Wisconsin WisDOT Standard Specifications (within FDM) — Section 416

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.

Effective with the December 2018 Letting 158 2019 Standard Spec ifications (3) Add calcium chloride, in solution, by an engineer-approved pro cedure to the batch ingredients while placing them in the mixer. Provide sufficient water in job-mixe d solutions to dissolve the calcium chloride completely, and ensure that the solution is of a unifo rm and known conce ntration. Reduce the quantity of mixing water by the quantity of solution used. Intr oduce the correct quantity of calcium chloride into the mixer using a method by which the quantity added cannot vary appreciably from the target value.

(4)Discharge all concrete within 45 minutes after adding mixing w ater to the cement, or the cement to the

aggregates, or within 30 minutes a fter adding an accelerating a dmixture, whichever comes sooner. 416.2.5.2 Evaluating Strength

(1)At least 3 business days befores tarting construction, provide the engineer with adequate evidence

that the required strength is obt ainable in the field with the materials used and at the various temperatures encountered. Conduc t a continued strength evaluati on, if the engineer requires, during the course of the work to ensure continued compliance with the strength requirements.

(2)Notify the engineer before making test cylinders and, if the e ngineer chooses, make arrangements for

the engineer to observe cylinder production. Use a department q ualified laborat ory and an HTCP- certified technician to conduct preliminary and continued stren gth evaluations. Base each reported value on a minimum of 2 cylinders. After submitting data showin g obtainment of the required strength, do not change the mix without first submitting a complete new s et of test data showing compliance with the requirements.

416.3Construction

416.3.1 General

(1)The engineer will inspect ancillary concrete, as defined in 416.5.2 and built under 416 , for transverse

cracking as specified in 415.3.17. Repair cracked concrete as the engineer directs. 416.3.2 Concrete Driveways and Truck Aprons

(1)Construct concrete driveways and truck aprons conforming to 415.3 except the contractor may use

engineer-approved wood or plastic fo rms. Color concrete for rou ndabout truck aprons red as specified in 405. 416.3.3 Placing Tie Bars in Existing Concrete 416.3.3.1 Force Driven

(1)Drill a suitably sized hole into the edge of the existing conc rete. Force drive the ti e bar to a depth of 6

inches into the prepared hole as the plans show. 416.3.3.2 Epoxied

(1)Drill holes into the edge of the existing concrete to the dime nsions the plans show. Anchor the tie bars

into the existing concrete with an epoxy conforming to 416.2.3.2 and install conforming to 416.3.4 except no bond breaker is required. 416.3.4 Placing Dowel Bars in Existing Concrete

(1)Drill holes into the edge of the existing concrete to the dime nsions the plans show. Anchor the dowel

bars into the existing concrete with an epoxy conforming to 416.2.3.2 .

(2)Clean drilling dust, debris, and excess moisture from drill ho les before inserting the epoxy and dowel

bar.

(3)Inject the epoxy into the back of the drill hole. Use an epoxy with a workable viscosity, pumpable, yet

thick enough to remain in the hole. Insert a sufficient volume of epoxy into the hole to provide a small quantity of excess material at the face of the concrete after f ully inserting the dowel.

(4)Insert dowel bars in the drill holes and rotate 1/2 turn. Do n ot force drive dowel bar s into the drill holes.

(5)Completely fill the annular space between the dowel bar and th e concrete with epoxy. Insert a

retaining ring over the bar, and push the ring flush against th e concrete surface to retain the epoxy.

(6)Coat the protruding portion of each dowel bar with a thin unif orm layer of bond breaking lubricant.

(7)Use a positive fixed displacement dispensing system, equipped with a nozzle of sufficient length to

deposit the epoxy at the back of t he drilled hole. Use a system equipped with a means of checking the mix ratio of the epoxy components . Use the manufacturer’s recom mended mix ratio and check the ratio at least once a day.

(8)For minor quantities of dowel b ars, the contractor may use han d-powered mixing and injecting

equipment capable of thoroughly mixing and depositing the epoxy at the back of the drill hole.

