9-20Concrete Patching Material, Grout, and Mortar

9-20 Concrete Patching Material, Grout, and Mortar9-20 Concrete Patching Material, Grout, and Mortar

9-20.1 Patching Material for Cement Concrete Pavement

Concrete patching material will be prepackaged mortar extended with aggregate. The amount of aggregate for extension shall conform to the manufacturer’s recommendation. Patching mortar and patching mortar extended with aggregate shall contain cementitious material and conform to Sections 9-20.1(1) and 9-20.1(2) . The Manufacturer shall use the services of a laboratory that has an equipment calibration verification system and a technician training and evaluation process in accordance with AASHTO R 18 to perform all tests specified in Section 9-20.1 .

9-20.1(1) Patching Mortar

Patching mortar shall conform to the following requirements: Compressive Strength ASTM Test Method Specification at 3 hours C 39 Minimum 3,000 psi at 24 hours C 39 Minimum 5,000 psi Length Change at 28 days C 157 0.15 percent maximum Total Chloride Ion Content C 1218 1 lb/yd3 maximum Bond Strength at 24 hours C 882 (As modified by C 928, Section 9.5)Minimum 1,000 psi Scaling Resistance (at 25 cycles of freezing and thawing)C 672 (As modified by C 928, Section 9.4)1 lb/ft2 maximum

9-20.1(2) Patching Mortar Extended With Aggregate

Patching mortar extended with aggregate shall meet the following requirements: Compressive Strength ASTM Test Method Specification at 3 hours C 39 Minimum 3,000 psi at 24 hours C 39 Minimum 5,000 psi Length Change at 28 days C 157 0.15 percent maximum Bond Strength at 24 hours C 882 (As modified by ASTM C928, Section 9.5)Minimum 1,000 psi Scaling Resistance (at 25 cycles of freezing and thawing) C 672 2 Maximum Visual Rating Freeze thaw C 666 Maximum expansion 0.10% Minimum durability 90.0%

9-20.1(3) Aggregate

Aggregate used to extend the patching mortar shall meet the requirements of Section 9-03.1(4) and be AASHTO Grading No. 8. A Manufacturer’s Certificate of Compliance shall be required showing the aggregate source and the gradation. Mitigation for Alkali Silica Reaction (ASR) will not be required for the extender aggregate used for concrete patching material. M 41-10 Page 9-123 Concrete Patching Material, Grout, and Mortar 9-209-20.1(4) Water Water shall meet the requirements of Section 9-25.1 . The quantity of water shall be within the limits recommended by the manufacturer.

9-20.2 Patching Material for Concrete Structure Repair

Concrete patching material shall be a prepackaged mixture of portland or blended hydraulic cement, aggregate, and admixtures. Fly ash, ground granulated blast furnace slag and microsilica fume may be used. The concrete patching material may be shrinkage compensated. The concrete patching material shall also meet the following requirements: • Compressive strength of 6000 psi or higher at 28 days in accordance with AASHTO T 22 (ASTM C 39), unless noted otherwise • Bond strength of 250 psi or higher at 28 days or less in accordance with ASTM C 1583 or ICRI 210.3R • Shrinkage shall be 0.05 percent (500 microstrain) or lower at 28 days in accordance with AASHTO T 160 (ASTM C 157) as modified by ICRI 320.3R • Permeability shall be 2,000 coulombs or lower at 28 days in accordance with AASHTO T 277 (ASTM C 1202) • Freeze-thaw resistance shall have a durability factor of 90 percent or higher after a minimum of 300 cycles in accordance with AASHTO T 161 Procedure A (ASTM C 666) • Soluble chloride ion limits in Section 6-02.3(2) shall be satisfied

9-20.3 Grout

Grout is a mixture of Portland or blended hydraulic cement and water with or without aggregates and with or without admixtures. Grout may also contain fly ash and/or concrete admixtures. Grout may be a Contractor’s submitted mix design or a Manufacturer’s prepackaged grout product. All prepackaged grouts shall be used in accordance with the manufacturer’s recommendations, including but not limited to, shelf life, mixing, surface preparation, and curing. Where required, all 2-inch cube specimens fabricated in the field shall be made in accordance with WSDOT T 813. All 2-inch cube specimens fabricated in a laboratory shall be made in accordance with FOP for AASHTO T 106. All 2-inch cube specimens shall be tested in accordance with FOP for AASHTO T 106. When coarse aggregate is used, specimens shall be fabricated in accordance with FOP for AASHTO R 100 and tested in accordance with AASHTO T 22.

