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Home / DOT Specifications / Wisconsin / WisDOT Standard Specifications (within FDM) / 509
General Provisions (00100-00999)

509Concrete Overlay and Structure Repair

WI · 2019 Standard SpecificationsBook pages 282–286View official source ↗

Effective with the December 2018 Letting 273 2019 Standard Spec ifications Section 509 Concrete Overlay and Structure Repair

509.1Description

(1)This section describes cleaning or scarifying areas of decks a nd approach pavements to be overlaid;

removing and disposing any remaining asphaltic patches or unsou nd concrete from those areas; the furnishing, placing and curing concrete overlays; and full dept h deck, surface, curb and joint repairs, as required.

509.2Materials

(1)Furnish a neat cement bonding grout. Mix the neat cement in a water-cement ratio approximately

equal to 5 gallons of water per 94 pounds of cement.

(2)Furnish grade E conforming to 501 for overlays.
(3)Furnish grade C, C-FA, C-S, C-IS , C-IP, C-IT, or E concrete co ncrete conforming to 501 for surface

repairs. The contractor may incre ase the slump for grade E conc rete to a maximum of 4 inches. The contractor may apply an engineer- approved commercial grout or s urface coating to surfaces being repaired instead of the grades of concrete designated above if it is impracticable to apply that masonry, if the engineer specifi cally approves in writing.

(4)Furnish grade C, C-FA, C-S, C-IS , C-IP, C-IT, or E concrete co nforming to 501 for joint repairs, curb

repairs, and full-depth deck r epairs; except as follows:

1.The contractor may increase slump of grade E concrete to 3 inches.
2.The contractor may use ready-mixed concrete.
(5)Provide QMP for class II ancilla ry concrete as specified in 716.

509.3Construction 509.3.1 General

(1)Repair damage to existing epoxy-coated reinforcement remaining in place that is either uncovered by

or damaged by the contractor's operations. Use engineer-approved patching or repair material compatible with the existing coating and inert in concrete. 509.3.2 Equipment

(1)Use a finishing machine to finish concrete overlays conforming to 502.3.7.8 and the following:
1.The machine shall have 2 li nearly oscillating transverse sc reeds. For the front screed use, a synchronous

vibratory screed with a variabl e frequency the operator can adj ust. Provide enough ident ical vibrators to provide at least 2 vibrators fo r each 5 feet of screed length. Ensure that the bottom face of each screed is at least 7 inches wide with a rounded leading edge. Each screed shall have an effective weight of at least 75 pounds per square foot of botto m face area. Provide each scr eed with the capability to positively control of the vertical pos ition, the angle of t ilt and the shape of th e crown.

2.The machine shall have an adjustable metering device ahead of the leading screed that traverses the

width of the machine.

3.The machine shall have capa bility of forward and reverse mo tion under positive control. Make provisions

for raising the screeds to clear the screeded surface for trave ling in reverse.

(2)If placing concrete in a line next to a previously completed l ane, equip the side of the finishing

machine next to the completed lane, to travel on the lane. 509.3.3 Cleaning

(1)Under the Cleaning Decks and Cleaning Approaches bid items, cl ean the decks and approach

pavements before placing the concrete overlay.

(2)Use construction methods conforming to 502 and the following:
1.Clean the entire surface o f the bridge deck or approach pav ement receiving the new concrete by using a

suitable mechanical scarifyer. A ccomplish this in a way that pr events hooking or tearing the reinforcing steel and that removes at least one inch of concrete from the deck or pavement surface but not more than the maximum depth the plans show.

2.If scarification is impracticable, as along curb faces or a t expansion joints, remove deteriorated concrete to

sound material by using chippers conforming to 509.3.4 for chippers.

3.Perform scarification before preparation. After completing scarification, remove the remaining asphaltic

patches and unsound concrete as specified for preparation in 509.3.4.

4.Blast clean the entire surf ace of the deck and approach pav ements being overlaid, all exposed reinforcing

steel, the vertical faces of cur bs, sidewalks and parapets to the depth of the adjoini ng concrete overlay after completing preparation.