Effective with the December 2018 Letting 159 2019 Standard Spec ifications 416.3.5 Surface Drains

(1)Install and maintain temporary su rface drains at locations des ignated for permanent drains until

permanent drains are completed.

(2)Place and secure steel reinfor cement and tie bars in their pla n position before placing concrete. Place

and cure the concrete conforming to 415.3 .

(3)Excavate, prepare the subgrade and aggregate base, and backfil l as required to place the drains and

restore the grade after placement. 416.3.6 Concrete Rumble Strips

(1)Mill shoulder rumble strips int o new or existing concrete shou lders. Mill or form intersection rumble

strips into new concrete pavement or, if inlaid into existing H MA or concrete pavements, into work built under the Concrete Pavement Replac ement bid item except use con crete conforming to 416.2.2. Do not apply rumble strips across bridges.

(2)If milling, use a rotary head m ill with a cutting tip pattern that will produce a rela tively smooth cut of the

size, shape, spacing, and alignment the plans sh ow. Ensure that cutting heads are on a suspension independent from the power unit to allow the heads to self-alig n with slopes and irregularities. Also ensure that the machine has a guidance system that consistently provides the plan alignment of the rumble strips.

(3)If forming rumble strips into freshly placed concrete, form or finish the concrete to consistently produce

the size, shape, spacing, alignm ent, and smoothness the planss how.

(4)Before beginning the work, demonstrate to the engineer that th e proposed operation achieves the

desired surface inside each depr ession without damaging the pav ement. Place rumble strips in the pattern and shape the plans show. For shoulders carrying temporary traffic during construction, do not install rumble strips until after routing traffic back to the m ainline.

(5)At the end of each work day, move equipment and material out of the clear zone and sweep or

vacuum the traveled way pavement and shoulder areas. Sweep away or vacuum up milling debris before opening adjacent lanes to traffic. Dispose of waste material as specified in 203.3.4 ; do not place on the finished shoulder surface. 416.3.7 Concrete Pavement Repair and Replacement

(1)Repair concrete pavement at the locations the plans show or wh ere the engineer directs. Conform to

the pavement repair plan details. F or individual repair areas at least one lane wide and greater than 15 feet to less than 300 feet long, conform to the pavement replac ement plan details.

(2)Construct conforming to the following:

- Remove concrete pavement, rem ove asphaltic patch, and prepare the base as specified under 416.3.8.1. - Place concrete in repair areas as specified under 416.3.8.2 . Disregard the same-day requirements for completion of curing and opening to traffic and instead conform to 415.3.12 through 415.3.15 . - Place concrete in replacement areas conforming to 416.3.8.3 except disregard the same-day requirements for completion of curing and opening to traffic. 416.3.8 Special High Early Strength Concrete Pavement Repair and Replacement 416.3.8.1 General

(1)Repair concrete pavement at the locations the plans show or wh ere the engineer directs. Conform to

pavement repair plan details. For individual repair areas at le ast one lane wide and greater than 15 feet to less than 300 feet long, conform to pavement replacemen t plan details. 416.3.8.1.1 Removing Concrete Pavement

(1)Remove deteriorated slabs wit hout damaging adjacent pavement. If removing only a portion of an

existing slab, make a straigh t full lane-width full depth saw c ut to facilitate removal without damaging the remaining pavement. Ensure that repair areas in adjacent la nes match longitudinally.

(2)If the contractor dam ages pavement designated to remain in place, repair damaged pavement as the

concrete pavement repair and replacement details show. Ensure t hat the length of the damage repair and the adjacent planned repair ar e the same and both are a ful l lane wide. If damage is done to pavement not adjacent to a planned repair, conform to the minim um removal length the repair and replacement details show and remove and repair the full lane width.

(3)Remove concrete with minimal disturbance to the aggregate base . At the close of each day's work,

ensure that all slabs have been removed from the project limits and stored away from the roadway. Incorporate or dispose of removed pavement as specified in 203.3.4.