9-20.3(1) Grout Type 1 for Post-Tensioning Applications

Grout Type 1 shall be a Class C prepackaged material conforming to the requirements of the latest edition of PTI M55.1 Specification for Grouting of Post-Tensioned Structures.

9-20.3(2) Grout Type 2 for Nonshrink Applications

Grout Type 2 shall be a nonshrink, prepackaged material meeting the requirements of ASTM C1107. The minimum compressive strength shall be 4,000 psi at 7 days.

9-20.3(3) Grout Type 3 for Unconfined Applications

Grout Type 3 shall be a prepackaged material that does not include expansive admixtures meeting the following requirements: • Compressive strength shall be 4000 psi or higher at 28 days in accordance with AASHTO T 22 (ASTM C 39) for grout extended with coarse aggregate or AASHTO T 106 (ASTM C109) otherwise. Page 9-124 M 41-10

9-20 Concrete Patching Material, Grout, and Mortar• Bond strength shall meet one of the following:

ҽ250 psi or higher at 28 days or less in accordance with ASTM C1583. ҽ2000 psi or higher at 28 days or less in accordance with ASTM C882. The following modification to ASTM C882 is acceptable: use Type 3 Grout in lieu of epoxy resin base bonding system and freshly mixed portland-cement mortar in the procedure for testing Type II and V systems. • Drying shrinkage shall be 0.08 percent (800 microstrain) or lower at 28 days in accordance with AASHTO T 160 (ASTM C157). The following modification to AASHTO T 160 is acceptable: use a standard specimen size of 3 x 3 x 11-1/4 inches.

9-20.3(4) Grout Type 4 for Multipurpose Applications

Grout Type 4 shall be a multipurpose grout material for structural and nonstructural applications. The grout shall be produced using portland cement Type I/II. The water to cementitious material ratio shall not exceed 0.45 and water-reducing admixtures may be used. Multipurpose grout may be extended up to three parts fine aggregate to one part cement. The minimum compressive strength shall be 4,000 psi at 7 days. Substitution of fly ash for cement is allowed up to 20 percent.

9-20.4 Mortar

Mortar shall be material made from Portland or blended hydraulic cement, water, and fine aggregate.

9-20.4(1) Fine Aggregate for Mortar

Fine Aggregate for mortar shall conform to the requirements of Section 9-03.2 .

9-20.4(2) Mortar Type 1 for Concrete Surface Finish

Mortar Type 1 for concrete surface finishing shall be either prepackaged or a Contractor- recommended blend of portland cement Type I/II and fine aggregate conforming to Section 9-20.4(1) . If the Class 1 concrete surface finishing mortar is a Contractor- recommended blend, it shall conform to the sand-to-cement ratios specified in Section 6-02.3(14)A .

9-20.4(3) Mortar Type 2 for Masonry Applications

Mortar Type 2 for masonry shall be either prepackaged or a Contractor-recommended blend of portland cement Type I/II and fine aggregate conforming to Section 9-20.4(1) .

9-20.4(4) Mortar Type 3 for Concrete Repair

Mortar Type 3 shall be a prepackaged material that does not include expansive admixtures. Aggregate extension and mixing procedures shall be in accordance with the manufacturer’s recommendation. The minimum compressive strength shall be 4,000 psi at 7 days.

9-20.5 Bridge Deck Repair Material

Bridge deck repair material shall be either an ultra-low viscosity, two-part liquid, polyurethane-hybrid polymer concrete, or a pre-packaged cement based repair mortar, conforming to the following requirements: