Wisconsin WisDOT Standard Specifications (within FDM) — Section 415

Effective with the December 2018 Letting 146 2019 Standard Spec ifications Section 415 Concrete Pavement

415.1Description

(1)This section describes constru cting concrete pavement as well as approach slabs, alleys, and

pavement gaps.

415.2Materials

415.2.1 Concrete

(1)Furnish grade A, A2, A3, A-FA, A-S, A-S2, A-T, A-IS, A-IP, or A-IT, air-entrained concrete conforming

to 501 as modified for class I pavement concrete in 715 . Provide QMP for class I pavement concrete as specified in 715.

(2)Furnish high early strength conc rete under the HES bid items. The contractor may use special high

early strength concrete as specified for SHES concrete repair a nd replacement in 416.2 for concrete pavement placed in conjunction with the SHES repair and SHES re placement items for repair areas 300 feet long or longer.

(3)Maintain a uniform consistency in consecutive batches of concr ete. Use the following slumps for the

technique used: SLIP-FORMED NOT SLIP-FORMED 2.5 inches or less 4 inches or less 415.2.2 Reinforcement

(1)Furnish steel reinforcement conforming to 505.2.4 . Furnish dowel bars and tie bars as the plans show

and conforming to 505.2.6 . 415.2.3 Expansion Joint Filler Revise 415.2.3(1) to include foam expansion joint materials. This change was implemented in ASP 6 effective with the December 2017 letting.

(1)Furnish expansion joint fille r conforming to AASHTO M153, AASHTO M213, or ASTM D8139 in

lengths equal to the pavement lane width and of the thickness and height the plans show. Where dowel bars are required, use fille r with factory-punched holes at the dowel bar locations and with a diameter not greater than 1/8 in ch larger than the nominal dowe l bar diameter. 415.2.4 Concrete Curing Compounds

(1)Furnish poly-alpha-methylstyr ene (PAM) liquid curing compound conforming to ASTM C309 , type 2,

class B as modified here in 415.2.4 and as modified for testing in 501.2.9 .

(2)Furnish curing compound with a resin consisting of 100 percent poly-alpha-methylstyrene and with, by

weight, 42 percent or mo re total solids. Modify ASTM C309 to ensure the following: - Loss of water in 24 hours does not exceed 0.15 kg/m2. - Loss of water in 72 hours does not exceed 0.40 kg/m2. - Reflectance in 72 hours is greater than or equal to 65 percen t. - The volatile organic compoun d (VOC) content does not exceed 3 50 g/L. 415.2.5 Concrete Pavement Gaps

(1)Use concrete of the same mix design used for the contiguous pa vement. If the engineer allows paving

through the gap, use a concret e mix design that will develop 25 00 psi opening strength in an engineer- approved maximum time. 415.2.6 Joint Filler

(1)Furnish a hot-poured elastic joint sealer according to ASTM D6690 type II.

415.3Construction

415.3.1 General

(1)Use handling, weighing, batching, mixing, and hauling equipmen t and procedures conforming to 501.

In addition proportion aggregates and cement for concrete pavement in batching plants by weight using semi-automatic or automatic batching plants.

(2)If using ready-mixed concrete, ensure production and uniform d elivery of at least 80 cubic yards per

hour to support two-lane slip-form operations and at least 40 cubic yards per hour for single-lane slip- form or hand placement operations.

Effective with the December 2018 Letting 147 2019 Standard Spec ifications 415.3.2 Concrete Placement and Finishing Equipment 415.3.2.1 Slip-Form Paver

(1)Use an engineer-approved, self- propelled slip-form paver capable of consolidating, screeding, and

float-finishing freshly placed c oncrete in one complete pass of the machine for the required thickness. Use machines equipped to interna lly vibrate the concrete for th e full width and depth placed in a single pass as required to produce a dense, homogeneous pavement. Equi p the slip-form paver with devices that accurately space and positio n required tie bars and that a llows for automatic or manual tie bar insertion.

(2)Ensure that paver vibration equipment is capable of producing the frequency and amplitude the paver

manufacturer recommends for the placement at hand. 415.3.2.2 Hand Vibrators

(1)Use hand-operated single spud int ernal vibrators capable of co nsolidating concrete pavement

adjacent to forms, joints, or fixtures. Ensure that vibrators p roduce a minimum of 7000 impulses per minute. 415.3.2.3 Screeds for Formed Pavement

(1)Use air-vibrated or mechanically-vibrated truss screeds designed for and capable o f striking off fixed-

form concrete pavement for the size of placement at hand. 415.3.2.4 Forms

(1)Use clean, straight, un-warped st eel forms with a vertical fac e as high or higher than the pavement

thickness minus 1 1/2 inches. E nsure that forms have side and b ase supports capable of supporting finishing equipment and are sufficiently strong to resist concrete pressure without bulging.

(2)The contractor may u se wood or plastic forms for forming fille ts, widened areas in intersections, curves

less than 100-foot radius, and in o ther engineer-approved locations. 415.3.2.5 Hand Finishing Tools

(1)Use aluminum, magnesium, or wooden hand finishing tools. Do no t use steel hand finishing tools.

415.3.2.6 Concrete Saws

(1)Use saws light enough to operat e on and capable of sawing new concrete with minimal raveling,

chipping, spalling, or otherwis e damaging the pavement. Ensure that saws have diamond blades with functioning blade guards and are equipped with guides or other devices to control cut alignment and depth. 415.3.3 Preparing the Foundation

(1)Prepare the base course as specified in 211.3.4 before placing concrete. Repair and re-compact

rutted or disturbed base resulting from hauling or paving operations. The engineer may suspend paving operations if the contract or fails to repair and maintain the base course in advance of the paving operation.