Effective with the December 2018 Letting 160 2019 Standard Spec ifications (4) Replace areas of the asphaltic sh oulder removed during these pavement removal operations to the elevation of the adjacent shoulde r using a commercially produced asphaltic patching material. Before patching, clean, dry, and provide a uniform edge for the repair area. 416.3.8.1.2 Removing Asphaltic Patches

(1)Remove existing asphaltic patches. Saw back t he existing pavem ent full depth in an area of sound

concrete as the plans show. 416.3.8.1.3 Base Course

(1)Place the concrete on existi ng base course shaped to the requi red cross-section. Remove concrete

rubble and foreign material wit h minimal disturbance of the bas e.

(2)Fill low areas or depressions in the base following removal operations with either compacted

aggregate base or additional concrete. 416.3.8.2 Placing Concrete in Repair Areas

(1)Place, cure, and open special high early strength concrete to traffic on the same day removing the old

pavement. Place each repair i n one continuous, full depth operation. Consolidate the concrete in place using an immersion type vibrator . Finish the surface by screedi ng twice, floating, and texturing. Orient the length of the screed parallel to the pavement centerline, u nless the repair is over 12 feet in length.

(2)Make the transverse edges of the finished repair flush with th e edges of the existing concrete

pavement. Make the longitudinals urface form a straight line fr om edge to edge with a tolerance of +/- 1/8 inch.

(3)Finish the final surface of t he full depth concrete repair to match the edge of existing HMA or concrete

pavement and, if the abutting pavement is concrete, match the e xisting pavement texture. Cure, protect, open to service, and adhere to cold weather concreting as specified in 415.3.12 through 415.3.15 . 416.3.8.3 Placing Concrete in Replacement Areas

(1)Place, cure, and open special high early strength concrete to traffic by sunset on the same day

removing the old pavement. Place each repair in o ne continuous, full-depth operation conforming to 415.3.6 through 415.3.15 except date each replacement slab with the month and year of c onstruction.

416.4Measurement

(1)The department will measure the Co ncrete Driveway bid items by the square yard acceptably

completed, measured as specified in 415.4 for Concrete Pavement including the intersection with the sidewalk and the associated driveway apron. The department will only measure area outside the specified limits for the pavement, curbs, gutters, combination curb & gutter or other structures.

(2)The department will measure the Co ncrete Truck Apron bid items by the square yard acceptably

completed.

(3)The department will measure the Drilled Tie Bars and Drilled D owel Bars bid items as each individual

bar acceptably completed.

(4)The department will measure the Concrete Surface Drains bid it ems by the cubic yard acceptably

completed, based on the dimensions the plans show or the engineer directs.

(5)The department will measure Conc rete Shoulder Rumble Strips by the linear foot acceptably

completed, measured as the length along each side of the traveled way from the center of the first groove in a segment to the center of the last groove in thatse gment. A segment is a series of grooves including 50-foot and shorter gaps as well as skips at transverse joints the plans show. Gaps greater than 50 feet define a new s egment. The department will deduct for skips at transvers e joints greater than the plans show.

(6)The department will measure Conc rete Intersection Rumble Strips by the square yard acceptably

completed, measured to include the area between the milled or c ast-in-place grooves, or if inlaid into existing HMA or concrete pavement, the area of the inlay. The d epartment will not deduct the area of embedded fixtures with an area of one square yard as measured i n the plane of the pavement surface.

(7)The department will measure the Concrete Pavement Repair and Concrete Pavement Replacement

bid items by the square ya rd acceptably completed.

