5-01Cement Concrete Pavement Rehabilitation

5-01 Cement Concrete Pavement Rehabilitation

5-01.1 Description

This Work consists of rehabilitating or replacing section(s) of cement concrete pavement in accordance with these Specifications and in conformity with the lines, grades, thicknesses, and typical cross-sections shown in the Plans or established by the Engineer.

5-01.2 Materials

Materials shall meet the following requirements of the following sections: Cement 9-01 Fine Aggregate 9-03 Coarse Aggregate 9-03 Combined Aggregate 9-03 Joint Filler 9-04.1 Joint Sealants 9-04.2 Closed Cell Foam Backer Rod 9-04.2(3)A Dowel Bars 9-07.5 Tie Bars 9-07.6 Concrete Patching Material, Grout, and Mortar 9-20 .1 Curing Materials and Admixtures 9-23 Water 9-25 Epoxy Resins (bonding agents) 9-26 Parting Compound shall be a curing compound, grease or other substance approved by the Engineer. Dowel Bar Retrofit Dowel bar expansion caps shall be tight fitting and made of non-metallic material, which will allow for ¼ inch of movement at each end of the bar. Chairs for supporting the dowel bar shall be epoxy coated according to Section 9-07.3 or made from non-metallic material. The foam insert shall be closed cell foam faced with poster board material or plastic faced material on each side commonly referred to as foam core board by office suppliers. The foam insert shall be capable of remaining in a vertical position and tight to all edges during the placement of the concrete patching material. Caulking filler used for sealing the transverse joint at the bottom and sides of the slot shall be a silicone caulk.

5-01.3 Construction Requirements

5-01.3(1) Vacant

5-01.3(1)A Mix Designs

The Contractor shall use either concrete patching materials or cement concrete for the rehabilitation of cement concrete pavement. Concrete patching materials shall be used for spall repair and dowel bar retrofitting and cement concrete shall be used for concrete panel replacement.

5-01.3(1)A1 Concrete Patching Materials

5-01 Cement Concrete Pavement Rehabilitation2. Submittals and Mix Approval – The Contractor shall use the Manufacturer’s

recommended proportions for the mix design to be submitted to the Engineer for the concrete patching material. The Contractor’s submittal shall include the mix proportions of the prepackaged concrete patching material, water, aggregate extender, and the proposed sources for all aggregates. If not approved for use on the QPL, submit test data indicating compliance with Section 9-20.1 .

5-01.3(1)A2 Cement Concrete for Panel Replacement

Cement concrete for panel replacement shall meet the requirements of Sections 5-05.3(1) and 5-05.3(2) and be air entrained with a design air content of 5.5 percent. Cement concrete for panel replacement may use rapid hardening hydraulic cement meeting the requirements of Section 9-01.2(2) . Rapid hardening hydraulic cement will be considered a cementitious material for the purpose of calculating the water/cementitious materials ratio and the minimum cementitious materials requirement.

5-01.3(1)B Equipment for Panel Replacement

In addition to Sections 5-05.3(3)A , 5-05.3(3)B , 5-05.3(3)D , and 5-05.3(3)E the following shall apply:

5-01.3(2) Material Acceptance

5-01.3(2)A Concrete Patching Material

Acceptance shall be based on field verification of the prepackaged patching material, and whether the amount of added water and aggregate extender complies with the mix design.

5-01.3(2)B Cement Concrete for Panel Replacement

The point of acceptance will be at the discharge of the placement system. The concrete producer shall provide a certificate of compliance for each truckload of concrete in accordance with Section 6-02.3(5)B . Acceptance testing for compliance of air content and 28-day compressive strength shall be conducted from samples obtained according to FOP for WAQTC TM 2. Air content shall be determined by conducting FOP for AASHTO T 152. Compressive Strength shall be determined by FOP for AASHTO T 22 and FOP for AASHTO R 100. The lower Specification limit for air content shall be 3 percent, and the upper Specification limit for air content shall be 7 percent. The lower Specification limit for compressive strength shall be 4,000 psi. The Contractor shall provide cure boxes in accordance with Section 6-02.3(5)H , and protect concrete cylinders in cure boxes from excessive vibration and shock waves during the curing period in accordance with Section 6-02.3(6)D .

