, belting, or burlap dragging the surface without disturbing the rounding of the corner of the slab. Where preformed expansion joint filler is used, the Contractor will remove all concrete on top of the preformed expansion joint filler. All joints will be tested with a 10 foot straightedge before the concrete has set and correction made if one side of the joint is higher than the other or if they are higher or lower than the adjacent slabs. K.Protection of Concrete: For the protection of the pavement surface, the Contractor will have available covering materials, including but not limited to, insulating blankets, curing blankets, and plastic sheeting. The Contractor will maintain the concrete surface temperature above 35F until the concrete has attained a compressive strength of at least 1,500 psi. In addition, when the air temperature is forecasted to be below 32F for more than 4 hours, the Contractor will cover the concrete surface with the covering material. This protection will be in addition 380 Page 232to one of the curing methods specified in Section 380.3 M. The Contractor will remove and replace concrete damaged by cold weather at the expense of the Contractor. The pavement will not be opened to traffic until meeting the requirements of Section 380.3 Q. When rain appears imminent, paving operations will stop, and the unhardened concrete will be covered with the protective covering. Pavement not properly protected from weather will be subject to corrective action as determined by the Engineer. The Contractor will protect the concrete pavement and its appurtenances against all traffic. This will include watchmen to direct traffic and the erection and maintenance of warning signs, lights, pavement bridges, crossovers, etc. Crossovers will not be permitted until the concrete is at least 24 hours old. Any damaged or defective pavement will be repaired or removed and replaced as directed. When pavement must be removed and replaced, the Engineer will determine the dimensions of the pavement to be removed. L.Joints: Curing membrane damaged or protective cover removed during the sawing operation will be repaired or replaced by the Contractor as directed by the Engineer at no cost to the Department. 1.Longitudinal Sawed Joints: Deformed steel tie bars will be placed perpendicular to the longitudinal joints by approved methods. Tie bars will not be painted or coated with asphalt or other material or enclosed in tubes or sleeves. Longitudinal sawed joints will be cut to the dimensions specified. Suitable guidelines or devices will be used to assure cutting the joint to a true line. The sawed joint will not require reapplication of curing compound. The joint will be sealed as required in Section 380.3 P. Sawing of the longitudinal joint will commence as soon as the concrete has hardened sufficiently to permit sawing without raveling. All joints will be sawed to the specified depth as shown on the plans before uncontrolled shrinkage cracking occurs. Repair or correction of uncontrolled cracks will be as directed by the Engineer and at the expense of the Contractor. 2.Longitudinal Construction Joints: When adjacent lanes of pavement are constructed separately, a keyway will be formed along the construction joint. The keyway may be omitted at the Contractor's option if the longitudinal joint is tied with deformed steel tie bars. When deformed steel tie bars are required, they may be bent at right angles, with a minimum inside bend radius of 1-7/8 inch, for the first lane constructed and straightened into final position before the concrete of the adjacent lane is placed. Tie bars damaged during the straightening process will be replaced by drilling and epoxy installation at the Contractor’s expense. The longitudinal construction joint will be sawed shortly after the end of the curing period and will be sealed as required in Section 380.3 P. 380 Page 233When adjacent lanes of pavement are constructed separately, epoxy-coated deformed steel tie bars of specified length, size, spacing, and material will be placed across the longitudinal construction joint to tie the lanes together. The epoxy-coated tie bars installed in drilled holes along the vertical edge of the first lane placed, will be installed in accordance with Section 380.3 C.1 with an epoxy resin adhesive conforming to Section 380.2 L and will meet or exceed the minimum pull strength requirement of 8,200 pounds. The Contractor will load test 5% of the first 500 tie bars that are drilled and epoxied in place. No further installation will be allowed until the initial 5% testing has been completed and approval to continue installation has been given by the Engineer. Testing will be required for 0.5% of the bars installed