(2)Identify areas of yielding subgrade. The engineer may direct or allow EBS to correct subgrade

problems as specified in 301.3.5 . 415.3.4 Setting Forms

(1)Set forms to the required grade and alignment. Firmly support and anchor forms in a manner that

prevents movement during concre te placement. Ensure that forms are sufficiently tight to prevent loss of concrete either under or through the forms.

(2)Immediately before placing concrete recheck the foundation as well as the grade and alignment of the

forms. Ensure that the forms ar e not twisted. Make necessary co rrections to the forms and foundation before placing concrete. 415.3.5 Reinforcement

(1)Reinforce the concrete if and as the plans specify. Keep reinforcement clean, free of rust and scale,

and supported to prevent distorti on. Store reinforcement steel, received on the job, in engineer- approved storage and di stribute only as needed for placement.

(2)Protect epoxy coated steel from cumulative exposure to sunligh t for more than 2 months by covering

with an opaque engineer-approved ma terial. Clear plastic shrink wrap for dowel bar bars and dowel baskets is sufficient protection for up to 4 months exposure.

Effective with the December 2018 Letting 148 2019 Standard Spec ifications 415.3.6 Placing Concrete 415.3.6.1 General

(1)Unless the engineer allows otherwise, slip-form work that is 3 00 feet or more in length, a minimum of

10 feet in width or greater, and a constant width. Also use sli p-formed placement wherever practicable for other work unless the engineer directs or allows otherwise. In irregular areas or areas inaccessible to self-propelled slip-form paving equipment, construct the pav ement using fixed forms.

(2)Use machine methods to strike- off and consolidate the concrete . The contractor may, if the engineer

allows, use hand methods for areas with variable slab width, fo r strips or lanes of pavement uniformly less than 10 feet wide, for transition sections on curves or at other points with variable pavement crown, and for other areas where it is impracticable to use mac hine methods.

(3)Deposit concrete on the base c ourse continuously in a manner t hat minimizes segregation. Place to a

depth sufficiently above grade so, after consolidating and fini shing, the required slab thickness is obtained and the surface conforms to the specified grade and sl ope.

(4)Use two-lane placement for rural pavement unless project stagi ng dictates single-lane paving. Delay

placement of adjoining lanes unt il completed lanes are sufficie ntly cured to preclude damage to work already placed. Do not operate paving equipment on pavement not meeting the opening to service criteria specified in 415.3.15 .

(5)Shut down placement if paving tr ain equipment breaks down, fin ishing and curing operations are

delayed, or if the materials or w ork are nonconforming. Cover t he concrete at the unf inished end of the placement to maintain moisture d uring temporary shutdowns. Prov ide construction joints if interruptions are long enough for the concrete to develop its i nitial set.

(6)Check the surface of the newly placed concrete with a long-handled 10-foot or longer straightedge.

Overlap successive passes by about 1/2 the straightedge length. Cut down high areas. Fill depressions immediately with fres hly mixed concrete and strike off, consolidate, and refinish the concrete. Do not add water to cor rect surface deficiencies exce pt in emergency cases or with engineer authorization.

(7)Set castings and frames for manh oles, catch basins, inlets, an d other fixtures conforming to 611.3.3 .

Adjust to required alignment and grade while adjacent concrete is plastic. Hand vibrate concrete adjacent to fixtures to fill voids and openings between fixtures and support structures. Fill remaining voids beneath the base of these fixtures with an engineer-appro ved non-shrink grout before opening to traffic. 415.3.6.2 Slip-Formed Placement

(1)Coordinate the mixing, delivering, and spreading operations to provide uniform progress. Check and

adjust string lines, sensors, and other paver guidance equipmen t during paving to assure uninterrupted placement to t he plan alignment and grade.

(2)Advance the paving train at a s low uniform pace stopping and s tarting the paver as little as possible. If

it is necessary to stop the forw ard movement of the paver, stop vibrating and tamping immediately, and restart when forward motion resumes.

(3)Ensure that concrete is uniformly consolidated throughout its width and depth, free from honey

combed areas, and has a consistent void-free closed surface.

(4)Keep hand finishing efforts on the surface to a minimum to avo id over finishing. H and-float the surface

only as needed to produce a unifo rm surface and sharp corners. Do not use excess mortar to build up slab edges or round the slab corners.

(5)Measure edge slump according to CMM 8-70 . Maintain an edge slump, exclusive of edge rounding, no

greater than of 3/8 inch at free edges or 1/8 inch, where abutting other concrete. Correct excessive edge slump before concrete harde ns and adjust operations to red uce edge slump to an acceptable level. Tool pavement edges to a 1/4-inch radius ensuring that edges are smooth and true to line. 415.3.6.3 Formed Placement

(1)Deposit concrete as near a possible to its final location to minimize segregation. Consolidate uniformly

throughout the depth and systemati cally across the area of the placement to produce a dense, homogeneous pavement.

(2)Strike off with vibrating scr eeds unless the engineer directs or allows otherwise. Maintain a uniform

quantity of concrete in front of the screed sufficient to fill voids or low areas. Do not allow excessive concrete accumulation in front o f the screed, causing the concrete to surge under the screed, or produce ridges or waves in the surface. Do not make more than 2 passes of the vibr atory screed on a

Effective with the December 2018 Letting 149 2019 Standard Spec ifications given area of concrete. Coordinate forward movement of the screed with vibration frequency to optimize consolidation. Do not v ibrate the concrete with the sc reed in a stationary position.

(3)Augment vibrating screeds with internal vibration in front of the screed for placements over 5 inches

deep. Insert single spud hand vibrat ors vertically in a grid pa ttern just long enough to bring mortar to the surface. Ensure that areas visibly affected by successive vibrator insertions overlap by 2 - 3 inches. Do not drag spud vibrators through the concrete or move concrete laterally by vibration.

(4)Use single spud hand vibrators to consolidate the concrete adj acent to transverse construction joints

and along the full length of dowel basket assemblies. Vibrate t o a depth that consolidates the concrete above and below the dowel bars. Vibrate along the forms as requ ired to achieve a void-free formed edge. Do not allow vibrators to contact reinforcement, forms, o r the grade during vibration.

(5)Float the surface as needed to produce a uniform surface. Befo re the concrete's initial set, tool the

pavement edges and along each side of transverse isolation join ts, formed joints, transverse construction joints, and fixed fo rms to produce a true-to-line 1/4-inch radius with a smooth, dense mortar finish.

(6)Remove forms after the pavement has cured sufficiently to avoid damaging the concrete. The

contractor may remove individual forms sooner to saw transverse joints. Fill voids in the formed surface as soon as practicable a fter form removal using a well- mixed grout composed of one part cement and 3 parts fine aggregate. 415.3.7 Jointing 415.3.7.1 General

(1)Construct joints as and where the plans show perpendicular to the pavement surface. Use

construction joints as dictated by contractor operations to joi n together work at locations where the plans show no joints. Join new wor k to existing concrete paveme nt using tie bars epoxied into the existing pavement as specified in 416.3.3.2 or dowel bars epoxied into the existing pavement as specified in 416.3.4 . The contractor may use cast-in -place tie bars or dowel bars i n construction joints of pavement placed under the contract.

(2)Maintain the alignment of dowel bars, tie bars, and other rein forcing or embedments when placing

joints. Augment machine vibration with hand vibrators if necessary to ensure complete consolidation at joints.

(3)Test joints with a straightedge before the concrete sets. Corr ect if one side of the joint is higher than

the other or if higher or lowe r than adjacent slabs. Remove any concrete, mortar, or laitance resulting from paving operations before i t hardens. Remove concrete fins extending across isolation joints, doweled joints, and expansion joints after the concrete hardens .

(4)Saw joints in a single cut to the width and dept h the plans sh ow. Begin sawing as soon as the

concrete hardens sufficiently to prevent excessive raveling alo ng the saw cut and finish before conditions induce uncontrolled cracking. Provide artificial lig ht if sawing between sunset and sunrise.

(5)The contractor may saw the trans verse joints by the skip metho d, wherein every thir d joint is sawed as

soon as possible. Following this skip sawing, make the cuts of the remaining intermediate joints.

(6)The contractor may temporarily hand tool joints to reduce the the potential for early cracking. Ensure

that hand-tooled joints have a 1/ 4-inch radius and are smooth a nd true to line. Saw h and tooled joints to the plan depth as soon as practicable. 415.3.7.2 Longitudinal Joints

(1)If the plans do not show a specific location, construct parallel to the centerline along lane edges. On

two-lane pavements, construct a long the pavement centerline. On multilane pavements, construct along traffic and taper lane edges . Make joints perpendicular to the pavement surface. Do not deviate more than 1/2 inch in 10 feet from the required line. 415.3.7.3 Transverse Joints

(1)Extend transverse joints across the entire width of paving and through curb or median placed integrally

with pavement. When the pavement a buts existing pavement, curb and gutter, or median, construct transverse joints in locations matching existing joints or crac ks.

(2)Install dowel bars as follows:

- Within one inch of the planne d transverse location and depth. - Within 2 inches of the planned longitudinal location. - Parallel to the pavement surface and centerline within a tole rance of 1/2 inch in 18 inches.

Effective with the December 2018 Letting 150 2019 Standard Spec ifications (3) Hold dowel bars in the correct p osition and alignment using an engineer-approved device during construction. Do not allow bonded longitudinal bars or reinforc ement to extend across transverse expansion or contraction joints. The contractor need not cut do wel basket tie wires.

(4)If using a mechanical device to install dowel bars, conform to the following:

- Place and consolidate the pav ement to full depth before inserting the dowel bars. - Insert the dowel bars into the plastic concrete in front of the finishing beam or screed. - Ensure that the inst alling device consolid ates the concrete w ith no voids around the dowel bars. - Do not interrupt the forward movement of the finishing beam or screed while inserting the dowel bars. - Provide a positive method of marking the locations of the tra nsverse joints.

(5)Remove concrete directly abov e expansion joint filler, if nece ssary, by sawing the fu ll width of the filler

to remove concrete bridging the joint.

(6)Form a construction joint at the end of each day's run or when an interruption long enough for the

concrete to develop its initial set occurs by doing one of the following: - Set a header board to support dowel bars. Use production qual ity concrete, hand vibrated behind the header board, and protect protruding steel from anything that m ight damage the bars or weaken the bond. - Saw back the concrete full dep th to expose solid concrete the n drill and epoxy in dowel bars. 415.3.8 Surface Finishing 415.3.8.1 General

(1)Finish the pavement surface after straightedging, after excess moisture disappears, and while it is still

possible to produce a uniform striated surface texture. 415.3.8.2 Design Speed Less Than 40 MPH

(1)Provide an artificial turf drag surface finish. Use a seamless strip of artificial turf approximately full

pavement width and of sufficient length to provide approximatel y 2 feet of turf in contact with the pavement surface. Pull the drag with a device that allows contr ol of the time and rate of texturing. Operate the drag in a longitudinal direction parallel with the centerline to produce a straight finish. Weight the drag as necessary to m aintain contact with the pavem ent. Keep the drag cl ean and free of particles of hardened concrete.

(2)Where it is impracticable to apply a turf finish, apply a broo m finish.

(3)Restore pavement texture damaged by rain by re-dragging the co ncrete while still plastic.

415.3.8.3 Design Speed - 40 MPH and Higher 415.3.8.3.1 General

(1)Texture and tine freshly placed pavement as soon as practicabl e after floating. Texture with an

artificial turf drag as specified in 415.3.8.2 .

(2)Longitudinally tine with a self-propelled tining machine. Wher e using a tining machine is impracticable,

tine by hand. Produce uniformly deep grooves approximately 1/8 to 3/16 inch deep. Provide a finished surface free of tining defects. C omplete before tining tears or unduly roughens the concrete.

(3)For hand work, use longitudinal tining unless the engineer dir ects or allows otherwise.

(4)When paving next to existing pavement and for repair work, mat ch the existing tining direction whether

using machine or hand methods. The contractor may apply transve rse tining in locations where the engineer directs or allows. 415.3.8.3.2 Longitudinal Tining

(1)Use a tining machine with an automated horizontal and vertical alignment control system to ensure

that tining runs straight and par allel to the longitudinal axis of the pavement. Use a rake with individual 1/8-inch wide tines spaced unifo rmly 3/4 inches on center. Do not tine, but instead apply an artificial turf drag finish, within 2 inches of a longitudinal sawed joint . 415.3.8.3.3 Transverse Tining

(1)Use a rake with individual 1/8-inch wide tines spaced uniformly 5/8 inches on center. For machine

work, use a 10-foot rake drawn transversely across the full pav ement width without overlapping passes. 415.3.9 Stamping

(1)At the beginning of each day's r un and at the end of the job, stamp the contractor's name and the year

of pavement construction into t he pavement. Use 2-inch numbers for the year of construction.

Effective with the December 2018 Letting 151 2019 Standard Spec ifications 415.3.10 Surface Testing and Correction

(1)Test the pavement surface at engineer-selected locations with a 10-foot straightedge or other

engineer-specified device. The engi neer may direct the contract or to mark and grind down areas showing high spots greater than 1/8 inch but not exceeding 1/2 inch in 10 feet. Gri nd until there are no deviations greater than 1/8 inch when retested with the straigh tedge. The engineer may direct the contractor to remove and replace areas with deviations greater than 1/2 inch in 10 feet.

(2)Perform grinding as specified in 415.3.11 .

(3)If the engineer directs removal, remove an area at least 6 fee t long and extending across the full lane

width. Also remove adjacent pav ement less than 6 feet from a tr ansverse joint. 415.3.11 Pavement Grinding

(1)Perform grinding with an engineer-approved device specifically designed for pavement grinding having

diamond blades uniformly spaced with at least 50 blades per lin ear foot. Perform additional light grinding as necessary to provide a neat rectangular area of uni form appearance. Perform the grinding parallel with the centerline. Do not use a bush hammer or other impact device.

(2)Complete required grinding or replacement before determining t he pavement thickness.

415.3.12 Curing Concrete 415.3.12.1 General

(1)Maintain adequate moisture throughout the concrete mass to sup port hydration until the concrete

develops sufficient strength to open it to service. Except as a llowed under 415.3.12.3 , apply curing compound as specified in 415.3.12.2 . Use PAM except, use curi ng compound conforming to 501.2.9 on pavement that will get an overlay under t he contract.

(2)If the contractor does not cure concrete as specified in this subsection, the engineer may suspend

concrete placement operations. 415.3.12.2 Impervious Coating Method

(1)After finishing operations, and as soon as the free water disa ppears, spray the concrete surface with a

uniform coating of curing compound. Seal moisture in the concre te by applying a continuous water- impermeable film on exposed concrete surfaces.

(2)Provide sufficient agitation while spraying to ensure uniform consistency and dispersion of pigment

within the curing compound during application.

(3)Apply the curing compound wit h an engineer-approved self-propelled mechanical power sprayer

whenever practicable. The contractor may use hand-operated spra ying equipment for the following: - Irregular, narrow, or variable width sections. - Re-coating applications or after form removal. - Special applications the engineer approves.

(4)For tined surfaces, apply the cu ring compound uniformly at or exceeding a minimum rate of one gallon

per 150 square feet. F or other surface finishes, apply the curi ng compound uniformly at or exceeding a minimum rate of one gallon per 200 square feet.

(5)If the curing compound coating is damaged within 72 hours afte r application, immediately recoat the

affected area. If removing forms within 72 hours after placing the concrete, coat newly exposed surfaces within 30 minutes after form removal. 415.3.12.3 Alternate Curing Methods

(1)If the contractor requests, the engineer ma y approve the use o f alternate materials or curing methods.

If the engineer requests, supply te chnical specifications, test results, or performance records to support the proposed alternative method.

(2)The engineer will approve delayed a pplication of curing compou nd if the contractor uses the

impervious sheeting method as specified in 502.3.8.1.2 to protect freshly placed concrete from rain damage, protect adjacent propert y from overspray damage, or to otherwise accommodate specific job conditions. Apply PAM curing compound immediately after removin g the impervious sheeting. 415.3.13 Cold Weather Concreting 415.3.13.1 General

(1)The contractor is responsible for the quality of the concrete placed in cold weathe r. Take precautions

necessary to prevent freezing of t he concrete until it has deve loped sufficient strength to open it to service. Remove and replace frozen or frost damaged concrete.

Effective with the December 2018 Letting 152 2019 Standard Spec ifications (2) Unless the engineer issues written permission to continue, suspend concreting operations if a descending air temperature in the shade and away from artificia l heat falls below 35 F. Do not resume concreting operations until an as cending air temperature in the shade and away from artificial heat reaches 30 F. The engineer may r equire the contractor to measur e the concrete temperature, at the point of placement, if the ambien t air temperature falls below 40 F. Maintain the temperature of the concrete at or above 50 F a t the point of placement.

(3)If necessary to maintain placem ent temperature, the contractor may heat the water, aggregates, or

both. Uniformly heat, with steam or by other means, aggregates frozen or containing frost. Accurately control the temperature of the mixing water as it is heated. Do not allow the temperature of either the mixing water or the aggregates to exceed 100 F when placed toge ther with the cement in the mixer. Control the temperature of the water and the aggregates so that the temperature of the concrete discharged from the mixer is between 50 and 80 F inclusive.

(4)Do not heat the cement, add salt or chemical admixtures to the concrete mix to prevent freezing, or

place concrete on a fr ozen base or subgrade. 415.3.13.2 Protective Covering

(1)Arrange to have available a sufficient quantity of material to provide thermal protection for concrete

that has yet to conform to the opening criteria specified in 415.3.15 . The contractor may provide clear, black, or white polyethylene sheeting conforming to the requirements, except for color and reflectance, specified in 501.2.9 . The engineer may allow other cu ring materials with suitable w ater resistance, strength, and insulating properties.

(2)If the national weather service forecast fo r the construction area predicts temperatures of less than 17

F within the next 24 hours, arrang e to have available a suffici ent quantity of straw or hay to protect concrete that has yet to conform to the opening criteria specif ied in 415.3.15 . If the engineer approves, the contractor may use other materials placed to the thickness necessary to provide the same insulating protection as the required thickness of loose, dry s traw or hay.

(3)At any time of the year, if the national weather service forec ast for the constructi on area predicts

freezing temperatures within the next 24 hours, or when freezing temperatures actually occur, provide the minimum level of thermal protection specified below for con crete that has yet to conform to the opening criteria specified in 415.3.15. PREDICTED OR ACTUAL AIR TEMPERATURE MINIMUM EQUIVALENT LEVEL O F PROTECTION 22 to <28 F single layer of polyethylene 17 to <22 F double layer of polyethylene <17 F 6" of loose, dry straw or hay between 2 layers of polyethylene

(4)Place protective material as soon as the concrete is finished and sets sufficiently to prevent excessive

surface marring. Maintain the protective material in place until the concrete conforms to the opening criteria specified in 415.3.15 . If necessary to remove the coveri ngs to saw joints or perform other required work, and if the engineer approves , the contractor may remove the covering for the minimum time required to complete that work. 415.3.14 Protecting Concrete

(1)Erect and maintain suitable barricades and, if necessary, prov ide personnel to keep traffic off the

newly constructed pavement until it is opened for service as sp ecified in 415.3.15 . Conform to 104.6 for methods of handling and facilitating traffic.

(2)Protect the pavement against bot h public traffic and construction activities. Repair or replace, as the

engineer directs, pavement damaged by traffic or otherwise dama ged before acceptance.

(3)Arrange to have available materials for protecting the unhardened concrete against rain damage. If

rain is imminent, cover unhardened concrete immediately with pl astic or other engineer-approved material secured along pavement edges. Provide drainage as requ ired to protect the work. 415.3.15 Opening to Service 415.3.15.1 General

(1)Maintain moisture, temperature , and physical protection for co ncrete until it develops sufficient

strength to open it to service . The engineer will use the same criteria to allow opening of non- pavement concrete to service as are used to allow opening of pa vement to traffic.

(2)The engineer will allow the contractor to open pavement to construction and public traffic when the

concrete attains a verified compressive strength of 3000 psi. Absent compressive strength information, the engineer may allow the contractor to open pavement after th e following minimum times, as adjusted for changes in the ambient air temperature on the proj ect:

Effective with the December 2018 Letting 153 2019 Standard Spec ifications APPLICATION EQUIVALENT CURING DAYS High early strength concrete 3 General purpose concrete (grades A, A2, and A3) 4 General purpose concrete (gr ades A-FA, A-IP, and A-IT) 5 General purpose concrete (grades A-S, A-S2, A-IS, and A-T) 7

(3)The equivalent curing day is based on a daily average ambient temperature of 60 F. The daily average

ambient temperature is the aver age of the high and low engineer -recorded temperatures on the project site for each day. If this daily average ambient temper ature falls below 60 F, accumulate equivalent curing days at a reduced rate. For a daily average ambient temperature of:

1.60 F or more; accumulate one equivalent curing day per cale ndar day.

2.40 to less than 60 F ; accumulate 0.6 equivalent curing day per calendar day.

3.Less than 40 F; accumulate 0.3 equivalent curing day per ca lendar day.

(4)The contractor may operate concrete saws and lightweight profi lers on concrete that does not conform

to these opening criteria. If t he engineer approves, the contractor may operate other necessary light equipment on concrete that does not conform to these opening cr iteria. The engineer may suspend or delay operations that injure the surface or otherwise damage the concrete. Clean the surface before allowing traffic of any kind on the pavement. 415.3.15.2 Opening Strength 415.3.15.2.1 General

(1)Determine opening strength and pr ovide the engineer with the information required to verify that

strength by one or a combination of the following methods:

1.Compressive strength testing of cylinders.

2.Maturity method.

3.Compressive strength testing of cores.

(2)The resulting opening strength, after engineer verification, will apply to concrete on the same project

conforming to the following criteria: - Of the same mix design as the test location. - Cured under similar or more desirable conditions. - Placed on or before the test location.

(3)If direct compressive strength test results and maturity data are not available, the engineer may

estimate compressive strength ba sed on test results of concrete of the same mix design placed contiguously under similar conditions on the same project. 415.3.15.2.2 Compressive Strength Testing of Cylinders

(1)Submit the compressive strength test results to the engineer f or verification. Compute the opening

strength as the average of compr essive strength test results fo r 2 cylinders. If the strength of a cylinder is less than 90 percent of the re quired strength , the engineer will reject the resulting average. Field cure cylinders under conditionss imilar to those prevailing for the pavement they represent. Fabricate cylinders according to AASHTO T 23 and test the cylinders according to AASHTO T22. 415.3.15.2.3 Compressive Str ength Testing of Cores

(1)Submit core test results to the engineer for verification. Det ermine opening strength from the

compressive strength of cores o btained and tested according to AASHTO T24. 415.3.15.2.4 Maturity Method

(1)Conform to the concrete maturity method requirements of 502.3.10.1.3.3 .

415.3.16 Tolerance in Pavement Thickness 415.3.16.1 General

(1)Construct the plan thickness or thicker. The department will a ccept pavement thickness based on the

results of department-performed magnetic pulse induction acceptance testing. The department may accept thickness of special units using alternate methods. 415.3.16.2 Pavement Units

(1)Divide the pavement into basic units 250 feet long, measured a long the pavement centerline. Treat

fractional units less than 250 feet but greater than or equal t o 100 feet long as whole basic units. Include a fractional unit less than 100 feet long as a part of a contiguous basic unit.

(2)The basic unit is one lane wide, measured from the pavemented ge to the adjacent longitudinal joint;

from one longitudinal joint to the next; or between pavemented ges if there is no longitudinal joint.

Effective with the December 2018 Letting 154 2019 Standard Spec ifications (3) Establish special units for ar eas of fillets, intersections, g aps, and other areas not included in basic units. Also establish special units for shoulders, ramps, and other long areas of constant cross-section less than 10 feet wide. Limit the size of special units to a ma ximum of 350 square yards. 415.3.16.3 Locating Test Plates

(1)Locate department-furnished tes t plates at two random locations, within each pavement unit according

to CMM 8-70.4.7.2. Do not place plates within 4 feet of a transverse or longitud inal joint containing steel. Plates may not be required for special units where the e ngineer employs alternate methods.

(2)Anchor test plates to the grade with a 16D common nail or othe r engineer-approved fastener.

Designate each plate location with a sequential number and determine the center of each plate to within 2 feet. Paint the location of the plate center along with the sequential number for each plate location on the hardened concrete.

(3)Within 5 business days after paving, enter the sequential number and associated position data into the

department's materials reporting system (MRS) software availabl e at: http://www.atwoodsystems.com/ 415.3.16.4 Acceptance Testing

(1)The department will measure thickness according to CMM 8-70.4.7.3 at one random location in each

unit. If the initial measurement fa lls within the 80 to 50 perc ent pay range specified in 415.5.2 , the department will measure at the se cond plate in that unit and av erage the results to determine the pay adjustment. Pavement thinner than t he plan thickness by more th an 1 inch is unacceptable.

(2)The engineer will direct the cont ractor to core the hardened concrete to determine the extent of

unacceptable areas. Take cores a t points approximately 20 feet in each direction of an unacceptable test result on a line parallel to the centerline or longitudina l axis of the unit. Continue coring in each direction until locating a core that is not unacceptable. The engineer will determine the limits of unacceptable areas, at each end, b y drawing lines across the un it of pavement midway between the locations of the last 2 cores.

(3)Perform coring according to AASHTO T24. The engineer will eval uate the results according to

AASHTO T148. Fill core holes w ith concrete or mortar. 415.3.17 Concrete Crack Repair

(1)The engineer will inspect concrete pavement and ancillary conc rete for transverse cracking, twice, as

follows:

1.After attaining opening strength as specified in 415.3.15 but before opening to construction or public

service.

2.Before opening to public ser vice or before partial acceptance as defined in 105.11.1 , whichever comes

first.

(2)The engineer will determine if a tr ansverse crack needs repair and the type of repair needed. Repair

the cracked concrete as the engineer directs. 415.3.18 Pavement Gaps

(1)Construct gaps using either doweled or tied construction joints. Locate constructi on joints and joints

within the gap ensuring that the resulting slab lengths are gre ater than or equal to 6 and less than or equal to 15 feet long. Alternatively, if the engineer approves, the contractor may pave continuously through the gap using concrete conforming to 415.2.5 . 415.3.19 Approach Slabs

(1)Unless the engineer directs ot herwise, the contractor may cons truct the approach slab before, at the

time of, or after constructing the roadway pavement.