5-01.3(2)B1 Conformance to Mix Design

Acceptance of cement concrete pavement for panel replacement shall be in accordance with Section 5-01.3(2)B . The cement, coarse, and fine aggregate weights shall be within the tolerances of the mix design in accordance with Section 5-05.3(1) . M 41-10 Page 5-3 Cement Concrete Pavement Rehabilitation 5-015-01.3(2)B2 Rejection of Concrete Rejection by the Contractor: The Contractor may, prior to sampling, elect to remove defective material and replace it with new material at no expense to the Contracting Agency. The replacement material will be sampled, tested and evaluated for acceptance. Rejection without Testing: The Engineer may reject loads that appear defective prior to placement. Material rejected before placement shall not be incorporated into the pavement. No payment will be made for the rejected materials unless the Contractor requests that the rejected material be tested. If the Contractor elects to have the rejected materials tested, a sample will be taken and both the air content and strength shall be tested by WSDOT. Payment for rejected material will be based on the results of the one sample, which was taken and tested. If the rejected material fails either test, no payment will be made for the rejected material and in addition, the cost of sampling and testing, at the rate of $250.00 per sample shall be borne by the Contractor. If the rejected material passes both tests the mix will be compensated for at actual invoice cost and the cost of the sampling and testing will borne by the Contracting Agency.

5-01.3(3) Vacant

5-01.3(4) Replace Cement Concrete Panel

5-01.3(4)A General

Curing, cold weather Work, concrete pavement construction in adjacent lanes, and protection of pavement shall meet the requirements of Section 5-05.3(13) through Section 5-05.3(15) . The Contractor, at no cost to the Contracting Agency, shall repair all damage to existing pavement caused by the Contractor’s operations.

5-01.3(4)B Sawing and Dimensional Requirements

Concrete slabs to be replaced as shown in the Plans or staked by the Engineer shall be at least 6.0 feet long and full width of an existing pavement panel. The portion of the panel to remain in place shall have a minimum dimension of 6 feet in length and full panel width; otherwise the entire panel shall be removed and replaced. There shall be no new joints closer than 3 feet to an existing transverse joint or crack. A vertical full depth saw cut is required along all longitudinal joints and at transverse locations. An additional vertical full depth relief saw cut located 6 to 18 inches from and parallel to the initial longitudinal and transverse saw cut locations is also required unless the Engineer allows an alternate relief saw cut location. Removal of existing cement concrete pavement shall not cause damage to adjacent slabs that are to remain in place. Overcutting adjacent concrete pavement that will not be replaced under the Contract is allowed to the extent necessary to make full depth perimeter saw cuts along longitudinal joints and at transverse locations. Overcutting is not allowed on relief saw cuts. In areas that will be ground, slab replacements shall be performed prior to pavement grinding. Side forms shall meet the requirements of Section 5-05.3(7)B whenever a sawed full depth vertical face cannot be maintained.

5-01.3(4)C Dowel Bars and Tie Bars

For the half of a dowel bar or tie bar placed in fresh concrete, comply with the requirements of Section 5-05 . For the half of a dowel bar or tie bar placed in hardened concrete, comply with the Standard Plans and the following. After drilling, secure dowel bars and tie bars into the existing pavement with either an epoxy bonding agent Type I or IV as specified in Section 9-26.1 , or a grout Type 2 for non- shrink applications as specified in Section 9-20.3 . Page 5-4 M 41-10