Effective with the December 2018 Letting 274 2019 Standard Spec ifications 5. Clean the surface receiving the new concrete by mechanicall y dislodging contami nation or debris and removing loose particles and dust with high-pressure water or a ir. Ensure that no free-standing water remains before placing grout and that cleaning water conforms t o 501.2.4 . 509.3.4 Preparation

(1)Under the Preparation Decks and Preparation Approaches bid ite ms, remove all asphaltic patches and

unsound or disintegrated areas o f concrete decks and approach p avements as the plans show, or as the engineer directs.

(2)Use construction methods conforming to 203 and the following:
1.Under the Preparation Decks Type 1 bid item, remove existin g asphaltic patching and unsound bridge

deck concrete only to a depth t hat exposes 1/2 of the periphera l area of the t op or bottom bar steel in the top mat of reinforcement.

2.Under the Preparation Decks Type 2 bid item, remove existin g unsound bridge deck concrete below the

limit of the type 1 removal desc ribed above. One inch below the bottom of the top or bottom bar steel in the top mat of reinforcement is the minimum depth of type 2 rem oval. The engineer will direct any further removal.

3.Remove the existing asphalti c patching and unsound concrete using equipment that causes no damage to

the bridge floor. If chipping ex poses the existing bar steel re inforcement for more than 1/2 of its peripheral area, and where bond between exi sting concrete and reinforcing bar has been destroyed, remove the adjacent concrete to provide a minimum one-inch clearance aroun d the bar.

4.For chipping off the old conc rete surface, use air chippers or breakers that weigh no more than 35 pounds

and are equipped with flat, chise l-type points with a cutting e dge not less than 3/4 inch or greater than 3 inches wide.

5.After reaching the top of t he reinforcing steel, do not use hammers heavier than 15 p ounds within one inch

of the steel.

6.Dispose of old concrete and as phaltic patching removed away from the bridge site . Implement necessary

procedures to minimize debris dropping into the stream, streambed, roadway, or right-of-way below. 509.3.5 Joint Repair

(1)Under the Joint Repair bid item , remove and dispose of deterio rated concrete at existing joints over

piers, abutments and deck ends and other locations, and form ne w joints as the plans show, and the engineer directs.

(2)Use construction methods conforming to 203, 502 , and the following:
1.Remove the concrete at an ex isting joint to be replaced to the limits the plans sho w, or as the engineer

directs. Place a 1/2 inch deep saw cut at the line of removal on the bottom edge of t he deck to control concrete breakout or cover the line of removal with a 1 1/2 inc h thick layer of concrete to cover all reinforcing steel exposed duri ng joint repair. Use removal equi pment that causes no damage to the portion of the concrete floor, curbs, and reinforcing steel remaining i n place. Do not use tractor-mounted rams for removal operations within 9 inc hes of the edge, or within the d epth of the slab from t he edge, whichever is less.

2.The contractor shall preserve and utilize the required exis ting reinforcing steel, and blast clean, realign,

and retie, as the eng ineer considers nece ssary. If additional reinforcement is required, use grade 60 steel conforming to AASHTO M31, and to 505.2 .

3.Dispose of removed mate rial as specified in 509.3.4 .
4.Clean the surface receiving the new concrete by brooming an d water pressure using a high-pressure

nozzle to remove loose particles and dust.

5.Immediately before placing concrete, coat the surfaces of the old concrete receiving new concrete with

neat cement as specified fo r concrete overlays in 509.3.9.2 .

6.Restore painted surfaces damaged by any construction operation to the satisfaction of the engineer.
7.Place concrete as specified for joint repair in 509.3.9.1 .

509.3.6 Curb Repair

(1)Under the Curb Repair bid item, remove and dispose of portions of deteriorated concrete on the

concrete curbs and fo rm new curb faces, top or back as the plans show.

(2)Use construction methods conforming to 203, 502 , and the following:
1.Take the precautions necessary while removing deteriorated concrete to preserve existing reinforcing

steel. Clean, realign, and retie e xisting reinforcing steel, as the engineer considers necessary.

2.Remove concrete to sound conc rete or at least one inch behi nd existing reinforcing steel as the plans

show and the engineer directs.