(2)The contractor may u se built-up forms in stead of full depth me tal side forms. Place r einforcing steel as

the plans show. Employ engineer- approved methods to support bar steel and dowel bars in their plan position during concrete placing and finishing. 415.3.20 Filling Joints

(1)Fill contraction and expansion joints in concrete pavement not requiring tining under 415.3.8 and in the

adjacent curb and gutter with filler conforming to 415.2.6 . Fill both transverse and longitudinal joints as soon as practicable, but only after the engineer inspects them. Revise 415.3.20(2) to require sawing construction joints before filling. This change was implemented in ASP 6 effective with the December 2017 letting.

(2)Clean joints of laitance, curing compound, and other contamina nts before filling. Saw construction

joints at least 3/4 inches deep before filling. Sawing is not r equired for tooled joints in curb and gutter.

Effective with the December 2018 Letting 155 2019 Standard Spec ifications Sandblast or waterblast exposed jo int faces using multiple passes as required to clean joints surfaces of material that might prevent bonding. Blow clean and dry with oil-free compressed air immediately before filling.

(3)Heat filler to the manufacturer's recommended pouring temperature in an engineer-approved double

boiler with the space between t he inner and outer shells filled with oil or other engineer-approved heat transfer medium. Ensure that the heating kettle is equipped with a mechanical agitator, positive temperature control, and an engi neer-approved thermometer. Do n ot operate the heating kettle on concrete without insulation or a heat shield to protect the con crete surface. If applying only a small amount of filler, the engineer may allow alternate heating equi pment.

(4)Do not heat above the maximum safe temperature the filler manu facturer recommends. Discard over-

heated material.

(5)Maintain a uniform filler tem perature within the manufacturer' s recommended working range

throughout the filling operation . Cease filling if the temperature in the applicator falls more than I0 F below the manufacturer's recommended pouring temperature.

(6)Completely fill joints without overflowing so that the finishe d filler is approximately flush with the

adjoining surfaces after shrinking. If one pass gives unsatisfa ctory filling, use 2 passes making sure that at least half of the required filler is poured on the firs t pass. Make the second pass as soon as practicable after the first pou r attains maximum shrinkage but not later than an hour after the first pour.

415.4Measurement

(1)The department will measure the Concrete Pavement and Concrete Alley bid items by the square yard

acceptably completed, measured using the centerline length and the width from outside to outside of completed pavement, but limited to the width the plans show or the engineer directs. The department will include fillets for widened sections, or at drain basins a nd similar locations, placed monolithic with the pavement. The department will not deduct for fixtures with an area of one square yard or less as measured in the plane o f the pavement surface.

(2)The department will measure the Concrete Pavement Approach Sla b bid items by the square yard

acceptably completed, based on t he pay limits the plans show.

(3)The department will measure Concrete Pavement Gaps as each ind ividual gap acceptably completed

including eliminated gaps the engineer allows the contractor to pave through, measured separately for each roadway. The department will me asure multiple gaps at one roadway location as required to conform to contract staging provisions, but not solely to accom modate the contractor's means and methods.

(4)The department will measure Conc rete Pavement Joint Filling by the square yard acceptably

completed, measured as the concrete pavement area plus the leng th times nominal width of adjacent curb and gutter.

415.5Payment

415.5.1 General

(1)The department will pay for measured quantities at the contrac t unit price under the following bid

items: ITEM NUMBER DESCRIPTION UNIT

415.0060 - 0199 Concrete Pavement (inch) SY

415.0210 Concrete Pavement Gaps EACH

415.0310 Concrete Alley SY

415.0410 Concrete Pavement Approach Slab SY

415.1080 - 1199 Concrete Pavement HES (inch) SY

415.1310 Concrete Alley HES SY

415.1410 Concrete Pavement Approach Slab HES SY

415.4100 Concrete Pavement Joint Filling SY

(2)Payment for the Concrete Pavement bid items is full compensati on for providing pavement; for

preparing the foundati on, unless provided otherwise; for placin g thickness plates; and for thickness coring and filling core holes as required under 415.3.16.4 . Payment also includes providing tie bars and dowel bars within concrete placed under the contract. The d epartment will pay separately for tie bars and dowel bars used to connect the work to c oncrete not pl aced under the contract under the Drilled Tie Bars and Drilled Dowe l Bars bid items as specified in 416.5 . The department will not pay for removal and replacement of pavem ent not meeting the surface smo othness tolerances specified in 415.3.11 .

Effective with the December 2018 Letting 156 2019 Standard Spec ifications (3) Payment for Concrete Pavement G aps is full compensation for pr oviding pavement gaps. If the engineer allows paving through a gap, the department will pay t he full contract price for each gap eliminated. Payment for furnishi ng and placing concrete materia l is included under Concrete Pavement.

(4)Payment for the Concrete Pavement Approach Slab bid items is f ull compensation for providing the

approach slab; and for bar steel r einforcement, dowel and tie b ars, and jointing materials.

(5)The department will pay for engineer-approved EBS to corrects ubgrade problems beyond the

contractor's control as specified in 301.5 . Add 415.5.1(6) specify paymen t for protective covering. Revise 415.5.1(6) to specify that sawing required before join t filling is incidental. This change was implemented in ASP 6 effective with the December 2017 letting.

(6)Payment for Concrete Pavement Joint Filling is full compensation for filling concrete pavement joints;

for filling adjacent cur b and gutter joints ; and for sawing . 415.5.2 Adjusting Pay for Thickness

(1)The department will adjust pay fo r pavement thickn ess under th e Nonconforming Thickness Concrete

Pavement administrative item as follows: FOR PAVEMENT PERCENT OF THE THINNER THAN PLAN THICKNESS BY: CONTRACT UNIT PRICE[1] > 1/4 inch but <= 1/2 inch 80 > 1/2 inch but <= 3/4 inch 60 > 3/4 inch but <= 1 inch 50 [1] The department adjusts pay based on the average of 2 measureme nts per unit as specified in 415.3.16.4(1) .