5-01 Cement Concrete Pavement RehabilitationDowel bars shall be placed at the mid depth of the concrete slab, centered over the

transverse joint, and parallel to the centerline and to the Roadway surface, within the tolerances within the table below. Dowel bars may be adjusted to avoid contact with existing dowel bars in the transverse joint at approach slabs or existing panels provided the adjusted dowel bars meet the tolerances below. Tie bars shall be placed at the mid depth of the concrete slab, centered over the joint, perpendicular to centerline, and parallel to the Roadway surface, within the tolerances in the table below. The horizontal position of tie bars may be adjusted to avoid contact with existing tie bars in the longitudinal joint where panel replacement takes place, provided the adjusted tie bars meet the tolerances below. Placement Tolerances Dowel Bars Tie Bars Vertical: Center of Bar to Center of Slab Depth± 1.00 inch max ± 1.00 inch max Dowel Bar Centered Over the Transverse Joint ± 1.00 inch max N/A Tie Bar Centered Over the Longitudinal Joint N/A ± 1.00 inch max Parallel to Centerline Over the Length of the Dowel Bar± 0.50 inch max N/A Perpendicular to Longitudinal Joint Over the Length of the Tie BarN/A ± 1.00 inch max Parallel to Roadway Surface Over the Length of the Bar± 0.50 inch max ± 1.00 inch max Dowel bars and tie bars shall be placed according to the Standard Plan when multiple panels are placed. Panels shall be cast separately from the bridge approach slab. Dowel bars to be drilled into existing concrete or at a new transverse contraction joint shall have a parting compound, such as curing compound, grease, or other Engineer accepted equal, applied to them prior to placement. Clean the drilled holes in accordance with the epoxy or grout manufacturer’s instructions. Holes shall be clean and dry at the time of placing the epoxy, or grout and tie bars. Completely fill the void between the tie bar and the outer limits of the drilled hole with epoxy or grout. Use retention rings to prevent leakage of the epoxy or grout and support the tie bar to prevent movement until the epoxy or grout has cured the minimum time recommended by the manufacturer.

5-01.3(4)D Foundation Preparation

The Contractor shall smooth the surfacing below the removed panel and compact it to the satisfaction of the Engineer. Crushed surfacing base course, or hot mix asphalt may be needed to bring the surfacing to grade prior to placing the new concrete. If the material under the removed panel is uncompactable and the Engineer requires it, the Contractor shall excavate the Subgrade 2 feet, place a soil stabilization construction geotextile meeting the requirements of Section 9-33 , and backfill with crushed surfacing base course. This Work may include:

5-01.3(4)F Joints

All transverse and longitudinal joints in panels that have been replaced shall be sawed and sealed in accordance with Section 5-05.3(8) . The Contractor may use a hand pushed single blade saw for sawing joints.

5-01.3(4)G Cracked Panels

Replacement panels that crack shall be repaired as specified in Section 5-05.3(22) at no cost to the Contracting Agency. When repairing replacement panels that have cracked, epoxy-coated dowel bars meeting the requirements of Section 9-07.5(1) may be substituted for the corrosion resistant dowel bars specified.

5-01.3(4)H Opening to Traffic

Opening to traffic shall meet the requirements of Section 5-05.3(17) .

5-01.3(5) Partial Depth Spall Repair

Removal of the existing pavement shall not damage pavement to be left in place. Existing pavement that is to remain that has been damaged shall be repaired at the Contractor’s expense. If jackhammers are used for removing pavement, they shall not weigh more than 30 pounds, and chipping hammers shall not weigh more than 15 pounds. All power driven hand tools used for the removal of pavement shall be operated at angles less than 45 degrees as measured from the surface of the pavement to the tool. The patch limits shall extend beyond the spalled area a minimum of 3 inches. Repair areas shall be kept square, rectangular or circular. Repair areas that are within 12 inches of another repair area shall be combined. A vertical cut shall be made to a minimum depth of 2 inches around the area using a saw or core drill to be patched as marked by the Engineer. The Contractor shall remove material within the perimeter of the saw cut to a depth of 2 inches, or to sound concrete as determined by the Engineer. The surface patch area shall be sand blasted and all loose material removed. All sandblasting residue shall be removed. Spall repair shall not be done in areas where dowel bars are encountered. When a partial depth repair is placed directly against an adjacent longitudinal joint, a bond-breaking material such as polyethylene film, roofing paper, or other material as approved by the Engineer shall be placed between the existing concrete and the area to be patched. Patches that abut working transverse joints or cracks require placement of a compressible insert. The new joint or crack shall be formed to the same width as the existing joint or crack. The compressible joint material shall be placed into the existing joint 1 inch below the depth of repair. The compressible insert shall extend at least 3 inches beyond each end of the patch boundaries. Page 5-6 M 41-10