3.Make a 1/2-inch deep saw cu t at the limits of curb repair b efore removing the deteriorated concrete.
4.Dispose of removed mate rial as specified in 509.3.4 .

Effective with the December 2018 Letting 275 2019 Standard Spec ifications 5. Clean the surface against which placing the new concrete to remove loose particles and dust, and keep continuously wet for 2 hours before placing new concrete. Immed iately before placing concrete, coat the surfaces of old concrete with neat cement as specified in 509.3.9.2.

6.Place concrete as specified in 509.3.9.1 .

509.3.7 Concrete Surface Repair

(1)Under the Concrete Surface Repair bid item, remove those porti ons of abutments, piers, girders, and

other elements that the plans show, and the engineer directs, a nd replace those portions with concrete.

(2)Use construction methods conforming to 203, 502 , and the following:
1.Take necessary precautions w hile removing deteriorated conc rete to preserve existing reinforcing steel.

Clean, realign, and retie existing reinforcing steel, as the en gineer considers necessary.

2.Remove concrete to sound concrete or to one in ch behind the existing reinforcing steel, whichever depth is

greater, at locations the plans show or as the engineer directs .

3.Make a 1/2-inch deep saw cu t at the limits of the concrete surface repair before removal of the

deteriorated concrete.

4.Dispose of removed mate rial as specified in 509.3.4 .
5.Clean the surfaces against which placing the new concrete to remove loose particles and dust, and keep

continuously wet for a period of 2 hours be fore placing new con crete. 509.3.8 Full Depth Deck Repair

(1)Under the Full-Depth Deck Repa ir bid item, perform full-depth removal of unsound concrete at

locations on the deck as the engineer directs, and then prepare and form these areas.

(2)Use construction methods conforming to 203, 502 , and the following:
1.Completely remove the existi ng concrete deck areas being re paired using equipment that causes no

significant damage to that portion of the structure remaining i n place. The contractor shall preserve and utilize the required existing reinforcing steel.

2.If damage occurs to anything designated for re-use in the n ew work repair, or replace it at no expense to

the department.

3.Dispose of removed mate rial as specified in 509.3.4 .
4.Blast clean, realign, and ret ie the existing reinforcing st eel to be re-used, as the engineer considers

necessary.

5.Clean the vertical surface r eceiving the new concrete by br ooming and water pressure to remove loose

particles and dust, and keep cont inuously wet for 2 hours befor e placing concrete . Immediately before placing concrete in the full dep th deck replacement, coat the e ntire surface receiving the new concrete with neat cement as specified in 509.3.9.2 .

6.Place the concrete for the repair as specified in 509.3.9.1 .

509.3.9 Concrete 509.3.9.1 General

(1)Under the Concrete Masonry Overlay Decks and Concrete Masonry Overlay Approaches bid items,

construct a concrete overlay course on concrete deck and approa ch pavement to the lines, grades, thickness, and cross-section the plans show, or the engineer di rects.

(2)Use construction methods conforming to 502 and the following:
1.For joint repair, place the concrete and consolidate by vibrating in the prepared join ts before placing the

overlay.

2.For curb repair, place the c oncrete, consolidate, and strike off to the required ali gnment for curb faces,

tops, and backs.

3.For full depth deck repair, p lace the concrete; consolidate by internal vibration, and strike off to the existing

deck elevation before placing the overlay. 509.3.9.2 Placing Concrete Overlays

(1)Do not place the concrete overl ay less than 24 hours after placing concrete in the joint repair and full-

depth deck repair areas.

(2)Immediately before placing the concrete overlay, coat the surf ace of the bridge decks or approach

pavement being overlaid, and all ve rtical joints with a neatce ment mixture. Ensure the surface of the existing deck is moist without any standing water before coatin g with the neat cement mixture. Brush the neat cement over the prepared concrete surface to ensureal l parts receive an even coating and do not allow excess neat cement to collect in pockets. Apply th e neat cement at a rate that ensures the cement does not dry out before covering with the new concre te.