after the initial 500. For each bar that fails to pass the minimum requirements, two more bars selected by the Engineer will be tested. Each bar that fails to meet the minimum load requirement will be reinstalled and retested. The equipment and method used for testing will meet the requirements of ASTM E488. All tests will be performed within 72 hours of installation. The tie bars will be installed and approved before concrete is placed in the adjacent lane. 3.Transverse Contraction Joints: Transverse contraction joints will be created by sawing. The initial saw cut will commence when the concrete has hardened sufficiently to permit sawing without raveling. If required, the widening cut will not commence until completion of the concrete cure period. Joints will be sawed before uncontrolled shrinkage cracking takes place. If necessary, the initial sawing operations will be performed both day and night, regardless of weather conditions. The initial sawed joint will not require reapplication of curing compound. If an early entry saw is used, the cut may remain approximately 1 inch from the edges of the concrete slab to control spalling at the edge. Unless specified otherwise, the early entry saw cut will be to a minimum depth of 1.0 inch. If an early entry saw is used, the Contractor will complete the initial saw cut on all joints where a crack has not developed for the entire width and to the required depth before the end of the 72 hour curing period. The Engineer will not require the Contractor to complete the saw cut to the final required depth at joint locations where the early entry saw cut resulted in the concrete pavement cracking, as determined by the Engineer. The early entry saw will not induce micro cracking along the saw cut. The Contractor will repair damaged areas resulting from incorrect early entry sawing practices. 4.Random Cracks: The sawing of a joint will be omitted if a crack occurs within 3 inches of either side of the joint location prior to the time of sawing. Sawing will be discontinued when a crack develops ahead of the saw. Any procedure which results in premature and uncontrolled cracking will be revised immediately by adjusting the sequence of cutting the joints or the time interval involved between the placing of the concrete or removal of curing media and the cutting of joints. Longitudinal random cracks penetrating the full depth of the pavement will be repaired to the satisfaction of the Engineer. The method of repair will be approved by the Engineer. The methods will include, but are not limited to, cross-stitching, epoxy injection, routed and sealed, or removal and replacement. Cross stitching and epoxy injection repair methods will not be allowed for pavement panels cracked into more than two pieces or pavement panels where the random crack is diagonal in orientation (approximately 45° from the centerline or transverse joint). 380 Page 234Repair or correction of uncontrolled or random cracks will be as directed by the Engineer and at the expense of the Contractor. If an uncontrolled crack develops within 6 feet of the contraction joint, a minimum of 6 feet of pavement removal and replacement will be required. Removal and replacement of the pavement will be done at the Contractor's expense. If cracking occurs on both sides of the joint, the dowel bar assembly and a minimum of 3 feet of pavement each side of the joint will be removed and replaced. Removal and replacement of the pavement will be done at the Contractor's expense. If an uncontrolled crack develops on one side of the contraction joint in the mid panel area between 6 feet from the joint and the midpoint of the panel, the entire panel will be replaced on that side of the joint within the lane containing the cracking. Removal and replacement of the pavement will be done at the Contractor's expense. No section of pavement less than 6 feet in length will be allowed to remain in place. The Department will provide drawings and specification of repair procedures to the Contractor. If extreme conditions exist which make it impractical to prevent erratic cracking by early sawing, the contraction joint groove will be formed in a manner approved by the Engineer prior to initial set of the concrete. 