415Concrete Pavement Repair

Concrete Pavement Repair

415.1DESCRIPTION

1 This section describes the requirements for removing and replacing existing concrete pavement slabs (full depth repair), repairing spalled locations in concrete pavement (partial depth repair), and grinding and texturing the surface of existing concrete pavement.

415.2MATERIALS

415.2.1 Slab Replacement

1 Provide materials in accordance with the following:

Material Subsection Admixtures 801.4 Aggregate for Concrete 803 Curing Materials 802 Dowel Bars and Tie Bars 811.2 Epoxy Resin Grout 819.2 Fly Ash 801.2 Joint Materials 807 Portland Cement 801.1 Water 814

415.2.2 Spall Repair

1 Provide materials in accordance with the following:

Material Subsection Concrete Patching Material 810.1 Curing Materials 802.1 Joint Materials 807 Water 814

1 Provide bonding agents in accordance with the manufacturer’s recommendations of the spall repair material.

415.3EQUIPMENT

415.3.1 Slab Replacement

1 Provide equipment in accordance with Section 513, Structural Concrete, including a vibrating screed unless otherwise approved by the engineer.

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2 Provide a HSIP, if slab replacement locations include four or more contiguous slabs; ensure the HSIP complies with Subsection 415.3.3, Grinding and Texturing.

415.3.2 Spall Repair

1 Provide the following:

tools, or combination capable of removing concrete;

the placement site that accurately proportions materials for the mixture, discharges a uniform mixture, and maintains a continuous, steady flow of mixture; and

equipment to charge the mixer with the correct proportions of materials.

415.3.3 Grinding and Texturing

1 Provide grinding equipment with diamond blades mounted on a minimum 3-foot [1 m] wide head mounted on a self-propelled machine designed for grinding and texturing concrete pavements.

2 Provide an approved and calibrated HSIP meeting the requirements of ASTM E950, Class 1. Ensure HSIP includes automated photo triggering device; can function while traveling at the posted speed limit. HSIP will measure and record elevation profile of roadway surface; computer software will process raw profile data to:

adjustment, and.

Use a 0.1-inch [2.5 mm] (+0.05-inch [+1.25 mm], -0.05-inch [-1.25]) blanking band.

E nsure HSIP and operator are certified in accordance with Materials Testing

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Manual, Section 401.0, Verification and Certification of High Speed Inertial Profiler; provide proof of certification to the engineer.

415.4CONSTRUCTION

415.4.1 General

1 Repair damage caused by the work to existing concrete pavement, reinforcing bars and joints outside the limits of the slab replacement, spall repair, or grinding and texturing area at no additional cost to the department.

2 Haul, dispose of, and furnish waste locations for removed concrete pavement, excavated material, and slurry from grinding operations.

415.4.2 Slab Replacement

415.4.2.1 General

1 Follow the weather limitations in Subsection 513.4.2, Weather Limitations.

2 Use the approved mix design and place concrete pavement that achieves a compressive strength of at least 3000 psi [21 Mpa] in 48 hours.

415.4.2.2 Mix Design

1 Submit the following to the engineer for approval at least 28 calendar days before the placing concrete pavement:

specified early strength gain, and designating proportions of all materials;

Laboratory, in accordance with Subsection 513.4.4, Mix Design; and

Testing Manual, documenting the project number, manufacturer, source, type, and brand for the materials.

415.4.2.3 Replacement Procedures

1 Saw-cut full-depth the existing concrete slabs and partial slabs for removal. Cut along the existing longitudinal and transverse joints to remove full-length, full-width slabs, and along an engineer-designated outline for partial slabs. For transverse joints with existing load transfer dowel bars, cut full-depth through the dowel bars. Alternatively, cut down to the top of the dowel bars only, in which case the bars may be reused in their present position if they remain undamaged and firmly embedded in the undisturbed slab.

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2 In areas specified or determined by the engineer for excavation and backfill, level and consolidate existing subgrade and base material to 95 percent of maximum density in accordance with AASHTO T 99 for subgrade and AASHTO T180 for base material. Mix, place, and cure concrete in accordance with Section 513, Structural Concrete.