Effective with the December 2018 Letting 276 2019 Standard Spec ifications (3) Place concrete for deck prepar ation immediately in front of th e overlay course and vibrate internally in addition to surface screed vibration. Place concrete in a single operation, with no construction joints in the overlay section except as the plan show or the engineer directs. Do not place concrete if the ambient air temperature is above 88 F.

(4)The contractor may operate the finishing machine with the tran sverse screeds normal to the centerline

of the structure. Conduct bridge deck finishing operations so t hat the elapsed time between depositing the concrete on the deck and fi nal screeding does not exceed 10 minutes.

(5)If the plan requires constructi on joints, make them sharp-edge d, perpendicular to the overlay surface,

at the locations the plan show, and true to the alignments the plan show.

(6)Provide the final surface finish specified in 502.3.7.8 for floors of structures having approach

pavements with design speeds of 40 mph or greater, except there is no requirement for the turf drag or broom finish.

(7)Form or saw contraction joints to the width, depth, and at loc ations the plans show and seal as the

plans show. Begin sawing joints within 6 hours after placing th e concrete, unless the engineer directs otherwise, and complete within 12 hours. 509.3.9.3 Curing Concrete Overlays

(1)Cure concrete overlays as specified for curing concrete in flo ors, wearing surfaces, and sidewalks in

502.3.8 , including fogging, and allow to cure for 3 days. 509.3.9.4 Opening to Traffic

(1)Do not allow traffic on the completed overlay for a minimum of 3 days after placement. The engineer

may extend this time if conditions warrant. 509.4 Measurement

(1)The department will measure Preparation Approaches and the Pre paration Decks bid items by the

square yard acceptably comple ted. The department will not subtract areas of type 2 removal from areas of type 1 removal. The depa rtment will subtract areas of full-depth deck repair, the engineer directs before beginning the type 1 or type 2 deck removals, fr om the areas of the type 1 or type 2 removals. The department will no t subtract areas of full-depth deck repair, the engineer directs after type 1 or type 2 deck removals a re underway, from the areas of the type 1 or type 2 removals. The department will not measure areas of joint repair under these bid items.

(2)The department will measure Cleani ng Decks, Cleaning Approaches, Joint Repair, and Full-Depth

Deck Repair by the square y ard acceptably completed.

(3)The department will measure Curb Repair by the linear foot acc eptably completed.
(4)The department will measure Concre te Surface Repair by the squ are foot acceptably completed,

measured as the exposed surface area, following removal, as del ineated by the saw cuts.

(5)The department will measure the Co ncrete Masonry Overlay bid i tems by the cubic yard acceptably

completed. The department will in clude the volume of concrete u sed in associated approach and deck preparation, joint repair, curb repair, and in full-depth deck repair as part of the Concrete Masonry Overlay bid items. The department will compute yardage based on the nominal cubic yard of concrete defined in 501.3.2.2 . The department will not measure wasted concrete.

509.5Payment

509.5.1 General

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

items: ITEM NUMBER DESCRIPTION UNIT

509.0200 Preparation Approaches SY

509.0300 - 0399 Preparation Decks (type) SY

509.0500 Cleaning Decks SY

509.0600 Cleaning Approaches SY

509.1000 Joint Repair SY

509.1200 Curb Repair LF

509.1500 Concrete Surface Repair SF

509.2000 Full-Depth Deck Repair SY

509.2500 Concrete Masonry Overlay Decks CY

509.2600 Concrete Masonry Overlay Approaches CY

Effective with the December 2018 Letting 277 2019 Standard Spec ifications (2) Repairing damage to existing reinforcement is incidental to the contract. 509.5.2 Preparation

(1)Payment for Preparation Approaches and the Preparation Decks b id items is full compensation for

removing asphaltic patches and unsound concrete; and for disposing of waste materials.

(2)The department will pay separately for the volume of concrete used under the Concrete Masonry

Overlay bid items. 509.5.3 Cleaning

(1)Payment for Cleaning Decks and Cleaning Approaches is full com pensation for scarifying, and

cleaning the deck or approaches; and for blast cleaning the ent ire deck or approaches, including all exposed existing reinforcing steel. 509.5.4 Joint Repair

(1)Payment for Joint Repair is full compensation for removing and disposing of deteriorated concrete,

and for forming new joints.