5.Transverse Construction Joints: Transverse construction joints will be made at the end of each day’s run and where an interruption is of duration long enough that the concrete is no longer plastic and cannot be vibrated. If the Contractor constructs the transverse construction joint in the plastic concrete, the Contractor will construct the joint either at the contraction joint or a minimum of 5 feet from the nearest contraction joint in accordance with the details in the plans. With this method, the Contractor will have supplemental hand vibrators immediately available to provide satisfactory consolidation at joints. Paving in the area of a transverse construction joint will not be permitted for 12 hours after installation. If the Contractor constructs the transverse construction joint in hardened concrete, the Contractor must construct the joint as a contraction joint in accordance with the details in the plans. With this method, the Contractor will install epoxy-coated steel bars in drilled holes as detailed in the plans and in accordance with Section 380.3 C.1 utilizing an epoxy resin adhesive conforming to Section 380.2 L. M.Curing : Immediately after the finishing operations have been completed and marring of the concrete will not occur, the entire surface, and exposed edges of the pavement, will be properly cured. The concrete will not be left exposed for more than 1/2 hour between stages of curing or during the curing period. Curing will be maintained for at least 72 hours after concrete placement. One of the following curing methods will be used: 1.Curing Blankets and White Polyethylene Sheeting Method: The surface of the concrete pavement and both pavement edges will be covered with curing blankets. The mats will be thoroughly saturated with water and placed with the wettest side down. 380 Page 235Immediately after placement, the curing blankets will be covered with white polyethylene sheeting placed in accordance with Section 380.3 M.3. Combination burlap-polyethylene sheeting may be substituted for the layer of curing blanket and the polyethylene sheeting with the Engineer’s approval. The curing blankets will be kept moist by periodic applications of water. 2.Impervious Membrane Method: The entire surface of the pavement will be sprayed uniformly with white pigmented curing compound immediately after the finishing of the surface. If the pavement is cured initially with curing blankets, the impervious membrane will be applied immediately upon removal of the curing blankets. The curing compound will not be applied during or immediately after rainfall. Curing compound will be applied under pressure by approved self-propelled mechanical sprayers. The curing compound may be applied in one or two applications. If applied in two applications, the second will be applied within 30 minutes after the first. The Contractor will apply curing compound at the minimum application rate of 1 gallon per 150 square feet for carpet drag or broom finished surfaces and 1 gallon per 125 square feet for metal tined finished surfaces. The sprayer equipment will be equipped with a tank agitator and will be fully atomizing. The spray fog will be protected from the wind by a shield. During application the compound will be thoroughly mixed and continuously agitated by mechanical means. Hand spraying of odd width or shapes and concrete surfaces exposed by form removal will be permitted. Curing compound will not be applied to the inside faces of joints to be sealed, unless the compound is completely removed by subsequent sawing operations. Curing membrane damaged or protective cover removed on the surface of the pavement during the sawing operation will be repaired or replaced by the Contractor as directed by the Engineer at no cost to the Department. Should the film become damaged within the curing period, the damaged portions will be repaired immediately with additional compound. The sides of the exposed slab will be protected with a curing treatment equal to that provided for the surface. 3.White Opaque Polyethylene Sheeting Method : The top surface and sides of the pavement will be entirely covered with polyethylene sheeting. The units used will be lapped at least 18 inches. The sheeting will be placed and weighted down to maintain intimate contact with the surface covered. The sheeting will be sized so each unit as laid will extend beyond the edges of the slab at least twice the thickness of the pavement. In cold weather the substitution of dark sheeting for white sheeting will be permitted. N.Removing Forms: Forms will not be removed until concrete has set for at least 12 hours, except for auxiliary forms used temporarily in widened areas. Forms will be removed without damaging the pavement. After the forms have been removed, the exposed sides of the slab 380 Page 236will be cured by one of the methods indicated above, unless the forms are left in place for more than 72 hours. O.Surface Test: The pavement surface will be checked for deviations using either a 10 foot straightedge or a profilograph/profiler (when specified). When the use of a profilograph/profiler is specified, the 10 foot straightedge check may also be required in locations determined by the Engineer.