5-01 Cement Concrete Pavement RehabilitationPatches that abut the lane/shoulder joint require placement of a formed edge, along the

slab edge, even with the surface. The patching material shall be mixed, placed, consolidated, finished, and cured according to manufacturer’s recommendations. Slab/patch interfaces that will not receive pavement grinding shall be sealed (painted) with a 1:1 cement-water grout along the patch perimeter. The Contractor shall saw and seal all joints in partial depth spall repairs accordance with Section 5-03.3(6)C . Opening to traffic shall meet the requirements of Section 5-05.3(17) .

5-01.3(6) Dowel Bar Retrofit

Dowel bars shall be installed in the existing concrete pavement joints and transverse cracks where shown in the Plans or as marked by the Engineer. Saw cut slots will be required in the pavement to place the center of the dowel at mid- depth in the concrete slab. The completed slot shall provide a level, secure surface for the feet of the dowel bar chairs. Slots that intersect longitudinal or random cracks shall not be retrofitted. When gang saws are used, slots that are not used shall be cleaned and sealed with either Type I or IV epoxy resin as specified in Section 9-26 . The transverse joint between cement concrete pavement and a Bridge approach slab shall not be retrofitted. Saw cut slots shall be prepared such that dowel bars can be placed at the mid depth of the concrete slab, centered over the transverse joint, and parallel to the centerline and to the Roadway surface. Placement Tolerances for Dowel Bars

5-01.3(7) Sealing Existing Concrete Random Cracks

Sealing existing random cracks in cement concrete pavement shall be in accordance with Section 5-03 .

5-01.3(8) Sealing Existing Transverse and Longitudinal Joint

Sealing existing transverse and longitudinal joints in cement concrete pavement shall be in accordance with Section 5-03 .

5-01.3(9) Cement Concrete Pavement Grinding

Pavement grinding shall begin within 10 working days of placing dowel bar retrofit patching materials. Once the grinding operation has started it shall be continuous until completed. If new cement concrete pavement, in accordance with Section 5-05 , is to be placed next to rehabilitated cement concrete pavement, grind one pass along the edge of the rehabilitated cement concrete pavement adjacent to where the new cement concrete pavement is to be placed before the new cement concrete pavement is placed. The pavement shall be ground in a longitudinal direction beginning and ending at lines normal to the pavement centerline. Ninety-five percent of the surface area of the pavement to be ground shall have a minimum of ⅛ inch removed by grinding. Bridge decks, bridge approach slabs, and bridge overlay insets shall not be ground. The ground pavement shall be feathered to match the elevation of the above features.

5-01.3(9)A Surface Finish

The final surface texture shall be uniform in appearance with longitudinal corduroy type texture. The grooves shall be between 3/32 and 5/32 inches wide, and no deeper than 1/16 inch. The land area between the grooves shall be between 1/16 and ⅛ inches wide.

5-01.3(10) Pavement Smoothness

Pavement surface smoothness for cement concrete pavement grinding on this project will include International Roughness Index (IRI) testing. Ride quality will be evaluated using the Mean Roughness Index (MRI) calculated by averaging the IRI data for the left and right wheel path within the section. Smoothness Testing Equipment and Operator Certification Use an inertial profiler and operator that meet the requirements of Section 5-05.3(3)E . Surface Smoothness Operate the inertial profiler in accordance with AASHTO R 57. Collect two longitudinal traces, one in each wheel path. Collect the control profile at locations designated in Table 2 prior to pavement rehabilitation Work on the areas to be tested. Collect an acceptance profile at locations designated in Table 2 after completion of all cement concrete pavement grinding on the project. Profiles shall be collected in a continuous pass including areas excluded from pay adjustments. Provide notice to the Engineer a minimum of seven calendar days prior to testing. Page 5-8 M 41-10

5-01 Cement Concrete Pavement RehabilitationTable 2 Locations Requiring MRI Testing