3 Ensure at least 7 days concrete curing time before sealant placement, unless otherwise recommended by the sealant manufacturer . Seal longitudinal and transverse joints for concrete slab replacements with silicone joint sealant, hot -poured elastic sealant, or preformed elastomeric compression sealant in accordance with Section 417, Sealing Existing Concrete Pavement Joints and Cracks. Use silicone joint sealant, if the sealant type is not specified.

415.4.2.4 Surface Variation

1 Do not leave deviations in the traveled way greater than 0.2 inches in 10 ft [5 mm in 3 m] when tested by a string line or straightedge

2 If repair locations include four or more contiguous new slabs, measure surface smoothness with a HSIP. Grind smooth surface variations that exceed must-grind values in accordance with Table 415.4.2-1, Must-Grind and PI Acceptance Levels.

Table 415.4.2-1 Must-Grind and PI Acceptance Levels Speed Limit (mph) Must Grind Bumps Acceptance PI S > 55 0.3 in [8 mm] in 25 ft [7.6 m] 10 in/mi [160 mm/km] 45 < S ≤ 55 0.4 in [10 mm] in 25 ft [7.6 m] 14 in/mi [224 mm/km] 35 < S ≤ 45 0.4 in [10 mm] in 25 ft [7.6 m] 22 in/mi [352 mm/km] S ≤ 35 0.5 in [13 mm] in 25 ft [7.6 m] 26 in/mi [416 mm/km]

415.4.2.5 Repair of New Slabs

1 Grind smooth or remove and replace new slabs that do not meet the surface tolerance specification.

2 Replace areas with uncontrolled cracks, corner cracks, rough areas not corrected by grinding, or other unacceptable pavement sections. Remove full panels to existing joints. Provide replacement panels of the same quality and dimensions specified.

415.4.3 Spall Repair

415.4.3.1 General

1 At least 14 calendar days before its expected use, give to the engineer enough patching

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material, including the extension aggregate, for a 0.5 ft³ [0.01 m³] batch. Also provide the Material Safety Data Sheet.

2 Do not place patching material if the air temperature is below 50 ºF [10 ºC] or expected to fall below 40 ºF [4 ºC] within 24 hours of placement.

3 Use the bonding material and bonding procedure for the concrete patch recommended by the patching material manufacturer . Ensure the presence of the manufacturer’ s technical representative for the initial placement.

4 Prepare for patching only those areas that can be completed and sufficiently cured, in accordance with the manufacturer’s recommendations, to open to traffic by nightfall the same day. Do not open repaired areas to traffic before the repair material obtains a compressive strength of 4000 psi [27.6 MPa].

5 If a mobile, continuous mixer is used, calibrate the proportioning equipment for each component of the mixture in the presence of the engineer. The engineer may accept the previous calibration and require verification checks only at the settings indicated by the previous calibration . During calibration checks and normal use, operate proportioning equipment at the speed recommended by the manufacturer. When a portable batch type mixer is used, provide measuring devices and other necessary equipment.

415.4.3.2 Repair Procedures

1 The engineer will designate spall repair areas. Saw the outline of each area to a depth of at least 1 in [25 mm]. Remove unsound concrete down to sound concrete or to a depth of at least 2 in [50 mm]. Prepare square or rectangular repair areas at least 6 in [150 mm] wide and long, of uniform depth, and with vertical sides. After removing unsound concrete, clean exposed surfaces by sandblasting and air blasting.

2 A pply bonding material to exposed surfaces of the repair area in accordance with the manufacturer’s recommendations, and immediately place and consolidate patching material. Reapply bonding material if it cures and hardens before placement of the patching material.

3 Place patching material continuously in each repair area until the entire area is finished to grade and sloped to match the adjacent pavement surface. Do not add water to the patching material surface until the material hardens . Cure in accordance with the manufacturer’s recommendations.

4 If the repair area abuts or spans a working joint or crack, continue the joint or crack through the repair. This can be accomplished by inserting a temporary strip in the joint position before placing the patching material. Reestablish longitudinal and transverse joints throughout all repairs . Do not remove temporary insert material until 24 hours after patching.

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5 After repairs have cured, replace joint sealant in transverse and longitudinal joints and random working joints disturbed by patching in accordance with Section 417, Sealing Existing Concrete Pavement Joints and Cracks.

6 Do not open repaired areas to traffic before examination by the engineer. Remove and replace any portion of the repair with cracks or inadequate bonding at no additional cost to the department.

7 Grind smooth or remove and replace spall repair locations in accordance with Subsection 415.4.2.4, Surface Variation.

415.4.3.3 Surface Variation

1 Do not leave variations in the travel way greater than 0.2 inches in 10 ft [5 mm in 3 m] when tested by a string line or straightedge by the engineer.

2 Grind smooth or remove and replace spall repair locations that do not meet the requirements of Subsection 415.4.2.4, Surface Variation.

415.4.4 Grinding and Texturing

415.4.4.1 General

1 Submit a detailed grinding plan to the engineer for approval before starting work. Include a sequence to produce the desired surface ride qualities with the least grinding depth throughout the project.

2 Grind in longitudinal direction. Grind entire surface width specified until pavement surfaces on both sides of all transverse joints and random cracks are on same plane and meet requirements of Subsection 415.4.2.4, Surface Variation.

3 Use grinding equipment that does not strain or damage concrete pavement. Do not use grinding and texturing equipment that causes excessive raveling, aggregate fracturing, spalling, or disturbance of the transverse or longitudinal joints.

4 Leave neat, rectangular ground areas with a uniform surface appearance, uniformly tapered to adjoining pavement. Perform additional grinding as necessary to extend the ground area so that lateral limits of grinding are at a constant offset distance from, and parallel to, the nearest pavement edge. Feather vertical edges outside the area to be ground. Do not cause adverse drainage by grinding.

5 Grind mainline pavement to produce a skid-resistant surface consisting of groves from 3/32 in to ⅛ in [2.5 mm to 3 mm ] wide, spaced from 5/64 in to ⅛ in [2 mm to 3 mm] apart, an approximately 1/16 in [1.5 mm] deep relative to the tops of the adjacent ridges.

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6 Remove grinding slurry and residue continuously and immediately, leave pavement clean, and dispose of slurry as approved by the engineer.

415.4.4.2 Profile Index and Corrective Action

1 Before use on the project, check calibration of the HSIP in presence of the engineer . Before checking calibration, provide document indicating system specific measurement configuration of the HSIP to the engineer.

2 The engineer may spot check or retest areas with another HSIP. If a discrepancy exists, determine the cause and reprofile areas as requested by the engineer.

3 After grinding, measure surface smoothness with the HSIP. Measure profile traces at distance of 3 ft [1 m] from, and parallel to, outside edge of traveled way and 3 ft [1 m] from centerline joint.

4 Calculate profile index, in/mi [mm/km], in accordance with Materials Testing Manual ,

5 Within one working day of measuring surface smoothness, provide the engineer with the HSIP printouts of average profile index for each 0.1 mi [0.16 km] segment evaluated, along with printouts for areas with surface variations that exceed must -grind values in accordance with Table 415.4.2-1, Must-Grind and PI Acceptance Levels.

6 Grind smooth surface variations in accordance with Subsection 415.4.2.4, Surface Variation.

7 Regrind and texture concrete pavement until all areas comply with Table 415.4.2-1, Must- Grind and PI Acceptance Levels; re-measure corrective action locations for surface variation and submit results to the engineer.

415.5MEASUREMENT and PAYMENT

415.5.1 General

1 The engineer will measure:

meter] measured in the plane of the existing concrete pavement surface.

the paved surface.

surface ground.

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2 The department will pay as follows:

Pay Item

Pay Unit Measure to the Nearest Pay to the Nearest Conc Slab Replacement SY [m2] 0.1 ft [0.05 m] SY [m²] Conc Pvmt Spall Repair SF, CF [m2, m3] 0.1 ft, 0.1 ft [0.05 m, 0.05 m] SF, CF [0.1 m2, 0.1 m3] Grind/Texture Conc Pvmt SY [m2] 0.1 ft [0.05 m] SY [m2]

415.5.2 Referenced Sections for Direct Payment

1 When specified, the engineer will measure and pay for:

Courses, and Bed Course Material.

Existing Concrete Pavement Joints and Cracks.