1.10Foot Straightedge : The pavement surface will be tested with a 10 foot straightedge. The

permissible longitudinal and transverse surface deviation will be 1/8 inch in 10 feet. The permissible longitudinal and transverse surface deviation for pavement used in rest areas, weigh stations, ramp entrances, shoulders, and other similar areas will be 1/4 inch in 10 feet. The permissible transverse surface deviation on the outer 6 inches of the edge of pavement will be 1/4 inch under a 10 foot straightedge except where the edge will become a longitudinal crown joint. This test should not be performed within 3 feet of a rumble strip. Areas where the surface deviation exceeds the permissible deviation will be subject to the following at the discretion of the Engineer. Grind down to an elevation where the area or spot will be within the permissible deviation. Accept affected area without corrective action with price reduction as determined by the Engineer under the provisions of Section 5.3. Satisfactorily remove and replace deficient area. The Contractor will accomplish corrective grinding with specially prepared circular diamond blades mounted on a horizontal shaft. The Contractor will day light corrective grinding to the outside edge of the pavement. The Contractor will repair and replace joint sealant damaged by corrective grinding as directed by the Engineer and at no additional cost to the Department. The Contractor will not leave ground areas smooth or polished. The Contractor will ensure ground areas have a uniform texture equal in roughness to the surrounding unground concrete. When limestone is used as the coarse aggregate in the pavement and the current average daily traffic