(2)The department will pay separately for the volume of concrete used under the Concrete Masonry

Overlay bid items.

(3)The department will not pay for re storation of painted surfaces damaged by construction operations.

509.5.5 Curb Repair

(1)Payment for Curb Repair is fu ll compensation for removing and disposing of deterio rated concrete; for

forming; and for disposi ng of waste material.

(2)The department will pay separately for the volume of concrete used under the Concrete Masonry

Overlay Decks bid item. 509.5.6 Concrete Surface Repair

(1)Payment for Concrete Surface Repair is full compensation for providing the repair; for removing and

disposing of deterio rated concrete; for cl eaning reinforcing st eel; and for the volume of concrete used in the surface repair. 509.5.7 Full Depth Deck Repair

(1)Payment for Full-Depth Deck Re pair is full compensation for co mpletely removing the deteriorated

concrete areas; for disposing o f waste material; for forming; a nd for salvaging and using the existing bar steel reinforcement. The depa rtment will pay for this bid i tem at the contract unit price regardless of whether the engineer directs i t before or after beginning the type 1 or type 2 removals.

(2)The department will pay separately for the volume of concrete used under the Concrete Masonry

Overlay Decks bid item. 509.5.8 Concrete Overlays

(1)Payment for the Concrete Masonry Overlay bid items is full com pensation for providing the overlay; for

the concrete used including the volume needed to complete the w ork done under the associated Preparation Approaches, Preparati on Decks, Join t Repair , Curb Repair, and Full-Depth Deck Repair bid items; and for sawing and sealing joints.

Effective with the December 2018 Letting 278 2019 Standard Spec ifications Section 511 Temporary Shoring

511.1Description

(1)This section describes designi ng and providing temporary shori ng at locations the plans show.

511.2Materials

(1)Provide a shoring design for eac h location where the plan requires temporary sho ring. Conform to

AASHTO Load and Resistance Factor Design Specifications and the WisDOT Bridge Manual. Design to address all limit states using a design life of 36 months or the project specific duration, whichever is greater. Have a professional engi neer, registered in the state of Wisconsin and knowledgeable of the specific site conditions and requirements, verify the adequacy of the design. Submit one copy of each shoring design, signed and sealed by the same professional engi neer verifying the design, to the engineer for incorporation into the permanent project record.

511.3Construction

(1)Provide temporary shoring at each required location conforming to the design developed for that

location as follows: Under the Temporary Shoring bid item: for all temporary shoring locations the contract shows. Under the Temporary Shoring (str ucture) bid items: for temporar y shoring associated with structure ID numbers identified in the bid item supplemental descriptions . Under the Temporary Shoring (loc ation) bid items: for temporary shoring associated with roadway locations identified in the bid item supplemental descriptions.

(2)Remove temporary shoring no longer needed unless the engineer allows it to remain in place. Under

the left-in-place bid items, leav e the shoring in place as the special provisions specify or as the plans show. Place backfill conforming to 206.3.13 in excavated space not occupied by the new permanent construction.

511.4Measurement

(1)The department will measure the Te mporary Shoring bid items by the square foot acceptably

completed at locations the plans show, measured as the area of exposed face in the plane of the shoring from the ground line in front of the shoring to a maximum of one foot above the retained grade. Shoring used for staged construction in multiple configu rations without removal and reinstallation will be measured on ce based on the configuration with the largest area of exposed face.

511.5Payment

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

items: ITEM NUMBER DESCRIPTION UNIT

511.1100 Temporary Shoring SF

511.1200 Temporary Shoring (structure) SF

511.1300 Temporary Shoring (location) SF

511.2200 Temporary Shoring Left In Place (structure) SF

511.2300 Temporary Shoring Left In Place (location) SF

(2)Payment for the Temporary Shoring bid items is full compensati on for designing and providing shoring;

for providing a signed and sealed copy of the design; for removal or additional work required to leave in place; and for backfilling.

(3)The department will not pay for te mporary shoring for locations the plans do not show.
Source: Wisconsin Standard Specifications for Highway and Structure Construction, 2019 Edition. Pages 282–286 of 601.
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