416.5Payment

416.5.1 General

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

items:

Effective with the December 2018 Letting 161 2019 Standard Spec ifications ITEM NUMBER DESCRIPTION UNIT

416.0160 - 0199 Concrete Driveway (inch) SY

416.0260 - 0299 Concrete Driveway HES (inch) SY

416.0508 - 0520 Concrete Truck Apron (inch) SY

416.0610 Drilled Tie Bars EACH

20 Drilled Dowel Bars EACH

416.1010 Concrete Surface Drains CY

15 Concrete Surface Drains HES CY

416.1110 Concrete Shoulder Rumble Strips LF

80 Concrete Intersection Rumble Strips SY

416.1710 Concrete Pavement Repair SY

15 Concrete Pavement Repair SHES SY

20 Concrete Pavement Replacement SY

25 Concrete Pavement Replacement SHES SY

(2)The department will pay for the Co ncrete Driveway and Concrete Truck Apron bid items as specified in

415.5.1 and 415.5.2 for Concrete Pavement. The depar tment will pay separately for coloring concrete as required for roundabout truck aprons under the Coloring Concrete Red bid item.

(3)Payment for Drilled Tie Bars is full compensation for providing tie bars, including coating; for drilling

holes in concrete not placed under the contract; and for epoxyi ng or driving.

(4)Payment for Drilled Dowel Bars i s full compensation for providing dowel bars, inc luding coating; for

drilling holes in concr ete not placed under the contract; and f or epoxying.

(5)Payment for the Concrete Surface Drains bid items is full comp ensation for providing surface drains;

for steel reinforcement and dow el and tie bars; and for excavating, preparing the subgrade and aggregate base, and backfilling.

(6)Payment for Concrete Shoulder R umble Strips is full compensati on for milling; for sweeping or

vacuuming; and for disposing of waste materials.

(7)Payment for Concrete Intersecti on Rumble Strips is full compen sation for milling or forming grooves;

for sweeping or vacuuming; and for disposing of waste materials . The department will pay separately for new concrete pavement under the Concrete Pavement bid items; and for concrete inlaid in existing HMA or concrete pavement under t he Concrete Pavement Replacemen t bid item.

(8)Payment for the Concrete Pavemen t Repair and the Concrete Pavement Replacement bid items is full

compensation for furnishing, hauling, preparing, placing, curin g, and protecting materials; for replacing damaged pavement designated to remain in place; for removing an d disposing of existing pavements and excavated materials; for re pairing asphaltic shoulders; for sawing joints; fo r preparing the foundation; for backfilling; and for testing concrete cylinders . The department will pay for individual repairs at least one lane wide and greater than 15 feet to less than 300 feet long as Concrete Pavement Replacement. Payment inc ludes jointing a nd providing t ie bars and dowel bars in unhardened concrete. The departm ent will pay separately for ass ociated work as follows: - For tie bars and dowel bars pro vided in concrete not placed u nder the contract, exclusive of those necessary to repair contractor-caused damage, under the Drilled Tie Bars and Drilled Dowel Bars bid items. - For sawing existing concrete for removal, under the Sawing Co ncrete bid item as specified in 690.5 . - For repairs 300 feet long or longer, under the Removing Pavement bid item as specified in 204.5 and the Concrete Pavement bid items as specified in 415.5 . 416.5.2 Adjusting Pay for Anc illary Concrete Crack Repairs

(1)The department will adjust pay for crack repairs on ancillary concrete. Ancillary conc rete includes curb

& gutter whether separately or integrally placed, curb, gutter, medians, sidewalks, loading zones, safety islands, steps, concrete surface drains, truck aprons, and driveways. The engineer will allocate responsibility and costs for crack repairs, mobilization for tr affic control, and traffic control devices, according to CMM 4-24 . The department will adjust pay under the Crack Repair Ancilla ry Concrete administrative item.