(ADT)shown on the plans is greater than 1500, the Contractor will reestablish the tining with a

mechanical tining machine in all areas where the corrective grinding exceeds 50 feet measured longitudinally along the centerline of the road. The Contractor will remove and replace all joint sealant within the area where tining is replaced. The Contractor will replace all permanent pavement markings damaged, destroyed, or removed during corrective grinding at no additional cost to the Department. 2.Profilograph/Profiler: When the profilograph or profiler is specified, the following provisions will apply. a.Operations: The profilograph/profiler will be operated at the manufacturer’s recommended speed. Each wheel path will be tested per driving lane. The profilogram 380 Page 237(trace) will be marked and labeled at the beginning and end of each trace, equation, and 500 foot marker. Each profilogram will be completely labeled to show the project, stationing, lane, wheel path, date tested, and the operator’s name. Tests will be run no sooner than the day after paving. Results will be furnished to the Engineer within 2 working days after testing and again within 2 working days after corrections are made. Curing membrane damaged or protective cover removed during the testing operation will be repaired or replaced by the Contractor as directed by the Engineer at no cost to the Department. b.Evaluation: The profilogram will be furnished to the Department and become the property of the Department. Evaluation consists of determining the profile index to the nearest 0.05 inch per mile by measuring and summing scallops that appear outside a zero width blanking band. The average profile index will be determined from the two wheel paths in each driving lane. Individual bumps will be evaluated using a 0.3 inch bump template. The average of the two profile indexes per lane will be rounded to the nearest 0.1 inch. The Department will spot check or retest areas it desires, with a Department owned and operated profilograph or profiler. If a discrepancy between the profilograms exist, the cause of the discrepancy will be determined and the area re-run when ordered by the Engineer. c.Requirements: The pavement will conform to the following profile index requirements: 1)Pavement on tangent alignment and pavement on horizontal curves having a centerline radius of 600 feet or more and pavement within their respective superelevation transitions will not exceed an average profile index of 35.0 inches per mile. 2)Areas excluded from profile testing will be shoulders, transitions, area within 50 feet of existing pavement and bridges, existing curb and gutter sections, ramps, pavements on horizontal curves having a centerline radius less than 600 feet and their respective superelevation transitions. Pavement sections not subject to profile testing will meet the 10 foot straight edge test requirements in Section 380.3 O.1. The Contractor will accomplish corrective grinding with specially prepared circular diamond blades mounted on a horizontal shaft. The Contractor will day light corrective grinding to the outside edge of the pavement. The Contractor will repair and replace joint sealant damaged by corrective grinding as directed by the Engineer and at no additional cost to the Department. The Contractor will not leave ground areas smooth or polished. The Contractor will ensure ground areas have a uniform texture equal in roughness to the surrounding unground concrete. When limestone is used as the coarse aggregate in the pavement and the current ADT shown on the plans is greater than 1500, the Contractor will reestablish the tining with a mechanical tining machine in all areas where the corrective grinding 380 Page 238exceeds 50 feet measured longitudinally along the centerline of the road. The Contractor will remove and replace all joint sealant within the area where tining is replaced. The Contractor will replace all permanent pavement markings damaged, destroyed, or removed during corrective grinding at no additional cost to the Department. d.Pavement, with profile smoothness values from 35.1 to 40.0 inches per mile in any 0.1 mile section with bumps in excess of 0.3 inches, may be ground and corrected to a profile value of 35.0 inches per mile or less and receive 100.0% pay. This will require that the 0.1 mile section be reprofiled by the Contractor. e.Pavement, with an average profile index from greater than 40.1 inches per mile in any 0.1 mile section, will be subject to one of the following at the Contractor’s option. 1)Correct by grinding to a value of 35.0 inches per mile or less. 2)Remove and replace deficient areas. f.Individual bumps in excess of 0.3 inches will be subject to one of the following at the option of the Engineer: 1)Satisfactorily correct the deficient area by grinding with equipment meeting the requirements of Section 380.3 0.2.c.2 . 2)Bumps less than 1/4 inch in 10 feet may be accepted without correction. 3)Remove and replace deficient areas. g.Coring for pavement thickness measurement will be performed after all corrective action has been completed by the Contractor. h.Incentive Payment: Incentive payments will be made based on the chart below: Profile Index (inches per mile)Price Adjustment % of Contract Unit Price 10.0 or less 104.7 10.1 to 15.0 103.5 15.1 to 20.0 102.4 20.1 to 25.0 101.2 25.1 to 35.0 100.0 35.1 to 40.0 97.7 40.1 and greater grind*1 *1 Pavement at 40.1 and greater will be corrected (ground or removed and replaced) to a value of 35.0 or less in any 0.1-mile section. Incentive payments cannot be improved due to grinding regardless of the average profile index. 