Travel lanes where cement concrete grinding is shown in the plans Control profile Additional locations designated by the Engineer Control profile Travel lanes with completed cement concrete pavement grinding Acceptance profile Bridges, approach panels and 0.02 miles before and after bridges and approach panels and other excluded areas within lanes requiring testingControl and acceptance profile Ramps, Shoulders and Tapers Do not test Within 30 calendar days after the Contractor’s testing, the Engineer may perform verification testing. If the verification testing shows a difference in MRI greater than the 10 percent, the following resolution process will be followed:

5-01.3(11) Concrete Slurry and Grinding Residue

All concrete slurry and grinding residue shall be removed from the pavement surface on a continual basis immediately behind the grinding or cutting operations. Slurry shall not be allowed to drain into an area open to traffic, off of the paved surface, into drainage structures, water of the state, or wetlands. The Contractor shall collect the concrete slurry and grinding residue from the pavement surface and dispose of it in accordance with Section 2-03.3(7)C . The Contractor shall submit copies of all disposal tickets to the Engineer within 5 calendar days. Opening to traffic shall meet the requirements of Section 5-05.3(17) .

5-01.4 Measurement

Replacement cement concrete panels will be measured by the square yard, based on the actual width and length of the surface area placed. Retrofit dowel bars will be measured per each for the actual number of bars used in the completed Work. Cement concrete pavement grinding will be measured by the square yard, based on the actual width and length of area ground. Extra passes to meet the Specifications or overlaps will not be measured. Page 5-10 M 41-10

5-01 Cement Concrete Pavement Rehabilitation5-01.5 Payment

Payment will be made for each of the following Bid items that are included in the Proposal: “Replace Cement Concrete Panel”, per square yard. The unit Contract price per square yard shall be full payment for all costs to complete the Work as specified, including saw cutting full depth, removal and disposal of the existing panels off of the Contracting Agency’s Right of Way, preparing the surfacing below the new panel, provide, place and compact the crushed surfacing or hot mix asphalt, furnishing and placing polyethylene film or building paper, furnishing and placing the cement concrete, drilling the holes, providing and anchoring the dowel bars and tie bars, and for all incidentals required to complete the Work as specified. “Retrofit Dowel Bars”, per each. The unit Contract price per each shall be full payment for all costs to complete the Work as specified, including furnishing and installing parting compound, dowel bar expansion caps, caulking filler, foam core insert material, cement patch where pavement is removed for dowel bar retrofit and for all incidentals required to complete the Work as specified. “Partial Depth Spall Repair”, by force account as provided in Section 1-09.6 . To provide a common Proposal for all Bidders, the Contracting Agency has entered an amount in the Proposal to become a part of the total Bid by the Contractor. “Grinding Smoothness Compliance Adjustment”, by calculation. Grinding Smoothness Compliance Adjustments will be based on the requirements in A smoothness compliance adjustment will be calculated in the sum of minus $100 for each and every section of single traffic lane 0.01 mile in length and $1,000 for each and every section of single traffic lane 0.10 mile in length that does not meet the requirements in Section 5-01.3(10) after corrective Work. “Cement Concrete Pavement Grinding”, per square yard. The unit Contract price per square yard for “Cement Concrete Pavement Grinding”, when multiplied by the number of units measured, shall be full payment for all costs including additional pavement grinding and profiling to complete the Work as specified. “Replace Uncompactable Material”, by force account as provided in Section 1-09.6 . Payment for “Replace Uncompactable Material” will be by force account as provided in Section 1-09.6 and will be full payment for all work required to replace uncompactable material and provide base for the Concrete panel. This will include, but not be limited to, excavating the subgrade, placement of a soil stabilization construction geotextile, and backfilling with crushed surfacing base course, as well as the work detailed in items 1 through 5 noted in Section 5-01.3(4) . For the purpose of providing a common Proposal for Bidders, the Contracting Agency has entered an amount in the Proposal to become a part of the total Bid by the Contractor. All costs associated with the containment, collection and disposal of concrete slurry and grinding residue shall be included in the applicable concrete grinding or cutting items of Work. All costs associated with sawing and sealing existing cracks and sawing and sealing existing transverse and longitudinal joints shall be measured and paid for as provided in Section 5-03.