(2)Pay adjustment for crack repair costs includes mobilization fo r the repair work; sawing; removals;

furnishing and placing materials including dowel bars and steel reinforcement; drilled tie and dowel bars; and all incidentals. The engineer will compute the pay ad justment for repair costs as the contract unit price for the item, times the quantity replaced, multiplie d by the appropriate multiplier as follows:

Effective with the December 2018 Letting 162 2019 Standard Spec ifications COMPUTED AMOUNT MULTIPLIER PER Q UANTITY FOR ANCILLARY CONCRETE ITEM SHARED REIMBURSEMENT TOTAL REIMBURSEMENT REPLACED MULTIPLIER MULTIPLIER Quantity replaced 6 12

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

Effective with the December 2018 Letting 163 2019 Standard Spec ifications Section 420 Diamond Grinding

420.1Description

(1)This section describes continuous diamond grinding and intermi ttent diamond grinding for surface

restoration of existing or re paired pavement and profile correction for new pavement. 420.2 (Vacant)

420.3Construction 420.3.1 General

(1)Diamond grind the existing con crete pavement to provide a uniform surface that is reasonably plane,

free of excessively large scarif ication marks, and has the grad e and cross slope the plans show or the engineer specifies. Do not damag e the remaining pavement. Do no t grind deeper than 3/4 inch from the top of the original surface.

(2)Complete full-depth and partia l-depth concrete repairs, slabs tabilization, dowel bar retrofit, and other

pavement repair operations befor e grinding. Begin and end grinding at lines perpendicular to the roadway centerline at the projec t limits. Do not overlap adjace nt grinding passes by more than 1-inch. Do not leave un-ground surface area between passes.

(3)Grind joint or crack faults so there is no more than a 1/16-in ch differential between the adjacent sides

of the joints and cracks. Grind warped and curled slabs as requ ired to provide an acceptable ride. Provide smooth transitions from the edge of the mainline to sho ulders, adjacent lanes, and ramps leaving no more than a 3/16-inch ridge at transitions. Grind adjacent pavement and paved shoulders as necessary to feather in a smoot h transition and maintain drainage. Do not grind approach slabs unless necessary to provi de a smooth transition.

(4)Provide lateral drainage by maintaining a constant cross slope between grinding extremities in each

lane including feathered areas of t he shoulder. Ensure that the finished cross slope conforms to the plans and has no depressions or slope misalignment greater than 1/4-inch in 12 feet when measured perpendicular to the centerline with a 12-foot straightedge.

(5)Do not diamond grind over valves, manholes, or other fixtures. Provide a smooth taper from the

diamond ground surface to the top of the fixture. 420.3.2 Equipment 420.3.2.1 General

(1)Use self-propelled grinding ma chines with depth, grade, and slope controls designed for grinding and

texturing concrete. Equip grinding machines with diamond blades and a vacuuming system capable of removing liquid and solid residue from the ground surface. Shro ud the machine to prevent discharging loosened material into adjacent work areas or live traffic lanes.

(2)Do not use equipment that causes raveling, aggregate fractures , joint deflection, or other damage to

material remaining in place.

(3)Maintain equipment in proper working order. Ensure that the ma tch and depth control wheels are

round. Stop grinding and immedi ately replace out-of-round wheels. 420.3.2.2 Continuous Grinding

(1)Under the Continuous Diamond Grinding Concrete Pavement bid it em, ensure that the grinding

machine, including the grinding head, weighs 35,000 pounds or m ore, will grind a strip at least 4 feet wide, and has an effective wheel base of 25 feet or more. 420.3.2.3 Intermittent Grinding

(1)For intermittent grinding required for ride correction under 740, ensure that the grinding machine will

grind a strip at least 3 feet wi de and has an effective wheel b ase of 12 feet or more. The engineer may require continuous grinding equipment if intermittent grinding equipment does not produce acceptable results. 420.3.3 Final Surface Finish

(1)Produce a surface that is true in grade and uniform in appeara nce. Provide a longitudinal line-type

texture with corrugations parallel to the outside pavement edge .

(2)Select the number of diamond blades per foot that will provide the proper surface finish for the

aggregate type. Determine the seq uence of operations and number of passes required to meet the specifications.

(3)Ensure that ridges are 1/16 to 3/16 inches higher than the bot tom of the grooves and uniformly spaced

as follows: For limestone: 0.09 to 0.11 inches between grooves.

Source: Wisconsin Standard Specifications for Highway and Structure Construction, 2019 Edition. Pages 166–171 of 601.

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