380 Page 239The adjustments in the unit price will apply to the total area of the 0.1 mile-long section. The area will be computed using the total lane width (12 feet or less) and the total length of the section (0.1 mile or less if it is the segment at the end of the project or at the end of a paving section adjacent to an exception). P.Sealing Joints : Joints will be sealed with hot-poured elastic joint sealer or low modulus silicone sealant as specified. Joints will be sealed immediately after completion of the curing period, before the pavement is opened to traffic. Joint grooves with spalls greater than 1/2 inch in depth will be patched with an approved epoxy resin mortar in accordance with Section 390.2 C. All loose concrete will be removed from the spalled area and the spalled surface will be thoroughly cleaned. After cleaning, the spalled surface will be primed and an epoxy resin mortar of troweling consistency will be placed in the spalled area and finished as the original pavement surface. The epoxy binder components will be proportioned and mixed as recommended by the manufacturer. After the epoxy binder is thoroughly mixed, dry silica sand will be blended into the mixture to give an epoxy resin mortar of trowelable consistency. After the epoxy resin mortar has cured, the forming material will be carefully removed. The finished joint will have vertical faces and the joint width will be maintained. Patching of spalls will be done only within the temperature range recommended in AASHTO M 235, for the class of epoxy used. Joints to be sealed will be thoroughly clean and dry. All materials such as old sealant, oil, asphalt, curing compound, paint, rust, and other foreign materials will be completely removed. Cleaning will be accomplished by abrasive blasting and other tools as necessary. Joints to be sealed with silicone sealant will be abrasive blasted utilizing a mechanical device that holds the abrasive blaster at the appropriate angle and distance from the joint to ensure proper cleaning. The device will have a mechanism attached that will correctly guide the device in the joint. Just prior to sealing, each joint will be blown out using a jet of compressed air, at a working pressure of not less than 90 psi, to remove all traces of dust. Air compressors used for cleaning joints will be equipped with traps capable of removing all free water and oil from the compressed air. Joint sealer application will not be permitted when the air or pavement temperature near the joint is less than 40F or is 40F and falling. The sealant will be applied without spilling on the exposed surface. Sealant on the surface of the concrete pavement will be removed immediately and the pavement surface cleaned. Failure of the joint material in either adhesion or cohesion will be cause for rejection. Repair will be at the expense of the Contractor. Shoulder joints between Portland cement concrete pavement and asphalt concrete shoulders will be sealed in accordance with Section 320.3 K. 380 Page 2401.Hot-Poured Elastic Joint Sealer: Hot-poured elastic joint sealer will be stirred during heating so that localized overheating does not occur. All joints will be sealed with an approved pressure sealing device, equipped with a nozzle inserted into the joint, so sealing material will be forced from the bottom of the joint to the top. 2.Silicone Sealant: Silicone sealant will be applied with a mechanical device equipped with a nozzle or spout shaped to fit into the joint. The joint sealant will be applied under pressure from the inside of the joint to remove entrapped air and ensure good joint contact. Backer rod will be installed to the proper depth to produce the width and depth of sealant specified. The sealant surface will be tooled to produce a slightly concave surface below the pavement surface. Tooling will be accomplished before a skin forms on the sealant surface. The use of water, soap, or oil as a tooling aid will not be permitted. 3.Seasonal Limitations: Silicone sealing operations will only be permitted between May 1 and October 15, inclusive, unless the Contractor has received written permission from the Region Engineer to continue sealing later than October 15. Silicone sealing operations will only be permitted when the air and pavement surface temperatures are 40°F or greater and rising. Without approval from the Engineer to continue silicone sealing operations after the October 15 seasonal limitation, the Contractor will only perform the initial cut at all joints. Beginning no sooner than May 1 of the following year the Contractor will widen the joints, install the backer rod, and seal joint with silicone according to Section 380.3 P. All costs related to the sealing seasonal limitations including additional labor, materials, equipment, traffic control, mobilization, and incidentals will be at the expense of the Contractor. Q.Application of Live Load : The pavement will not be opened to traffic until the concrete has attained a compressive strength of 2,500 psi. The pavement will be cleaned prior to opening to traffic. When concrete is placed adjoining a previously constructed pavement, lightweight finishing equipment including working platforms, tining, and curing equipment may be operated on the existing concrete 48 hours after the concrete was placed or the concrete has attained a compressive strength of 2,000 psi. Paving machines, mechanical spreaders, and other heavy equipment will not be operated on the existing pavement until the concrete has attained a compressive strength of 2,000 psi. When operating on previously constructed lanes, measures will be taken to protect the previously constructed lane from damage and becoming marred by the equipment. Damage and random cracks will be repaired or replaced by the Contractor at the Contractor's expense. The concrete must obtain a minimum compressive strength of 4,000 psi at 28 days regardless of the strength the concrete pavement was opened to traffic. 380 Page 241R.Tolerance in Pavement Thickness : The pavement thickness will be determined by average caliper measurement of cores tested in accordance with AASHTO T 148. Cores will be sampled in accordance with AASHTO T 24. Cores may be taken in areas believed to be deficient in thickness. Pavement deficiencies verified by these core measurements will be considered under the provisions of Section 5.3. These core measurements will not be used to determine pavement thickness as set forth in the following: For establishing an adjusted unit price for pavement, units are to be considered separately. One random core location will be determined by the Engineer for each of the units as described in Table