(2)If the department determines are as of pavement have unacceptable final thickness, as specified in

415.3.16.4 , the engineer will direct t he contractor to either:

1.Remove and replace with concrete pavement of conforming thickness. The department will pay for the

replaced area at the full contract price.

2.Leave the concrete in place. The department will not pay for the unacceptable area.

415.5.3 Adjusting Pay for Pavement Crack Repairs

(1)The engineer will allocate responsibility and costs for crack repairs, mobilization for traffic control, and

traffic control devices, according to CMM 4-24 . The department will adjust pay under the Crack Repair Concrete Pavement administrative item.

(2)Pay adjustment for crack repair costs, based on the total repa ir area in a single panel, includes

mobilization for the repair wo rk; sawing; removing pavement; fu rnishing and placing materials including dowel bars; drilling in tie and dowel bars; and all i ncidentals. The department will adjust pay for contiguous repair areas i n adjacent panels separately. The engineer will compute the pay adjustment for repair costs as follows: Total Reimbursement = (unit price x repair area + $1700) Shared Reimbursement = 1/2 of the total reimbursement amount

(3)The department will adjust pay for traffic control devices and mobilization for traffic control separately.

Effective with the December 2018 Letting 157 2019 Standard Spec ifications Section 416 Concrete Pavement - Appurtenant Construction

416.1Description

(1)This section describes constructing concrete driveways; truck aprons; drilling in tie bars to tie existing

to new concrete and drilling in dowel bars to transfer load bet ween existing and new concrete; concrete surface drains; concrete rumble strips; and concrete p avement repair and replacement.

416.2Materials

416.2.1 General

(1)Furnish air-entrained concrete conforming to 501 as modified for class II concrete in 716. Provide

QMP for class II ancillary c oncrete as specified in 716.

(2)Furnish high early strength conc rete under the HES bid items. The contractor may use HES concrete

even where the contract does not require it.

(3)Furnish calcium chloride for concrete placed under SHES bid it ems as follows:

1.For use in solid form or on the job preparation of admixtur e solutions, conform to AASHTO M144, typeS,

grade 1 or grade 2.

2.For admixture delivered in premixed solution form, conform to AASHTO M144, type L, in a concentration

of approximately 30 percent. 416.2.2 Concrete Driveways, Truck Aprons, and Surface Drains

(1)Use grade A, A2, A3, A-FA, A-S , A-S2, A-T, A-IS, A-IP, or A-IT concrete as specified in 501.

416.2.3 Tie bars and Dowel bars 416.2.3.1 General

(1)Furnish tie bars and dowel bars conforming to 505.2.6 .

416.2.3.2 Epoxy for Anchoring Dowel Bars and Tie Bars

(1)Furnish epoxy consisting of a 2 -component epoxy material of contrasting colors and conforming to

AASHTO M235, grade 3 - non-sagging consistency, t ype IV epoxy, except as modified below:

1.Use class B material for mi d-depth slab temperatures betwee n 40 and 60 F.

2.Use class C material for mi d-depth slab temperatures betwee n 60 F and the highest temperature allowed

by the manufacturer of the product.

(2)Bond strength, tensile strength , and elongation testing is not required.

(3)Achieve a minimum compressive y ield strength of 5000 psi at 8 hours for special high early strength

concrete, or at 3 days for grades A, C, and E concrete. Test ac cording to AASHTO M235 and ASTM D695, with the followi ng restrictions:

1.Mold and cure compressive test specimens in cylinders with a one-inch nominal diameter.

2.Machine specimen ends square to produce a final specimenle ngth of 2 inches.

(4)Before using the epoxy submit a manufacturer's certificate of compliance, and a certified report of test

or analysis from a qualified i ndependent laboratory, to the eng ineer certifying that the epoxy conforms to these specifications. Identify the temperature classes and compressive strength cure times for which the product is certified.

(5)The contractor may furnish an engineer-approved acrylic adhesi ve that meets the same physical

requirements specified for epoxy. 416.2.4 Concrete Pavement Repair and Replacement

(1)Except as specified in 416.3.6 for inlaid rumble strips, use grade C, C-FA, C-S, C-IS, C-IP, or C-IT

concrete as specified in 501. 416.2.5 Special High Early Strength Concrete Pavement Repair and Replacement 416.2.5.1 Composition and Proportioning of Concrete

(1)For the concrete mixture, use a minimum of 846 pounds of cemen titious material per cubic yard of

concrete. Determine materials a nd proportions of the concrete m ixture to obtain a minimum compressive strength in the co ncrete of 3000 psi within 8 hours of placement. The contractor may add one or a combination of admixtures to the ingredients or to the mixture in order to obtain the required minimum strength and required air content. Do not retemper the concrete mixture.

(2)Provide calcium chloride, if used in the mix, either as a pre- mixed solution or as a job-mixed solution.

Ensure that job-mixed solutions contain 1.0 pounds per quart of 77 percent calcium chloride or 0.9 pounds per quart of 90 percent cal cium chloride. Do not exceed the manufacturer's recommended maximum dosage. If the engineer requests, provide a written cop y of the manufacturer's dosage recommendations.

Source: Wisconsin Standard Specifications for Highway and Structure Construction, 2019 Edition. Pages 155–165 of 601.

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416 Concrete Pavement - Appurtenant Construction