1.Additional cores, if needed, within the unit will be sampled at the interval for additional cores in

Table 1. The sizes of units taken from Table 1 are determined as follows. (For concrete shoulders, see Section 380.3 R.10.) 1.Width: The width of the pavement represented will be the pavement surface between adjacent longitudinal construction joints; between a longitudinal construction joint and the pavement edge; or between two pavement edges where the entire width is poured in one operation. 2.Length: The length of the unit is that corresponding to the width shown in Table 1. TABLE 1 Width of Pavement to be Represented by CoresLength of UnitIntervals for Additional Cores Up to and including 15 feet 1,500 feet 450 feet over 15 feet thru 30 feet 1,000 feet 300 feet 30 feet thru 42 feet 750 feet 225 feet over 42 feet 500 feet 150 feet The remaining fractional unit length in feet will be represented by cores in one of the following manners: a.If the fractional part of the unit length is 50% or less of the specified unit length from Table 1, either the fractional part is considered as a separate unit, or the fractional part will be added to the previous unit when possible. The intervals for the additional cores should equal approximately 30% of the total length. b.If the fractional part of the unit length is greater than 50% of the specified unit length from Table 1, it will be considered as a separate unit, and intervals for the cores should equal approximately 30% of the fractional unit length. Length measurements will start at the end of the pavement bearing the smaller station number. 3.Ramps, Gore Areas, Acceleration Lanes, and Deceleration Lanes: Each ramp, consisting of the ramp, gore area, and acceleration lane or deceleration lane will be considered separate from the mainline pavement, following the limits in Table 1 for the ramp areas. 380 Page 2424.Irregular Areas: Irregular areas such as intersections, entrances, crossovers, etc., may be considered as a separate unit or may be included as part of an adjacent unit. 5.Lane Tapers: Lane tapers will be included as part of the length of a unit shown in Table 1. To determine the width for Table 1, use the maximum width at the start or end of the taper. 6.Sampling: One core will be taken at random by the Department in each unit. 7.Measurements: When the measurement of the core from the unit is not more than 0.20 inch from the plan thickness, the core measurement will represent the unit. When the measurement of the core from a unit is deficient by more than 0.20 inch and not more than 1.00 inch from the plan thickness, two additional cores, at intervals specified in Table 1 for the width of pavement represented, will be taken. Random offsets will be used for the additional cores. The average thickness of the 3 cores will be used as the average thickness for that unit. When the measurement of any core is deficient by more than 1.00 inch, the following will apply: a.Additional cores will be taken at not less than 25 foot intervals parallel to the centerline in each direction from the affected location until, in each direction, a core is found which is not deficient by more than 0.20 inches. The point at which the pavement is deficient by exactly 0.20 inches will be found by assuming a straight line relationship between the cores. The deficient area will be defined by the point that is deficient by more than 1.00 inch to the points on each side within 0.20 inches of the specified depth. The deficient area will be removed and replaced at no cost to the Department. b.After the deficient area has been isolated, additional core(s) must be taken to represent the remaining portion of the unit. c.A final core will be taken to represent the repaired area. 8.Averaging: Measurements of cores will be averaged for a unit and the thickness will be reported to the nearest 0.01 inch. Measurements of cores that are in excess of the specified pavement thickness by more than 0.20 inch will be considered as the specified thickness plus 0.20 inch. Location of cores will not be a factor in determining average thickness of a unit. 380 Page 2439.Payment: Payment for units will be in accordance with Table 2. Table 2 Portland Cement Concrete Pavement Deficiency in Thickness Determined by Cores From ThroughProportional Part of Contract Price allowed 0.00 inch 0.20 inch 100% 0.21 inch 0.30 inch 80% 0.31 inch 0.40 inch 72% 0.41 inch 0.50 inch 68% 0.51 inch 0.70 inch 57% 0.71 inch 1.00 inch 50% 10.Concrete Shoulders : The foregoing provisions for tolerance in pavement thickness will apply to Portland cement concrete shoulders with the following exceptions: a.Each shoulder will be cored separately. b.The unit length will be 2,000 feet. The last unit on each shoulder will be the appropriate length plus the fractional part of that length in feet remaining. c.Wherever in the foregoing 0.20 inch is mentioned, substitute 0.30 inch. d.When the measurement of the core from a unit is deficient by more than 0.30 inch and not more than 1.00 inch from the plan thickness, two additional cores will be sampled at intervals of 600 feet and used in the average thickness for that unit. e.Payment for units will be in accordance with Table 3. Table 3 Portland Cement Concrete Shoulders Deficiency in Thickness Determined by Cores From ThroughProportional Part of Contract Price allowed 0.00 inch 0.30 inch 100 % 0.31 inch 0.40 inch 80 % 0.41 inch 0.50 inch 72 % 0.51 inch 0.60 inch 68 % 0.61 inch 0.80 inch 57 % 0.81 inch 1.00 inch 50 %

380.4METHOD OF MEASUREMENT

A.Portland Cement Concrete Pavement, Shoulders, and Miscellaneous Pavement: These items will be measured to the nearest 0.1 square yard. Pavement which is removed or for which no payment will be made, will not be measured. Area computations will be as set forth in Section 9.1. When an item for miscellaneous PCC pavement is provided in the contract, the areas of concrete pavement to be measured under this item will be described on the plans. 380 Page 244B.Dowel Bar Assemblies: Dowel bar assemblies will be measured by the actual number of bars furnished and installed. C.Insert Steel Bar in PCC Pavement: Insert steel bar in PCC pavement will be measured by the actual number of steel bars furnished and installed.

380.5BASIS OF PAYMENT

A.Portland Cement Concrete Pavement, Shoulders, and Miscellaneous Pavement: These items will be paid for at the contract unit price per square yard or the adjusted unit price as set forth in Section 380.3 R. Payment will be full compensation for furnishing all materials (including reinforcing steel), labor, equipment, and all incidentals necessary. Payment will also be full compensation for trimming and water used to moisten the subgrade ahead of the paver, curing the concrete, sawing, and sealing joints and all costs involved in the furnishing, operating, and calibration of the profilograph/profiler. The amount bid on these items will be based on the specified amount of cement per cubic yard. If a cement factor is not shown on the plans, the amount bid will be based on 600 pounds per cubic yard for pavement, shoulders and pavement miscellaneous. B.Dowel Bar Assemblies: Dowel bar assemblies will be paid for at the contract unit price per each dowel bar. Payment will be full compensation for labor, materials, equipment, and all incidentals necessary to furnish and install the assemblies. C.Insert Steel Bar in PCC Pavement: Insert steel bar in PCC pavement will be paid for at the contract unit price per each steel bar. Payment will be full compensation for labor, materials, equipment, and all incidentals necessary to furnish and install the steel bar. 390 Page 245390 CONCRETE SPALL REPAIR

390.1DESCRIPTION

This work consists of removal of sealant from transverse contraction joints, repair of spalled areas, sawing, cleaning, and resealing joints.

390.2MATERIALS

A.Bonding Mortar for Concrete Patches: 1.Cement: Cement will conform to Section 750. 2.Water: Water will conform to Section 790. 3.Sand: Sand will conform to Section 810.1 . 4.Proportioning: Bonding mortar will be mixed in the following proportions by volume: 2 parts Portland cement. 1 part sand. Mix with only enough water to form a thick creamy consistency. B.Concrete Patch Material: Concrete patching material will be one of the following and approved by the Department’s Concrete Engineer: 1.Type I: A packaged, dry, rapid-hardening mortar conforming to the requirements of ASTM C 928, Type R-3 containing no chloride ions. A magnesium or phosphate based product will not be allowed. If extender aggregate is added, the extender aggregate will conform to Section 820. 2.Type II: A packaged, dry, rapid-hardening concrete conforming to the requirements of ASTM C 928, Type R-3 containing no chloride ions. A magnesium or phosphate base product will not be allowed. If extender aggregate is added, the extender aggregate will conform to Section 820. 3.Type III: A dry, bagged air entrained concrete patching material (known as 3U58M) meeting the following requirements: a.Materials: 1)Cement: Cement will conform to Section 750. 2)Coarse Aggregate: Coarse aggregate will conform to Section 820 except the gradation will conform to the gradation specified in Section 390.2 B.3.b . 3)Fine Aggregate: Fine aggregate will conform to Section 800 for Class M concrete except the gradation will conform to the gradation specified in Section 390.2 B.3.b .

Source: South Dakota Standard Specifications for Roads and Bridges, 2025 Edition. Pages 216–244 of 596.

← Previous

370 COLD IN PLACE RECYCLING (CIR) OF ASPHALT CONCRETE

390 CONCRETE SPALL REPAIR